[{"data":1,"prerenderedAt":-1},["ShallowReactive",2],{"detail-sidebar-cat-0-en-105":3,"doc-seo-297586-105":59,"doc-detail-297586-en":131},{"code":4,"msg":5,"data":6},0,"success",[7,13,18,23,28,33,38,43,48,51,55],{"id":8,"doc_module":4,"doc_module_name":9,"category_name":10,"show_sort_weight":11,"slug":12},1,"Document","Story & Novel",90,"story-novel",{"id":14,"doc_module":4,"doc_module_name":9,"category_name":15,"show_sort_weight":16,"slug":17},2,"Literature",80,"literature",{"id":19,"doc_module":4,"doc_module_name":9,"category_name":20,"show_sort_weight":21,"slug":22},4,"Exam",70,"exam",{"id":24,"doc_module":4,"doc_module_name":9,"category_name":25,"show_sort_weight":26,"slug":27},5,"Comic",60,"comic",{"id":29,"doc_module":4,"doc_module_name":9,"category_name":30,"show_sort_weight":31,"slug":32},6,"Technology",50,"technology",{"id":34,"doc_module":4,"doc_module_name":9,"category_name":35,"show_sort_weight":36,"slug":37},7,"Healthcare",40,"healthcare",{"id":39,"doc_module":4,"doc_module_name":9,"category_name":40,"show_sort_weight":41,"slug":42},8,"Research & Report",30,"research-report",{"id":44,"doc_module":4,"doc_module_name":9,"category_name":45,"show_sort_weight":46,"slug":47},9,"Religion & Spirituality",20,"religion-spirituality",{"id":46,"doc_module":4,"doc_module_name":9,"category_name":49,"show_sort_weight":46,"slug":50},"World Cup","world-cup",{"id":52,"doc_module":4,"doc_module_name":9,"category_name":53,"show_sort_weight":52,"slug":54},10,"Lifestyle","lifestyle",{"id":56,"doc_module":4,"doc_module_name":9,"category_name":57,"show_sort_weight":24,"slug":58},19,"General","general",{"code":4,"msg":60,"data":61},"ok",{"site_id":62,"language":63,"slug":64,"title":65,"keywords":66,"description":67,"schema_data":68,"social_meta":124,"head_meta":126,"extra_data":128,"updated_unix":130},105,"en","thermal-metal-spray-successes-failures-and-lessons-learned-willie-l-mandeno","THERMAL METAL SPRAY - SUCCESSES, FAILURES AND LESSONS LEARNED - Willie L Mandeno","","Thermally sprayed metal (TSM) is reviewed as a protective coating approach for steel structures in marine environments, highlighting proven long-term systems such as thermal sprayed zinc (TSZ) and thermal sprayed aluminium (TSA). The paper explains how the technology evolved, compares it with alternative zinc-based protection methods, and summarizes exposure trials and standards. Project case studies from New Zealand and overseas—including instances of premature failure—are used to derive practical recommendations for improving coating specifications and achieving long-life performance.",{"@graph":69,"@context":123},[70,84,106],{"@type":71,"itemListElement":72},"BreadcrumbList",[73,77,79,82],{"item":74,"name":75,"@type":76,"position":8},"https://docshare.wps.com","Home","ListItem",{"item":78,"name":9,"@type":76,"position":14},"https://docshare.wps.com/document/",{"item":80,"name":40,"@type":76,"position":81},"https://docshare.wps.com/document/research-report/",3,{"item":83,"name":65,"@type":76,"position":19},"https://docshare.wps.com/document/thermal-metal-spray-successes-failures-and-lessons-learned-willie-l-mandeno/297586/",{"url":83,"name":65,"@type":85,"image":86,"author":91,"headline":65,"publisher":94,"fileFormat":97,"inLanguage":63,"description":67,"dateModified":98,"datePublished":99,"encodingFormat":97,"isAccessibleForFree":100,"interactionStatistic":101},"DigitalDocument",{"url":87,"@type":88,"width":89,"height":90},"https://docshare.wps.com/thumbnails/thermal-metal-spray-successes-failures-and-lessons-learned-willie-l-mandeno/297586.png","ImageObject",300,407,{"name":92,"@type":93},"Dozel","Person",{"url":74,"name":95,"@type":96},"DocShare","Organization","application/pdf","2026-10-27","2026-09-18",true,{"@type":102,"interactionType":103,"userInteractionCount":105},"InteractionCounter",{"@type":104},"ViewAction",13,{"@type":107,"mainEntity":108},"FAQPage",[109,115,119],{"name":110,"@type":111,"acceptedAnswer":112},"What coating systems are discussed for long-term steel protection in marine environments?","Question",{"text":113,"@type":114},"The paper focuses on thermally sprayed zinc (TSZ) and thermally sprayed aluminium (TSA) as proven long-term protective coating systems for steelwork in marine exposure.","Answer",{"name":116,"@type":111,"acceptedAnswer":117},"What does the paper say about evidence from exposure trials and maintenance-free protection?",{"text":118,"@type":114},"It cites long exposure results for metallized coatings, including reports of decades-long performance at coastal and industrial sites, and references to maintenance-free corrosion protection expectations in wet, salt-rich bridge environments.",{"name":120,"@type":111,"acceptedAnswer":121},"Which standards are presented as key references for local specifiers?",{"text":122,"@type":114},"The paper names ISO 2063 (and its national equivalents) and the North America joint standard NACE 12/AWSC2.23M/SSPC-CS 23.00, along with supporting guidance standards for specification, operator qualification, and adhesion testing.","https://schema.org",{"og:url":83,"og:type":125,"og:title":65,"og:site_name":95,"og:description":67},"article",{"robots":127,"canonical":83},"index,follow",{"doc_id":129,"site_id":62},297586,1789745976,{"code":4,"msg":5,"data":132},{"doc_id":129,"user_id":133,"nickname":92,"user_avatar":134,"doc_module":4,"category_id":39,"category_name":40,"doc_title":65,"doc_description":67,"doc_content":135,"file_id":136,"file_url":137,"file_type":138,"file_size":139,"view_count":105,"is_deleted":4,"is_public":8,"is_downloadable":8,"audit_status":8,"page_count":140,"language":141,"language_code":63,"site_id":62,"html_lang":63,"table_of_contents":142,"faqs":143,"seo_title":144,"seo_description":67,"update_tm":130,"read_time":145,"preview_page_count":4},962085662650,"https://ap-avatar.wpscdn.com/davatar_29158cc5080c5b710cf443261637dec0","THERMAL METAL SPRAY: SUCCESSES, FAILURES AND LESSONS LEARNED  \nWillie L Mandeno  \nOpus International Consultants Ltd, Wellington, New Zealand  \nSUMMARY: Thermally sprayed metal (TSM) includes proven long term protective coating systems for steelwork in a marine environment such as thermal sprayed zinc (TSZ) and thermal sprayed aluminium (TSA); however specifiers have been slow to adopt these in Australia. This paper reviews the technology then looks at several projects in New Zealand and overseas, some where a premature failure has occurred, and discusses these and the lessons that should be learned. It concludes with recommendations as to how coating specifications could be improved so that TSM’s potential long life performance can be achieved.  \nKeywords: Thermal metal spray, Protective coating, TSZ, TSA, Specification  \n1. INTRODUCTION  \nThe process of spraying molten metal onto steel was first patented in Switzerland by Dr Schoop and introduced to the UK in 1912, but did not become a commercial reality until the early 1920's [1] . Metal spraying of bridge components (e.g. the Menai Straits Bridge) was carried out in Britain before World War II. Because of the significant reduction in maintenance, flame sprayed zinc supplemented by paint became widely specified by British engineers for many major structures around the world, including the Auckland Harbour Bridge (1958), the Forth Road Bridge (1964), and the Pierre-Laport suspension bridge across the St Lawrence at Quebec (where from 1978-84 some 165,000 sqm was coated after failure of the original paint system) [2] . Use of flame sprayed zinc as a primer declined with the introduction of the self-curing types of inorganic zinc silicates in the 1970's and has since mainly been used to coat steel components that could not be “galvanized”, ie by dipping into a bath of molten zinc. Typical production deposition or melt rates of zinc wire when flame spraying were 10-20 kg/hr.  \nThe arrival of arc spray technology in the mid 1960's greatly increased coating adhesion and gave typical application rates of 10-35 kg/hr using a 2.5 mm maximum sized wire, but the finish of the sprayed metal was rougher and spray efficiencies of 50% were typical. In 1990 high deposition low energy systems became available which were also much lighter and portable. These give deposition rates of 20-90 kg/hr with deposition efficiencies of over 70% when arcspraying 4.8 mm wire. However there was an inherent problem of arc shorting when spraying large diameter wire at low amperages (250-400 A) which was overcome by a patented control system that can adjust the arc gap while spraying in less than 0.02 of a second [3] . This and other recent developments in atomisation control giving smoother finishes have reduced application costs and have made thermal metal spray a very competitive long life coating system.  \nA description of the main processes involved in thermal spray, and a discussion of the advantages and disadvantages of TSM as a protective coating for steel when compared to galvanizing or coating with inorganic zinc silicate, have been given in an earlier paper by the author [4] .  \n2. EXPOSURE TRIALS  \nIn North America the TSM process is known as “metallizing” with early work being carried out by the American Welding Society who in 1953 exposed panels coated with flame sprayed zinc and aluminium and various sealers. Very favourable results were reported after 19, 34 and 44 years of exposure at coastal and industrial sites [5,6,7] . This work was followed  \nCorrosion & Prevention 2012 Paper 167-Page 1  \nup by the US Corps of Engineers with successful trials of TSM as a more abrasion resistant coating than vinyl on dam gates, and which resulted in a comprehensive design manual [8] which is available on the internet.  \nThe US Federal Highway Agency (FHWA) noted [9] that work by the AWS and US Navy showed that “properly applied metallized coatings (zinc, 85% Zinc/15% Aluminum, and Aluminum) of at least ","cbCaia0vhxbhNd7C","https://ap.wps.com/l/cbCaia0vhxbhNd7C","pdf",1906473,11,"English","# Introduction\n# Exposure Trials\n# Standards","[{\"question\":\"What coating systems are discussed for long-term steel protection in marine environments?\",\"answer\":\"The paper focuses on thermally sprayed zinc (TSZ) and thermally sprayed aluminium (TSA) as proven long-term protective coating systems for steelwork in marine exposure.\"},{\"question\":\"What does the paper say about evidence from exposure trials and maintenance-free protection?\",\"answer\":\"It cites long exposure results for metallized coatings, including reports of decades-long performance at coastal and industrial sites, and references to maintenance-free corrosion protection expectations in wet, salt-rich bridge environments.\"},{\"question\":\"Which standards are presented as key references for local specifiers?\",\"answer\":\"The paper names ISO 2063 (and its national equivalents) and the North America joint standard NACE 12/AWSC2.23M/SSPC-CS 23.00, along with supporting guidance standards for specification, operator qualification, and adhesion testing.\"}]","THERMAL METAL SPRAY - SUCCESSES, FAILURES AND LESSONS LEARNED - Willie L Mandeno | PDF",28]