THERMAL SPRAY & HARDFACING POWDERSTECHNICAL PRODUCT DATA

Zinc & ZnAl15 Anti-Corrosion Spray Powder

99.99% zinc and ZnAl15 spray powders for bridges, offshore and infrastructure steel. ISO 2063 compliant, bulk contractor supply, custom Zn-Al ratios.

Grades: Pure Zn (99.99%), ZnAl15 (85/15)
Application: Arc spray (primary), flame spray
Typical thickness: 100-300 µm (atmospheric), up to 500 µm (immersion)
Design life: 20-30 years (Zn), 30-50+ years (ZnAl15) atmospheric

Zinc & ZnAl15 Anti-Corrosion Spray Powder metal powder product sample

QUICK ANSWER

Performance Defined by Material and Process.

Zinc and zinc-aluminum (ZnAl15) spray powders are applied by arc or flame spray as sacrificial anti-corrosion coatings on steel infrastructure — bridges, offshore platforms, wind towers, pipelines, and water tanks. The coating corrodes preferentially, protecting the steel galvanically for 20-50 years depending on thickness and environment, with ZnAl15 offering roughly double the service life of pure zinc in atmospheric exposure.

Thermal-sprayed zinc (TSZ) and zinc-aluminum (TSA with aluminum, or ZnAl alloy) are the heavy-duty end of corrosion protection, specified by engineers where paint alone cannot deliver the design life: ISO 2063 and AWS C2.23 govern these systems. ZnAl15 (15% aluminum) is the sweet spot — the aluminum addition forms protective alumina films that slow zinc consumption while retaining full galvanic protection. This is a tonnage market driven by infrastructure steel tonnage, and buyers are spraying contractors who buy on deposit efficiency, purity, and price per protected square meter.

MATERIAL DATA

Chemistry and Technical Performance.

Lot-level controls focus on the chemistry, particle characteristics, and process values that influence manufacturing consistency and finished-part performance.

Chemical Composition

TYPICAL

Element	Content	Performance Role
Zinc (Zn)	Balance (99.99% for pure Zn; ~85% in ZnAl15)	Sacrificial anode — corrodes preferentially to protect steel galvanically
Aluminum (Al)	0% (pure Zn) or 14-16% (ZnAl15)	Forms alumina films that reduce zinc consumption rate and extend coating life
Lead (Pb)	< 0.003 wt%	Strictly limited — purity requirement for consistent electrochemistry
Cadmium (Cd)	< 0.001 wt%	Impurity limit per environmental and specification requirements
Iron (Fe)	< 0.005 wt%	Controlled low — iron contamination accelerates coating degradation

Technical Specifications

BASE GRADE

Grades: Pure Zn (99.99%), ZnAl15 (85/15)
Application: Arc spray (primary), flame spray
Typical thickness: 100-300 µm (atmospheric), up to 500 µm (immersion)
Design life: 20-30 years (Zn), 30-50+ years (ZnAl15) atmospheric
Standards: ISO 2063, AWS C2.23, EN ISO 14713
Sealer requirement: Epoxy or vinyl sealer recommended for maximum life

Final limits can be aligned with the agreed purchase specification.

APPLICATIONS

Developed for Demanding Industrial Applications.

Infrastructure is the dominant application

Infrastructure is the dominant application: steel bridges, highway gantries, port cranes, offshore wind transition pieces, transmission towers, and water treatment structures are arc-sprayed with zinc or ZnAl15 before top-sealing. The engineering logic is galvanic protection that works even when the coating is scratched — unlike paint, zinc heals coating defects by corroding sacrificially. Contractors spray on-site or in-shop, and powder/wire consumption scales directly with steel tonnage under protection, making this a stable, specification-driven repeat market.

The second market is industrial equipment and repair

The second market is industrial equipment and repair: tank externals, pipeline sections, structural steel in chemical plants, and marine deck equipment where maintenance painting cycles are expensive. ZnAl15 is increasingly specified over pure zinc because the aluminum addition stretches service life significantly in industrial and marine atmospheres — the difference between recoating at year 25 versus year 40 on structures where access scaffolding costs more than the coating itself.

Zinc & ZnAl15 Anti-Corrosion Spray Powder industrial application detail

THERMAL SPRAY & HARDFACING POWDERS

CUSTOM SUPPLY

A Supply Specification Built Around Your Process.

We supply 99.99% pure zinc and ZnAl15 powders for flame spray and as feedstock for arc spray cored wire production, in standard 45-106 µm cuts with certified purity. Custom Zn-Al ratios (ZnAl5, ZnAl30), magnesium-bearing ZnAlMg variants for extreme marine exposure, and matched sealer-compatible surface grades are available. Bulk packaging to 1-tonne containers for contractor supply programs. Not export-controlled.

We supply 99.99% pure zinc and ZnAl15 powders for flame spray and as feedstock for arc spray cored wire production, in standard 45-106 µm cuts with certified purity.

Custom Zn-Al ratios (ZnAl5, ZnAl30), magnesium-bearing ZnAlMg variants for extreme marine exposure, and matched sealer-compatible surface grades are available.

Bulk packaging to 1-tonne containers for contractor supply programs.

MATERIAL COMPARISON

Compare Materials Against the Production Requirement.

ZnAl15 vs Pure Zinc Spray

Comparison Point	This Product	Pure Zinc (TSZ)
Service life (atmospheric)	30-50+ years	20-30 years
Galvanic protection	Full — retained	Full
Marine/industrial performance	Superior — alumina film slows consumption	Faster consumption rate
Cost per kg	~15-25% higher	Baseline
Cost per year of protection	Lower	Higher
Immersion service	Good with sealer	Preferred for freshwater immersion

Thermal Spray Zinc vs Hot-Dip Galvanizing

Comparison Point	This Product	Hot-Dip Galvanizing
Part size limit	None — spray any structure	Limited by kettle size
On-site application	Yes — field repair and erection welds	No — factory process only
Coating thickness control	100-500 µm, adjustable	Fixed by steel chemistry, ~85 µm typical
Heat distortion risk	None — cold process	Possible on thin fabrications
Sealed duplex systems	Standard practice (spray + paint)	Possible but less common
Best fit	Large structures, field work, thick coats	Small parts, high volume, factory runs

TECHNICAL FAQ

Technical Questions About This Grade.

Need a different chemistry, particle range, or processing route? Our material team can review the requirement and supply window.

When should I specify ZnAl15 over pure zinc?

For atmospheric exposure in marine or industrial environments where design life exceeds 25-30 years, ZnAl15 is almost always the better economic choice. For freshwater immersion and alkaline exposure, pure zinc remains the traditional preference.

Does the coating need a sealer?

Recommended but not mandatory. An epoxy or vinyl sealer over the sprayed zinc roughly doubles the life-to-first-maintenance by blocking the pores that accelerate zinc consumption. Sealed duplex systems are the standard specification for critical infrastructure.

What surface preparation is required?

Grit blasting to Sa 2.5-3 with a 50-100 µm angular profile. The coating bonds mechanically, so blast quality determines coating life as much as powder purity does.

Can it be applied over welds and existing galvanizing?

Yes — sprayed zinc is the standard repair method for galvanized coating damage and weld zones, restoring galvanic continuity without stripping the original coating.

Is zinc spray powder export-controlled?

No. Zinc and zinc-aluminum powders are unrestricted.

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