I

'METCO

ANTI-CORROSION
SYSTEMS

METALLIZED
ZINCANO

ALUMINUMCOATINGS
GIVE

'

LONG-TERM,
LOWCOSTCORROSION
PROTECTION
FORIRONANOSTEEL
ELECTROGALVANIC
CORROSION
IS UNIVERSALLY
PRESENT
Iron is mined from the earth as an oxide. After being refined,
alloyed and fabricated into structural shares, it spends the rest of
its life attempting to return to its natural state. When iron or its
alloys are exposed to moisture in every day service, a minute
electrical differential develops. This small flow of current accelerates
the oxidation, or rusting, of the metal. Speed of rusting is further
accelerated by the presence of salts, higher temperatures, or by
contact with a noble metal. Unfortunately, iron is one of the least
noble metals, and therefore highly prone to corrode.

Structural
iron

METALLlZEDCOATINGSYSTEMS
OFFERTHREE-WAY
CORROSION
PROTECTION
There are four ways to protect iron and steel against corrosion:
1. Apply a barrier coat of an impervious film such as paint.
2. Provide electrolytic protection.
3. Use inhibitors such as zinc chromate.
4. Passivate by forming conversion films on the surface such as
phosphate and black oxide coating.
Of all the methods commonly used for corrosion protection,
metallized coating systems are the most versatile.

Primer and
Sealer

Metallized aluminum or zinc coatings can be used unsealed to

provide

electrolytic

protection

. . . both

metals are anodic

to steel

and therefore corrode preferentially to the steel.

If greater protection is wanted, a primer that acts as an inhibitor
plus one or more seal coats can be added to the metallized coating.
The sealing materials infiltrate the minute surface pores of the
coating, establishing a permanent barrier against corrosion. Should
the coating become scratched, the zinc and, to a lesser extent, the
aluminum exposed by the abrasive damage will sacrificially protect
the exposed steel area.

METALLlZED
COATING
SYSTEMS
PROVIDE
LOWEST-COST, LONGEST-TERM PROTECTION
In the long run, a sprayed coating is far less expensive than paint
films. A sprayed and sealed coating should hold up for 10 to 20 years
or more with little or no maintenance.
In less severe exposure, the metallized system may add a few
pennies per square foot to the first-time cost of a job, but this
initial cost is far less than the cost of a single re-coating job when
you include rigging, preparation and coating.
For severe exposure,

a paint system might require

4 to 6 oats

applied to sand blasted steel. A 3 or 4 mil thickness of metallized

aluminum or zinc plus one or two thin seal coats could be less
expensive'initially as well as far more durable and far less costly
over the years.

.
The top row, left three panels have 0.003 in. (0.08 mm) alumlnuf'(1 wlthout a sealer. The upper second row, left three panels have 0.003 In.
(0.08 mm) a/umlnum, a wash primer, and one coat of a/umlnum vlnyl.
The third row (from the top), left three paneis are the same except fo,
two coats of a/uminum vinyl. The remalning
unidentifled
panels are
0.006 in. (0.15 mm) and 0.009 in (0.23 mm) alumlnum w/th and wlthout
sea/ers. (American We/d/ng Society Tests, Kure Beach, N.C., after exposure for 19 years /n Severe Marine Envlronment.
Mounted 80 feet
(24 m) from norma'-mean t/de leve/, facing the surf.)

@1978 METCO Ine.

Test photos courtesy

of American

Welding Society.

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AWSTESTSPROVESUPERIORITY
OFMETALLlZEDSYSTEMS
In 1974 the American Welding Society completed a 19-year study
of corrosion protection afforded by wire metallized aluminum and
zinc coatings applied to low carbon steel. Here is a summary
of the results:
1. Aluminum coatings .003 inch to .007 inch (0.08mm to 0.15mm)
thick, both sealed and unsealed, gave complete base metal
protection from corres ion for 19 years in sea water, and in severe
marine and industrial atmospheres.

2. Unsealed zinc sprayed coatings required 0.012 inch (0.30mm) 'minimum thickness to give complete protection in sea water for
19 years. In severe marine and industrial atmospheres, 0.009
(O.23mm) of unsealed zinc or 0.003 inch to 0.006 inch (0.08mm to
0.15mm) of sealed zinc gave 19 year protection.
3. In severe marine atmospheres, application of one coa~ of wash
primer plus one or two coats of aluminum vinyl enhanced the
appearance and extended the life of zinc coating at least 100%.
With aluminum, the sealing system primarily enhanced appearance,
because both sealed and unsealed systems showed no base metal
rust after 19 years.
The only sealed zinc panels tested in sea water were sealed with
chlorinated rubber. This seal coat did not prove effective.
4. Thin coats of metallized aluminum perform better; have less
tendency to develop pits and blisters and therefore are expected
to give extended life.
5. Where aluminum coatings showed physical damage such as
chips or scrapes, corros ion did not progress, suggesting the
occurrence of galvanic protection.

RESULTSOFAWS19-YEARCORROS
IONTEST
OFMETALLlZEDcOATEDSTEEL

<iT~

&p!ta1~~

The below listed coatings afforded complete corrosion protection to

low carbon steel panels.

ami d/-pp.1U:4
TYP[ OF EXPOSURE

SeaWater
Exposure(o)
MarineAtmospheric
Exposufe(d)

IndustrialAfmospheric
Expo$u
re

METALLIZED
ALUMINUM
COATINGS
(a)

METALLlZED
ZINCCOATlNGS(b)

.003"(,08111111)
seaIed& unsealed
.0061/(0.15ml11)
sealed& unsealed

.0121/(.30mm)
unsealed

.003"(.08I11m)
to .006(0:15mm)
se81ed
&unsealed

.0091/(.23mm)
unsealed
.0031/(.08mm)
sealed

,0031/(.08mm)fo .006(0:15mm)
seaIed& unsealed

.0091/(.23mm)
unsealed
.0031/(.08mm)
sealed

NOTES
(a)AI.Isealedpaoelswere sealedwlth a wash Primerplus ooeor two coats of elther alumloum
vioyl.or clear vioyl.
(b) Atmospheritpaoels sealedwith a Washprimer plus ooe eoat of alumioumvioyl.
(e) 80th below.low-tideaodmean-tide level.
(d) 80th severemarioeand salt air.

This photomlcrograph
under po/arized light
shows the relatively smali
amount 01 aluminum
corros ion. Flame sprayed
aluminum
coating 0.003 in. (006 mm)
thick pius one coat 01
primer and two coats 01
vinyl. Exposed lor 18 years
below 101'1tide at Wrightsville Beach, N.C.

The top row, lelt three panels show the condition 01 0.003 in. zinc panels
wlthout a sealer. The upper second row, lelt two panels have 0.003
in. zinc, a wash primer, and one coat 01 aluminum vinyl. The third row
(Irom the top), lelt two panels have 0.003 in. zinc with chlorinated
rubber sealer. The top row, rlght two panels have 0.006 in. zinc with a
chlorinated rubber sealer. The remaini(Jg panels are 0.009 in. zinc wlth
and without sealers. (American
Welding Society Tests, Kure Beach,
N.C., alter exposure lar 19 years in Severe Marine
Environment.
Mounted 80 leet (24 m) Irom normal mean tide level, lacing the surl.)

Test photos courtesy 01 American Welding Society.

...

ea

ANTI-CORROSION
SYSTEMS

ANTI-CORROSION
METALLlZEDCOATINGSYSTEMS...DEFINEDFOREASEIN SELECTION
In order to ease the job of selecting the most effective corrosion protection for
any specific application, METCO has defined a set of system specifications. These
are outlined below; detailed specifications are available from METCO Westbury.
ZINC
METCOSYSTEM

1I2A
1I0A
108A

COATlNG

THICKNESS

FINALCOAT(S)
None
None
l-METCOSEAlPRPrimer
l-METCOSEAlAVAl.Vinyl

.002"-.005"(.05mm-.l3mm)
.008" (.20mm)
.003"(.08mm)

ALUMINUM

METCOSYSTEM

COATING THICKNESS

l26A

.003"(.08mm)

203

.006"(.15mm)

204

.003" (.08mm)

128

.003" (.08mm)

120

.006"(.l5mm)

FINALCOAT(S)
l-METCOSEAlPRPrimer
2-METCOSEAlAVAl. Vinyl
l-Plasite 7155Clear
l-Plasite 7155 Ivory
l-Plasite 7155Clear
l-Plasite 7133White
l-METCOSEAlPRPrimer
l-METCOSEAlAVAl.Vinyl
l-Vinyl TBTO
(Tri-ButylTinOxide)Anti-Foul
2-METCOSEAlSASilicon
Aluminum

NOTES
METCOSYSTEMS
apply in three steps:
1. Preparation.Basemetal must be thoroughly cleaned and adequately roughened.
Only acceptablemethodis grit blasting with silica grit, angular steel grit or aluminumoxide.
2.Metallizing. METCOcontrol equipmentcan aS5urethat proper spray
parametersare maintaineddespite minimal operator attention.
3. Sealing.Somecoatings(especiallythosedesignedfor longestlife) haveto be adequatelysealedwith
a final paint coat selected for its compatability with the metallized coating.

SELECTING
THEMOSTEFFECTIVE
METALLlZEDCOATINGSYSTEM
ATMOSPHERIC CORROSION

CONDITION
Industrial Atmospheres

DESIREDRESULT
lowest Cost

ZINC SYSTEMS AlUMINUM SYSTEMS

1I2A

longestlife
Bestlong-Term
Appearance

108A

SeaAir & SaltSpray

lowest Cost

108A

RuralAtmosphere

longestlife
Bestlong-Term
Appearance
lowestCost

HighTemperature

Longestlife
Bestlong-TermAppearance
OnlySolution

108A
108A
1I2A,108A
108A
108A
-

l26A
l26A

l26A
l26A

l26A
l26A
120

IMMERSION CORROSION

CONDITION
DrinkingWater
SoftWater
(notdrinkable)
SeaWater

DESIRED
RESUlT
LowCost/Long'life
LowestCost
WithstandsSevereAttacks
Longestlife
NoFouling

Chemical

Fouling
OnlySolution

Food

HighTemperature

..Only Solution

OnlySolution

ZINC SYSTEMS ALUMINUMSYSTEMS

1I0A
108A,1I0A

(PH>7)108A

l26A,204
(PH<7) l26A

l26A
128
203

204
120

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TYPICALAPPLlCATIONS
FORMETCOMETALLlZED
COATINGSYSTEMS
METCO Systems are used world-wide for protecting structural steel elements
against the ravages of atmospheric and immersion corrosion. Just a
few of the many and varied applications for METCO anti-corrosion systems
are presented here.
Every municipality faces the problem of storing drinking water in a manner that
preserves its purity and taste. The water troughs in one major U.S. city
water installation has been corrosion protected by a METCO system for over
20 years. Although periodically cleaned, and resealed twice during the first
20 years of service, the metal structures are still corrosion-free.
Elevated water storage tanks have been sprayed since the early 1930's.
Standards prepared by the American Waterworks Association for exterior
of water storage tanks recommend a .006" (.15mm) metallized aluminum
coating sealed with a vinyl butyl wash coat pretreatment and two
coats of vinyl paint. This system is recommended for "extremely corrosive
environments or for achieving maximum life".
The AWWA standards for interiors of water storage tanks recommend a
.010" (.25mm) metallized zinc coating where "long life or freedom from rust
contamination is essential".
METCO records show some of the following in-service performance figures for
the use of sprayed coatings on elevated storage tanks:
1. Buffalo, New York-Okay
after 31 years.
2. Indianapolis, Indiana-StiII in good condition after 24 years.
3. Cedar Rapids, lowa-Spot-painted
as necessary after 28 years.
4. Erie, Pennsylvania-In
perfect condition "no maintenance performed
since original coating 28 years ago".

Structural steel used in the building trades is a major application for METCO
anti-corrosion systems. A booklet published in Europe by the Society of
Steel Window Manufacturers describes quality requirements for steel windows
and doors and demands that all window frames and doors subject to
atmospheric corroson be metallized with zinc.

Another application is metallizing of steel scaffolding used by the building

and construction industry. Steel parts of the scaffolding are metallized with zinc
and then dipped in zinc chromate paint. In addition to the corrosion protection
given, experience has proven that, when the steel framework is connected
by clamps, the grip of the clamps is much stronger on the metallized
poies than it is on galvanized poles (15,600 psi vs. 11,400 psi), (10,750N/ cm2
vs. 7,860 N/Cm2). This presumably results from the slight surface roughness
of the metalized coating.

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METCO

ANTI-CORROSION
SYSTEMS

TYPICALAPPLlCATIONSFORMETCOMETALLlZED
COATINGSYSTEMS

... Contnued

Large concrete pipes used in sewers and waterlines are often connected with
steel joint rings. To assure long metallife, manufactuq~rs routinely corros ion
protect the pipe joint rings with metallized zinc. The pipeline shQwn here is
made of mi Id steel boiler quality plate. Located in Sidney, Australia, over 6000
individual pipes of 120 in. (3.1 m.) bore, 15 f1. (4.6 m.) long, were individuallysprayed. A total of over 3,000,000 square feet (278,700 square meters) of surface
was corrosion-protected.
Refrigeration plates must function in a constant corrosive atmosphere.
By using metallized coatings instead of stainless steel, manufacturers are
able to considerably reduce product cost while still providing excellent
corros ion protection.

'1
When threading galvanized pipe, fue galvanizing is machined away. Replaci
corrosion protective zinc by METCO metallizing is standard practice for
many manufacturers.
A cotton glycerin shippi 9 container used in the maritime industry is
deck-transported due to e highly explosive character of the cotton glycerin.
The lowest-cost and longe t-lived method of protection has proved to be a
METCO metallized anti-cor sion system.
Maintenance of metal structu es in canals and locks is complicated by the
physical damage resulting wh n river barges rub"against metal surfaces.
The galvanic corroson protectl n afforded by metallized aluminum and zinc
prevents physical abrasion from ausing rapid local corrosion. Metallized
locks and their connected areas re a big cost-saving applic:ltion for
METCO anti-corrosion systems. E ample: France maintains a vital land locked
water shipping system. AII steello
requirements are zinc metallized prior to
their service installation.
Anther example (pictured here) is s p gates used to control ice in the S1..
Lawrence River in Canada. Here the ab asive problem came from moving ice,
not barges. Again, metallized coatings rovided the corrosion-free solution.
Widely used household and industrial ite s such as the propane
gas containers must be corrosion protect d for long time periods.
They are subject to constant abuse during ransport and
by users. A painted container would start rus ing almost
immediately. Therefore, many manufacturers coat
containers in OEM production (1) to prevent
sting
that could make the container unsafe, and (2)
to provide a better gripping base for paint.

".

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n,nd cY~

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Wrought iron furniture is often exposed to extreme corrosive environments,

especially when used in seacoast locations and in resort areas such as the
aribbean. Use of metallized coatings has enabled leading manufacturers to
guarantee their wrought ron furniture for ten years against rust.
Steel bridges are subject to accelerated corrosion as atmospheric
are aggravated by the aggrssive elements of automotive exhaust
fumes and salt-spreading during winter storms.
lany European bridges are completely coated during construction; two
eX
les are the Firth of Forth Bridge and the Bridge over the Bospherous.
B dges in Gothernburg and Bremen have been partially or totally coated.

:l!
er example: a bridge over a main railroad terminal in Kansas is subject
to extreme corrosive environments as smoke-belching loco motives pass

Ano

nderneath. Metallized corrosion protection has lasted over 30 years in this

location and is still providing protection.
Pictured here is the Aukland Harbor Bridge in New Zealand, also completely
metallized for corrosion protection.
Gas engine muffler used in heavy-duty pumping and compressor service
ifineries is protected by METCO System 120. Corrosion was caused by a
bination of high exhaust temperatures and a heavy sea-salt atmosphere.
Electric capacitor cases are protected with a metallized zinc coating in
place of the previously used baked enameling. The manufacturer has been
able to vastly improve quality of the product without adding cost.
Many boat hulls have been protected against marine corrosion with
metal\ized coatings. Examples include shrimp trawlers and tun~aclippers,
where both hulls plus fish tanks are sprayed.
Cost of proqucing corrosion-resistant marine engine oil pans was cut in half
by switc\1ing from solid stainless steel o a METCO metallized aluminum
system
plied over a carbon steel base.
Stainless proved impractical because i is expensive, difficult to draw or
form, requires special tool and generates high scrap lss.
By metaIliZing, e marine engine manufacture gave the corrosion resistance
of stainle
to carbon steel oil pans that
d been mass produced on an
automobile pr uction line. Even when the en ine is installed in the hull of a
boat, and the pa nt unavoidably scraped, the me allized aluminum sacrificially
protects t e pan against corrosive effects of salt and fresh bilge water.