Metallizing

T BAILEY INC. has a certified and endorsed coatings department at our fabrication facility. Established in 2003, it occupies an expansive 14,000-square foot dedicated area. Our expert, the goal-oriented team is proficient at metallizing a variety of fabricated steel parts, pieces, and structures using advanced technology, including many proprietary innovations.

What is Metallizing?

Metallizing uses two zinc, aluminum, or other metal electrically charged wires of opposite polarity. On contact, they atomize in a molten arc. This spray is propelled onto a substrate using compressed air.

A metalizing coating has advantageous characteristics:

  • Size: Metallizes large structures that don’t fit in a galvanizing kettle.
  • Time: Instant solidification allows rapid return to service.
  • Location: Portable metalizing equipment coats immovable structures in situ, such as bridges or marine constructions.
  • Flexibility: Metalizing protects, adds anti-slip/non-skid enhancement, repairs surfaces, and is easily top-coated with color.
  • Durability: Metalized coatings from light to heavy military grade withstand all weather conditions.

Benefits of the Metallizing Process

When you partner with T BAILEY INC.’s metalizing services, you’ll enhance your steel structures and enjoy many cost-saving benefits.

  • Enhanced corrosion protection: Rust diminishes the strength and appearance of structures until they become unsafe and unsightly. Metalizing steel inhibits rust and boosts lifespan by approximately 20 years.
  • Increased durability: Metalizing has superior adhesion, resisting cracking, flaking, peeling, and blistering.
  • Providing electrical conductivity: Most non-metallic substances are electrically non-conductive. Metalizing provides a pathway for electric current.
  • Greater weather resistance: Metalization forms a shield against harsh weather conditions and environments.
  • Reduced maintenance costs: Metalized coatings don’t require constant repainting or upkeep.

What Are the Various Metallization Processes?

  • Vacuum metallizing vaporizes the coating inside a vacuum chamber. The vapor condenses on the substrate.
  • Hot-dip galvanizing involves immersing steel in liquid zinc in a galvanizing kettle. This produces a layered coating of zinc and zinc/iron alloy.
  • Zinc spraying uses a heated gun to melt and spray zinc onto the substrate using combustion or compressed air.
  • Thermal spraying techniques use electrical plasma or combustion to spray melted or heated material onto a surface.
  • Cold spraying uses a supersonic gas jet to accelerate unmelted metal powder onto the substrate. The powder particles undergo plastic deformation and adhere to the surface.

Different Types of Coating Systems

T BAILEY INC. performs:

  1. GalvanizingSteel is hot-dipped in a galvanizing kettle containing ASTM B6 graded zinc, producing a multi-layered coating of zinc/zinc-iron alloy. After cooling, steel may undergo post-treatment enhancements. The uniform coating is corrosion-resistant and affordable but limited by kettle size. Regalvanizing is inadvisable.
  2. MetalizingTwo electrically charged zinc, aluminum, or other wires of opposite polarity are fed through a metalizing machine. On contact, an atomized molten arc is propelled and deposited using compressed air. Surface preparation requires abrasive blasting for a sharp, angular profile. Metalizing meets industry standards SSPC, AWA, & NACE. It is superior to galvanizing.

Considering Different Coating Systems

Metalizing and galvanizing are two coatings systems that can be applied along with a coating as part of a duplex coating system. There are advantages and disadvantages to both systems that should be considered when determining which is best for your project.

What Is Galvanizing?

Hot-dip galvanizing is the process of immersing steel in a zinc bath to produce a corrosion resistant, multi-layered coating of zinc-iron alloy and zinc metal. The galvanizing kettle contains zinc specified to ASTM B6, which specifies the grade of zinc.

On occasion, other metals are added to the zinc in accordance with the desired coating system. Once removed from the kettle it is removed to cool. Depending on the coatings system, there might be other post-treatment steps to enhance the galvanizing coating. This process creates a uniform thickness throughout and creates a long-lasting corrosion protection at a reasonable cost.

The process is inherently simple but comes with limitations. Since the galvanizing process involves dipping the steel into multiple kettles, there are size restrictions on what can be processed. Depending upon the final size of your project, metalizing or partial galvanizing might be a better solution. Additionally, once an item has been galvanized it is difficult to regalvanize it down the road should repairs be necessary.

High-Quality Preparation for Metallizing

T. BAILEY INC. Maintains Quality Control in All Processes

As a specialist metallizing company, we implement a Quality Management System to control all aspects of production. Our coatings facility is AISC certified with all three Sophisticated Paint Endorsements. Additionally, we are an SSPC QP3 Certified Contractor for shop-applied coatings. We perform daily monitoring and check details from cleanliness to dry-film thickness of our applied coatings.

We are Committed to On-Time Product Delivery

T BAILEY INC. commits to meeting all contract requirements and addressing any customer concerns. We strive for continual improvement through rigorous self-examination and controlling the quality of all materials, workmanship, parts, and supplies we produce or procure on behalf of our valued customers.

We Follow International Standards & Inspection Protocols

In order to maintain our commitment to quality, we undergo annual recertification through third-party external audits. Our specialized technicians are trained to the highest standards and encouraged to update and improve their competence through ongoing learning and development. Furthermore, we employ internal Certified NACE Level III Coatings Inspectors to ensure we maintain our ratings in the USA and Canada.

Common Industries that Use Metalized Equipment

  • Oil and gas refineries and off-shore structures
  • Wind towers
  • Municipal water towers
  • Military (Army Corps of Engineer Applications)
  • US Waterways
  • Bridges
  • Department of Transportation
  • Facilities maintenance
  • Maritime and marine
  • Power generation
  • Medical devices
  • Agricultural equipment
  • Food production equipment
  • Automotive parts and manufacturing
  • Data centers, cloud computing, and printed circuit boards

T BAILEY, INC.:  Metallizing Solution for Coating System Needs

With our decades of experience, we confidently provide durable, cost-effective metalized coatings for a multitude of applications. We’ll metallize your steel structure from the smallest components to colossal constructions. If you can’t bring it to us, we can bring it to you! Contact us today for your specific metallizing requirements.

Services

Construction

Our roots in industrial construction have given us the experience your project needs.

Coatings

With a ride range of coating abilities, our industrial painting division can provide the surface preparation and coatings your project needs.

Main Equipment

Our facilities are geared to the fabrication of AWWA and API field-erected welded steel storage tanks, UL and API shop tanks, pressure vessels, AWWA C200 water pipe, wind energy towers, large plate exhaust duct, and large diameter casing. Fabricated materials can be primed and painted before being shipped directly to a client’s jobsite or tied in with our construction division.

  • 4-roll hydraulic plate bending rolls, up to 2.75” x 10’-0 wide plate
  • CNC plasma cutting machines, 11’ x 50’ water tables
  • Numerous tandem head welding manipulators
  • Numerous single head welding manipulators
  • Tank/vessel turning roll sets, up to 100-ton capacity
  • Automated blasting system
  • Iron workers
  • Several overhead bridge cranes, up to 50 tons capacity
  • Welding power sources for most welding processes
    • SAW
    • FCAW
    • SMAW
    • GMAW
    • GTAW
    • EWS
  • Angle iron bending rolls
  • 3 O’Clock automatic welders
  • Press brake
  • Multiple forklifts, up to 55 tons capacity
  • RT hydraulic cranes, up to 60-ton capacity
  • Scissor and snorkel personnel lifts
  • Extended boom forklifts
  • Dozer and excavators
  • Long haul trucks and trailers
  • Vertamatic welders

Projects

Quality Control Certifications

As part of our commitment to quality, we work toward continuous improvement and maintain compliance with industry codes and standards.

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What can we do for you?

Through experience, innovation, and planning, T BAILEY, INC. delivers each project on budget, with unmatchable quality, and precise timing. Contact us and see how we can help you complete your project.