Industrial Services
Thermal Metal Spray (TSA)
Long-term industrial corrosion protection with Thermally Sprayed Aluminium, zinc spray and wire arc spraying.
Makhaya Corrosion Control provides specialist Thermal Metal Spray (TSA) and wire arc spraying solutions for industrial steel assets exposed to harsh, corrosive and high-wear environments. TSA is the system of choice where conventional paint won't last — high-temperature service, splash-zone exposure, aggressive industrial environments and critical structural steel where frequent recoating is not practical or cost-effective.
By combining correct surface preparation, controlled application, thickness inspection and optional sealer or topcoat systems, Makhaya delivers durable corrosion protection designed to extend asset life and reduce maintenance frequency. Our TSA crews are qualified, audited and supported by NACE-trained inspection — every coat is thickness-checked and signed off. Substrate preparation is delivered by our HP and UHP water jetting team, and TSA is often sealed with a topcoat from our industrial lining and coating range for added aesthetic or chemical resistance.
Related services
Where TSA is applied to load-bearing structural steel in fire-exposed environments, it is normally specified together with passive industrial fireproofing. For long-distance pipework in aggressive service, the same TSA system is used by our pipeline fabrication and linings crew on external pipe surfaces before insulation, lagging and cladding.
Where we work & who we serve
Makhaya Corrosion Control delivers thermal metal spray (tsa) and the full range of industrial services across South Africa — including Gauteng, KwaZulu-Natal, the Western Cape, Eastern Cape, Mpumalanga, Limpopo, North West, Free State and the Northern Cape — as well as cross-border into Zambia through our in-country operation, Makhaya Zambia, based on the Copperbelt and serving North-Western, Lusaka, Central and Southern provinces.
Our crews support clients in mining and minerals processing, smelters and refineries, power generation, oil, gas and petrochemical, chemical and fertiliser plants, pulp and paper, water and wastewater, cement and lime, sugar and food processing, steel and heavy manufacturing, and renewable energy — from routine maintenance to full plant shutdowns. See our full industries page or read more about our Zambian operations.
What Is Thermal Metal Spray?
Thermal Metal Spray — also known as TSA or wire arc spraying — is a corrosion protection process where metal wire, usually aluminium or zinc, is melted and sprayed onto a prepared steel substrate to form a protective metallic coating.
In wire arc spraying, two consumable metal wires are fed into a spray gun at a controlled rate. The wires carry opposing electrical charges and melt when they meet. Compressed air then atomises and propels the molten metal onto the prepared surface, where it forms a durable protective coating layer.
The resulting metallic coating provides strong protection against corrosion, erosion, wear and elevated temperatures — making it a valuable solution for demanding industrial applications.
Advantages
Why specify Thermal Metal Spray
Long-Term Corrosion Protection
TSA is specified where extended coating life is required and where frequent recoating would be difficult, expensive or operationally disruptive — critical structures, high-exposure areas and plant equipment that must perform reliably over many years.
No Curing Period
Thermal Metal Spray dries on impact, so there is no conventional curing period between layers. That speeds up turnaround during shutdowns, maintenance windows and fast-track refurbishment work.
Suitable for High-Temperature Service
TSA performs in environments where conventional paint systems fall short — applications exceeding 200°C, including selected process equipment, high-temperature pipework and structural steel exposed to elevated temperatures.
Minimal Heat Distortion
The process transfers far less heat into the substrate than welding or hot-dip processes, reducing the risk of distortion and protecting the integrity of the treated asset.
On-Site or Workshop Application
TSA can be applied in a workshop or on-site depending on asset, access and operational constraints — giving project teams flexibility for new fabrication, refurbishment, shutdowns and maintenance.
Repair & Refurbishment
TSA and zinc spray can be used as a galvanizing-repair procedure where bath size or other constraints make conventional galvanizing impractical, and to refurbish existing protective coatings on aged assets.
Surface Preparation & Quality Control
The performance of Thermal Metal Spray depends heavily on correct surface preparation. Before application, steel substrates must be cleaned and prepared to the required standard so the metallic coating can bond properly to the surface.
Makhaya's TSA work is supported by our in-house HP and UHP water jetting capability, and TSA may be sealed with a topcoat from our industrial lining and coating range where additional aesthetic or chemical resistance is required.
Quality control runs through the entire process — surface preparation checks, application control, coating thickness verification and final inspection before sign-off, all overseen by NACE-trained personnel.
Applications
Where Thermal Metal Spray is used
Video
TSA application in action
Protect critical steel assets with TSA
Thermal Metal Spray is a proven solution for industrial clients who need long-term corrosion protection, reduced maintenance frequency and reliable performance in demanding environments. Contact Makhaya Corrosion Control to discuss TSA, zinc spray or wire arc spraying for your next project.
Contact our team