In the world of protective coatings, Hot Zinc Spray and Zinc Flame Spray have emerged as two highly effective methods for corrosion protection. Both techniques offer distinct benefits and operate on unique principles. This article delves into how each works and evaluates if one outperforms the other in specific contexts.

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Understanding Hot Zinc Spray

Process and Benefits

Hot Zinc Spray, also known as metallising, involves the application of zinc coating to a substrate for corrosion protection. The process is straightforward yet highly effective:


  • Preparation: The surface is cleaned and prepared, typically through abrasive blasting, to ensure proper adhesion.
  • Heating: Zinc wire is fed into an arc spray gun.
  • Spraying: The material is melted by electrically charging it and then propelled onto the substrate, forming a protective layer.


  • Corrosion Resistance: Zinc acts as a sacrificial anode, corroding in place of the underlying metal.
  • Durability: The coating is robust and can withstand harsh environments.
  • Versatility: Suitable for a variety of structures, including bridges, tanks, and marine applications.
  • Environmentally Friendly: Generates no toxic by-products.

Exploring Zinc Flame Spray: Process and Advantages

Zinc Flame Spray, sometimes referred to as flame metallising, utilises a similar approach but differs slightly in technique:


  • Surface Preparation: Like Hot Zinc Spray, the surface is cleaned and prepared.
  • Melting and Spraying: Zinc powder is melted in a flame spray gun and sprayed onto the surface. However, this method often uses a combustion of gases (like acetylene and oxygen) to create a higher temperature flame.
  • Application: The molten zinc is sprayed onto the surface, forming a coating.


  • Effective Corrosion Protection: Provides excellent protection against rust and corrosion.
  • High Purity: The high-temperature flame can result in a purer zinc coating.
  • Flexibility in Application: Can be applied to complex shapes and sizes.
  • Cost-Effective: Generally more economical than other coating methods.

Comparing Hot Zinc Spray and Zinc Flame Spray

While both methods serve the same primary purpose of corrosion protection, they have their unique advantages:

  • Temperature of Application: Zinc Flame Spray typically operates at a higher temperature, which can result in a purer and potentially more durable coating. However, this can warp the metal surface if it gets too hot. Hot Zinc Spray operates at a much lower temperature, so it is ideal for metals that could be subject to warping under heat.
  • Suitability for Different Applications: Hot Zinc Spray might be more suitable for larger, industrial projects due to its robustness, and the investment needed in rolls of zinc wire. While Zinc Flame Spray could be preferable for more occasional use.

Conclusion: Is One Better Than the Other?

Determining whether Hot Zinc Spray or Zinc Flame Spray is superior depends on the specific requirements of the project. Both methods offer excellent corrosion protection, and durability, and are environmentally friendly. The choice ultimately hinges on the specific application, the desired thickness of the coating, and the project’s budget.

For large-scale industrial applications where robustness is key, Hot Zinc Spray might be the preferred method. Conversely, for smaller projects requiring or cost-effectiveness, Zinc Flame Spray could be more suitable.

In summary, both Hot Zinc Spray and Zinc Flame Spray are invaluable in the protective coatings industry, each with its unique set of benefits. The decision between the two should be based on a thorough evaluation of the project’s specific needs and goals.

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NSP Coatings and Metallisation Limited: A Partnership for Quality

NSP Coatings elevates its Hot Zinc Spray service by utilising equipment from Metallisation Limited. This collaboration ensures high-quality application processes, aligning with NSP’s commitment to excellence in protective coatings. Metallisation Limited’s equipment enhances the efficiency, precision, and quality of the Hot Zinc Spray method, making NSP Coatings a top choice for clients seeking reliable and superior corrosion protection solutions.


While both Hot Zinc Spray and Zinc Flame Spray offer effective corrosion protection, the choice between them should be project-specific. NSP Coatings, with its use of top-tier equipment from Metallisation Limited, stands as a testament to the importance of quality and precision in protective coatings. This partnership not only reinforces NSP’s commitment to excellence but also ensures that clients receive the best possible solution for their corrosion protection needs.