Thermal Sprayed Aluminum (TSA) Corrosion Protection System - Technical Data & Application Overview

Sep 18, 2026

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Thermal Sprayed Aluminum (TSA) Corrosion Protection System is a durable solution for the offshore oil & gas industry, delivering total corrosion protection and extending service life compared with conventional barrier coatings. The system uses self-healing edges, tolerates limited bare surface, and eliminates the need for additional cathodic protection. It reduces reliance on sacrificial anodes, supports applications across marine, atmospheric, subsea, and high-temperature environments, and can be handled immediately after application. It applies via electric arc spraying with documented bonding performance and long-term use in seawater and saline mud.

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Overview

User Benefits

Typical Uses

Application Process

Technical Data

Thermal Sprayed Aluminum (TSA) Corrosion Protection System For The Offshore Oil & Gas Industry Description Sermatech’s Thermal Sprayed Aluminum (TSA) Corrosion Protection System is an extremely durable system that provides total corrosion protection and significant life improvement over conventional barrier coatings. The TSA Corrosion Protection System features self-healing edges, can tolerate a 4 - 6% bare surface and does not require additional cathodic protection. It is ideally suited for a variety of marine, atmospheric, subsea and high temperature applications. Users will realize significant savings in installed and long-term maintenance costs because the need for sacrificial anodes is reduced and coating repair is unnecessary. User Benefits The TSA Corrosion Protection System offers a wide range of benefits: • Minimum need for maintenance • Low cost • Superior adhesion • Excellent service life • Resistant to mechanical damage • No health hazard from solvents or other organic substances • No drying/curing time; can be handled almost immediately after application • Operating temperature range: -50°F to 1000°F (-45°C to 538°C) • Provides a sacrificial anode effect on steel in marine environments • Fast turn times A buoyancy can (9. 5’ in diameter x 180’ long) coated with the TSA Corrosion Protection System craned into a spar platform. The production riser and keel piping also were coated with the TSA Corrosion Protection System. The TSA Corrosion Protection System functions as the sole source of corrosion protection for subsea piping. Sermatech Texas 7615 Fairview Houston, TX 77041 Phone: 713-849-9474 Fax: 713-983-0631 Sermatech California 18502 Laurel Park Rd Compton, CA 90220 Phone: 310-604-0018 Fax: 310-635-3569 [www.sermatech.com](www.sermatech.com) SSE-03A 05/06 Distributive Anode In addition to being a barrier coating, the pure aluminum metal in the TSA Corrosion Protection System, when coupled with metals like steel (or those lower on the galvanic scale), will act as a sacrificial anode in a subsea environment. Rather than having to place anodes at certain intervals, the TSA Corrosion Protection System distributes sufficient anodic material over the full length of the component and functions as the sole source of corrosion protection for more that 30 years in seawater and saline mud with as much as 5% holidays. Typical Uses The TSA Corrosion Protection System is highly effective in a wide range of demanding applications for the offshore oil & gas industry. Some typical applications are listed below: • Risers - Production - Drilling -Catenary • Subsea Pipelines • Buoyancy Cans • New Offshore Platforms • Platform Retrofits • Dock Pilings & Fenders • Lifeboat Stations • Flare Booms • Access Bridges • Escape Staircases • Splash Zone Steelwork • Ship Topsides Estimated Service Life of the TSA Corrosion Protection System. Application Process Sermatech is a premier applicator of the TSA Corrosion Protection System and uses a specialized process to apply high quality aluminum metal for corrosion control. Electric arc spraying feeds two electrically conducting aluminum metal wires towards eachother and produces an electric arc at the point just before the two wires meet. As the arc melts the metal wires, a high pressure air line is used to spray fine droplets onto the properly cleaned and prepared steel surface. The arc spray process results in superior bonding (2000+ psi; ASTM C633) and high productivity. Sermatech has developed an automated process for applying the TSA Coating Protection System to piping up to 75 feet long. The TSA Corrosion protection System can be applied both manually and by an automoated process specifically designed for straight run pipe in sizes from 3 to 39 inches in diameter. Length capability for automated metallizing of piping is 25 to 75 feet. Internal diameter (I. D. ) of piping can also be coated.

FAQs

What makes the TSA Corrosion Protection System different from conventional barrier coatings?

The TSA system provides total corrosion protection with self-healing edges and improved life versus conventional barrier coatings, reducing maintenance needs and extending service life.

Does the TSA system require additional cathodic protection or sacrificial anodes?

No. It does not require additional cathodic protection, and it reduces the need for sacrificial anodes by distributing sufficient anodic material along the component.

How is TSA applied to steel surfaces?

Sermatech uses an electric arc spraying process that melts aluminum wires and sprays fine droplets onto properly cleaned and prepared steel, producing superior bonding performance.

Sep 18, 2026

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