When long-term corrosion protection matters, metalizing is one of the most effective coating solutions available. At T BAILEY LLC, our certified coatings department provides advanced thermal spray coating and thermal spray metalizing services for fabricated steel parts, components, and large-scale structures. Established in 1999, our coatings department operates within a dedicated 14,000-square-foot area at our fabrication facility, giving clients access to a streamlined, high-quality solution for surface preparation, coating, inspection, and delivery.
Our goal-oriented team is experienced in applying metalizing coatings to a wide range of fabricated steel products using advanced technology and proprietary innovations. Whether you need protection for tanks, piles, bridges, marine structures, pylons, or other industrial steel components, T BAILEY LLC delivers metalizing services built around durability, performance, and schedule.
What Is Metalizing?
The metalizing process uses two electrically charged zinc, aluminum, or other metal wires of opposite polarity. When the wires meet, they atomize into a molten arc. That arc is then propelled onto the steel substrate using compressed air, creating a highly durable metal spray coating. As described in our field experience, the process is similar to a flame spray application, where the metal is atomized and deposited directly onto the prepared surface to form a bonded protective layer.
This form of thermal spray application offers several important advantages:
- Size flexibility: Unlike galvanizing, metalizing can be applied to large structures that do not fit in a galvanizing kettle.
- Fast return to service: Because the coating solidifies instantly, projects can move quickly through production or back into service.
- Portable application: Metalizing spray equipment can be used in the shop or in the field on immovable structures such as bridges and marine facilities.
- Versatility: Metalized surfaces can provide corrosion protection, anti-slip or non-skid enhancement, surface repair capability, and can be top-coated in color.
- Durability: Metalized coatings range from light-duty to heavy military-grade systems and are designed to withstand demanding weather and environmental conditions.
Together, these advantages make metalizing a highly effective solution for protecting steel structures that require long-term corrosion resistance, flexible application, and dependable performance in demanding environments.
For high-traffic and harsh industrial environments, thermal spray metalizing provides a significantly more durable and efficient non-skid solution compared to traditional rolled liquid coatings. While conventional epoxy and polyurethane non-skids rely on mixed-in aggregates that are prone to chipping, flaking, and 24-to-48-hour cure times, our metalizing process atomizes molten metal directly onto a deeply blasted steel substrate to create a permanent, ruggedly abrasive walking surface. This creates an exceptionally strong mechanical bond that cures instantly upon contact—eliminating costly downtime—while delivering active galvanic corrosion protection that outlasts traditional painted barrier systems for decades.
Benefits of the Metalizing Process
When you choose T BAILEY LLC for metalizing thermal spray services, you gain more than a coating; you gain long-term value and protection for your steel structures.
Key benefits include:
- Enhanced corrosion protection: Rust weakens steel over time and affects appearance, safety, and service life. Metalizing corrosion protection helps inhibit rust and can extend a structure’s service life by approximately 20 years.
- Increased durability: Thermal spray metal coating systems offer strong adhesion and resist cracking, flaking, peeling, and blistering.
- Electrical conductivity: Since most non-metallic materials are not electrically conductive, metalization can provide a pathway for electric current where needed.
- Weather resistance: Metalized coatings create a protective barrier against severe weather and harsh operating environments.
- Reduced maintenance costs: Compared with conventional coatings that require more frequent repainting, metalizing coatings reduce long-term upkeep needs.
- Better performance in harsh outdoor conditions: Based on project experience, metalizing handles UV exposure and temperature changes well, making it a strong choice for marine, industrial, and transportation applications.
- Faster turnaround: Because the coating solidifies immediately, metalizing can reduce downtime and help projects move through fabrication, finishing, and delivery more efficiently.
For owners and contractors alike, these benefits make metalizing a practical, long-term investment in the safety, durability, and lifecycle performance of steel assets.
