Metal Coating (also known as Thermal Spraying) is used for the bonding of hot Zinc, Aluminium or various amalgams to blast cleaned surfaces.

It is generally used when hot-dip galvanising is not possible because the fabrications are too complex or may distort. This is because large fabrications that are hot dipped are often too big for the dipping tanks, so are dipped and turned over and dipped again. The galvanising dipping tank is around 450°C and the part not submerged acts as a radiator and the difference in heat can put large stresses through the material often causing permanent distortion.

As in the case of Aluminium welding of like metals, to prevent stress corrosion cracking. This treatment is specified by Network Rail, the Highways Agency and the Water Authorities as the base layer for further paint coats, particularly on immersed fabrications.

Thermal spray coating is ideal for smaller and intricate parts as well as large fabrications and structures and can act as a replacement for galvanizing, specifically in the form of hot zinc spraying. It is often used on very large bridge structures and lighting columns for the Highways Agency. Application is done in accordance with ISO 22093.

Thermal Metal Spraying

The Benefits of Thermal Spraying and Metal Coatings over galvanising are:

  • We can handle a much higher weight than most galvanising plants.
  • There is no tank limit size, so large fabrications can be metal sprayed easily.
  • The fabrication does not need to be heated to 450°C as with galvanising and the surface being sprayed remains cool. It therefore has no risk of heat distortion or adding stress into the part.
  • There is no heat input to have an adverse effect material properties for load bearing parts or parts in extreme environments.
  • Box sections and sealed areas can be externally coated without the risk of expansion or the need for vent holes to be drilled.
  • Can be easily painted for additional protection as the metal surface provides an excellent keyway.
  • It offers excellent long lasting protection, and depending on amalgams used can offer sacrificial action to prevent corrosion, even to areas where local surface damage has gone through the metal spray.
Thermal Spray Metal Coating

Facilities List

Stress Relief Furnace

  • Maximum Job Size: 6.2M by 2.6M by 1.9M high
  • Max Weight: 15 tonne

Baking Oven

  • Maximum Job Size: 9 by 5M by 2.8M high
  • Max Weight: 3 tonne

Shot Blasting Cabinets

  • Chilled Iron Grit Blast Room Dimensions:
  • 13M in length x 6M wide x 6M high
  • Max Weight: 16 tonne
  • Chilled Iron Grit Blast Room Dimensions:
  • 7.8M in length x 4.3M wide x 5.9M high
  • Max Weight: 16 tonne
  • Aluminium Oxide Blast Room Dimensions:
  • 7M in length x 3M wide x 3M high
  • Max Weight: 8 tonne

Wet Spray Booths

  • Wet spray filtered extraction booths.
  • 2 OFF 6M in length extraction booths
  • 2 OFF 3M in length extraction booths

Large Wet Spray Tack System

  • 80 hangers on the track
  • 450 KG per hanger
  • 6M max job length
  • Wet back extraction paint room
  • up to 90°c on track baking oven

Small Wet Spray Tack System

  • 40 hanger track
  • 30 KG per hanger
  • Dry back extraction paint room

Thermal Spraying

  • Thermal Spraying filtered extraction booths.
  • 1 OFF 3M in length extraction booth





Qualified NACE Inspector (Certified member of the National Association of Corrosion Engineers)
Radleigh-Nash can carry out the following tests to suit your requirements including:
  • Various test methods with calibrated digital and/or analog equipment
  • Bresle patch test using a digital conductivity meter
  • Soluble Salt Test for contamination of steel surfaces from soluble salts
  • DTF using a calibrated digital coating thickness gauge
  • Coating Thickness on Ferrous & Non-Ferrous Substrates
  • WFT using wet film combs to obtain correct DFT
  • Blast profile testing using peak-to-valley tape and calibrated thickness gauge
  • Pull-off Dolly tests using a calibrated hydraulic pull-off adhesion tester
  • Destructive adhesion tests using cross hatch cutter and tape
  • M.E.K. Rub Test for cure of primers and final coats
  • Holiday Test to check for pinholes and voids
  • Amine Blush Check
  • RAL / BS Colour matching
  • Coating Procedures according to ISO 12944 and NORSOK M501 Standards
  • Custom Coating Systems to client specification

Workshop Facilities

Heavy Paint Shop

Work Area:
1870 square metres (20100 sq. ft.)
Lifting capacity:
Maximum lift 16 tonnes
Maximum job height 5 metres
Door Access:
6M wide X 4.5M high

Medium Paint Shop

Work Area:
1350 square metres (14500 sq. ft.)
Lifting capacity:
Maximum lift 8 tonnes
Maximum job height 5 metres

Light Paint Shop

Work Area:
600 square metres (6400 sq. ft.)
Lifting capacity:
Maximum lift 2 tonnes
Maximum job height 5 metres

Storage yards

Outside Area:
Lifting capacity:
Maximum lift 2 tonnes
1858 square metres (20000 sq. ft.)