Aluminium Thermal Metal Spraying (TSA)
Long-lasting corrosion protection for steel structures. At TMF – Total Metal Finishing Ltd, we provide Aluminium Thermal Metal Spraying (TSA) to protect steel components operating in some of the harshest environments — from offshore structures and marine equipment to bridges, industrial plant and heavy engineering projects.
What is Thermal Spray Aluminium?
Thermal Spray Aluminium (TSA) is a process where aluminium wire is melted and sprayed onto a prepared steel surface using specialist equipment.
The molten aluminium forms a tough metallic coating that bonds to the steel, creating a highly effective barrier against corrosion. Unlike paint, TSA becomes part of the protective system itself, providing long-term protection even in aggressive environments. It's suitable for both new manufacture and refurbishment projects.
How Does TSA Protect Steel?
One of the biggest advantages of Thermal Spray Aluminium is the way it protects steel in two ways.
- Barrier Protection — the aluminium coating seals the steel from moisture, oxygen and other contaminants that cause corrosion
- Sacrificial Protection — if the coating is damaged, the aluminium continues to protect the exposed steel through galvanic action, helping to prevent corrosion from spreading
Why Choose Thermal Spray Aluminium?
Compared with many conventional coating systems, TSA offers several important advantages.
- Outstanding corrosion resistance
- Excellent performance in marine and coastal environments
- Long service life
- Minimal maintenance
- Low heat input during application
- No distortion of fabricated components
- Excellent adhesion to prepared steel
- Suitable for duplex coating systems
- Ideal for new manufacture and refurbishment projects
Our Thermal Spraying Process
Every project follows a carefully controlled process to ensure the best possible results.
- Project Assessment — reviewing the component, operating environment and coating specification to determine the most suitable solution
- Surface Preparation — abrasive blast cleaning to create the surface profile needed for maximum coating adhesion
- Thermal Metal Spraying — molten aluminium is applied in multiple passes until the required coating thickness is achieved
- Inspection — the finished coating is inspected and measured to ensure it meets the required specification
- Sealing & Topcoats — where required, the aluminium coating can be sealed or over-coated with compatible paint systems for even greater protection
Where is TSA Used?
Thermal Spray Aluminium is commonly specified for steelwork exposed to demanding environments.
- Offshore structures
- Marine equipment
- Coastal infrastructure
- Bridges
- Structural steel
- Water treatment facilities
- Industrial pipework
- Storage tanks
- Process plant
- Heavy engineering fabrications
- Energy infrastructure
Why Choose TSA Instead of Galvanising?
Hot-dip galvanising is an excellent solution for many applications, but Thermal Spray Aluminium is often preferred when:
- Components are too large to galvanise
- On-site repairs or refurbishment are required
- Existing structures cannot be dismantled
- Fabrications need to avoid heat distortion
- Marine or offshore performance is critical
Duplex Coating Systems
For maximum durability, TSA can be combined with a compatible paint system. The paint provides colour and additional environmental protection, while the aluminium continues to protect the steel beneath.
- Abrasive shot blasting
- Aluminium Thermal Metal Spraying
- Sealer (where required)
- Industrial primer
- High-performance topcoat
Quality You Can Trust
Every project is completed under controlled production conditions and inspected throughout the process.
- Surface preparation
- Blast profile verification
- Coating thickness measurement
- Visual inspection
- Batch traceability
- Process documentation
Industries We Support
We provide Aluminium Thermal Metal Spraying for customers across a wide range of industries. Every project is assessed individually to ensure the most suitable corrosion protection system is selected.
- Offshore Oil & Gas
- Marine
- Renewable Energy
- Utilities
- Water & Wastewater
- Construction
- Heavy Engineering
- Defence
- Infrastructure
- Industrial Manufacturing
Why Choose TMF?
TMF offers a complete range of industrial finishing services from one facility, making us a single source for corrosion protection and metal finishing.
- Aluminium Thermal Metal Spraying (TSA)
- Industrial Shot Blasting
- Powder Coating
- Wet Paint Spraying
- Electrophoretic Deposition (E-Coat)
- Chemical Pre-Treatment
Frequently Asked Questions
Common questions
Talk to Our Team
If you're looking for a corrosion protection system that delivers long-term performance in demanding environments, our team can help. Whether it's a new fabrication or an existing structure, we'll recommend the most suitable Thermal Spray Aluminium solution for your project.
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