Stainless  Restora​tion Ltd

Metal Finishing and Surface Engineering Technologies

Shot Blasting / Painting / Coating Services

Surface Engineers almalgamated with Stainless Restoration Ltd in early 2017 to form what is a very large and very capable blasting and painting facility in the north of England.

Surface Engineers specialise in abrasive blast cleaning and the application of protective coatings.

All coating applications are monitored on site and many tests are performed which are necessary to ensure the long term performance of the coating. This includes on site monitoring of climatic conditions, surface preparation, application of the coatings, wet film and dry film measurement.

We regularly shot blast and coat large, heavy duty applications/items in fully enclosed facilities for both shot blasting and coating. All Spray booths are heated producing  the correct climatic conditions before, during and after the coating process. 

 Coating Brochure

Our primary focus is on the application of protective coating systems that provide excellent corrosion control at the best value.

Stainless Restoration Ltd, Adamsons Industrial Estate, Hyde SK14 1EE

Coating Systems

T​hese high quality, cost effective surface preparation and protective coating systems are applied at our extensive 75,000 square foot processing and storage facility, with handling capacity up to 30 tonnes, in east Manchester.

Thermal Spray

ZInc or Aluminium

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Industrial Coating

NACE Certified Painting

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M501 Epoxy

Zinc Clad IV EU

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Powder Coating

Polymer Resin Systems

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Industrial Coating

In order to achieve a quality, reliable and long lasting coating, Surface Engineers follow good coating practices in line with recognised national and international standards. In short, the surface is prepared by abrasive blasting to create a surface profile which acts as an anchor for the coating. Surface preparation is to a coating system what a foundation is to a building. If a coating system has a poor foundation (Surface preparation) it will fail sooner than expected which can lead to great financial losses. Furthermore, any moisture on the surface will cause the coating to fail and therefore climatic conditions are measured prior to coating to prevent any failures. Single or multi coat systems are applied in line with customer or paint manufacturer's specifications. The wet film coating thickness is then measured, to check that it will cure to the specified dry film thickness. Finally, the dry film thickness is measured to ensure it complies with the specification.

Several very important processes are followed throughout the coating process:

  • Surface preparation: Abrasive blast to customer and/or paint manufacturers specification
  • Measurement of surface profile to customer and/or paint manufacturers specification
  • Climatic conditions (Dew point, relative humidity, surface temperature, air temperature)
  • Immediately after coating the wet film thickness is measured
  • After the coating has cured the dry film thickness is measured
  • Individual inspection for each layer for multiple coat applications.

Surface Preparation

Surface preparation is the essential first stage treatment of a substrate before the application of any coating. The performance of a coating is significantly influenced by its ability to adhere properly to the substrate material. It is generally well established that correct surface preparation is the most important factor affecting the total success of surface treatment. It affects the performance of the coating more than any other variable.

Surface preparation creates a foundation for the coating mechanically and chemically:

Mechanically: By providing an anchor/key for the coating
Chemically: By allowing intimate contact of coating material molecules with the steel (or other material) surface
Steel, when it is abrasive blasted, has a surface that is rough, with a series of tiny peaks and valleys called surface profile. Coatings anchor to the valleys of the profile and the peaks are like teeth. This is why the surface profile, created by blasting is called an "Anchor pattern" or a "Mechanical tooth".

The surface is blasted to standard grades of cleanliness in accordance with ISO 8501-1 1988 (BS 7079 Part A1 1989). This standard essentially refers to the surface appearance of the steel after abrasive blast cleaning and gives descriptions with pictorial references of the grades of cleanliness. Generally, Class Sa 2.5 is the most common:

Sa 1: Light blast cleaning
Sa 2: Thorough blast cleaning
Sa 2.5: Very thorough blast cleaning
Sa 3: Blast cleaning to visually clean standard

Abrasives Used
  1. Chilled Iron abrasive (For Carbon Steel)
  2. Aluminum Oxide (For Stainless Steels Duplex)
  3. Garnet (Light blast cleaning of non Ferrous substrates)
  4. Bristle Blaster (Mechanical surface preparation still achieving a suitable surface profile)
  5. Glass Bead (for enhancing the appearance of Stainless Steels)

Surface Profile

The surface profile is specified independently from cleanliness. The surface profile is created by the abrasive blasting. The correct height of the surface profile is essential, as it effects the coatings overall performance. There is no standard surface profile height that is suitable for all coatings. Basically, the surface must be roughened to get the coating to adhere to the surface. This is specified by the coatings (Paint) manufacturer. Generally, thin coatings require a low anchor profile. Too heavy a profile will result in the peaks of the profile in the steel sticking out and causing pin point rusting. However, thick coatings require a deep anchor.

Surface Preparation Testing

To ensure the correct level of surface preparation has been achieved various tests are carried out to the relevant international standards.

Elcometer 123 Surface Profile Gauge

Surface Profile Gauges are used to measure the profile height of a surface. The degree of the surface profile on the surface affects a coating's overall performance and determines aspects such as adhesion, coverage and overall volume of coatings used. If the surface profile is too large the amount of coating required increases, otherwise there is a danger that the peaks remain uncoated - allowing rust spots to occur. If the surface profile is too small there may be insufficient key for adequate adhesion leading to premature coating failure.
 
To ensure the correct surface preparation optimises the performance of the coating and material usage, the profile height of a surface needs to be accurately assessed and measured. It is essential to know this parameter as it determines the adhesion, coverage and overall volume of coating used.

Elcometer 138 Bresle Salt Kit.

It is essential that the level of contaminants on a surface is measured prior to application of the coating to ensure the quality of the coating and that its optimum lifetime is achieved.

If the coating is applied to a contaminated surface, which is not properly prepared, it could fail prematurely resulting in costly re-coating and high maintenance costs.
The Elcometer 138 Bresle Kit includes the This lightweight, portable conductivity meter accurately measures the salinity of the test samples.

The cartridge type sensor can be easily replaced when necessary and displays conductivity (µS/cm and mS/cm) and salinity (%) on the digital display.

Elcometer 142 ISO 8502 Dust Test

The Elcometer 142 Dust Tape Test kit allows assessment of the quantity and size of dust particles on surfaces prepared for painting. Dust on blast cleaned surfaces can reduce coating adhesion, leading to premature coating failure and sub-standard coating finish.

Elcometer 128 Pictorial Surface Standards

Pictorial Surface Standards are high quality photographs which are used for comparison purposes to assess the visual appearance of a steel surface. Elcometer's range of Surface Standards covers most of those required for surface cleanliness.

Climatic Conditions

Optimal environmental conditions are essential for surface preparation, application, and curing of coatings to maximise successful performance.Surface preparation and the application of coatings should be performed under optimum environmental conditions to help prevent failures. The following conditions should be observed:

Air temperature
Surface temperature
Relative humidity (RH)
Dew point temperature
Delta T: The difference between the surface and dew point temperatures

It is commonly known that most coatings will not dry properly at low temperatures and high RH. Surface moisture has a significant impact on the life and performance of the coating.Moisture forms on a surface when warmer, moist air comes into contact with it (condensation). Moisture will cause unprotected steel to rust. If it is trapped between a coating and a substrate, moisture will likely cause the applied system to fail prematurely.Instruments are used  to help assess the risk of moisture forming on the surface. Tests are performed to calculate the dew-point temperature before, during and after the coating process. Dew-point temperature is compared to the surface temperature to ensure the two are far enough apart that moisture formation is unlikely.Careful observation of atmospheric conditions and a good understanding of their impact on the quality and long term health of coating are essential.

Thermally Sprayed Zinc / Aluminium

Metal or thermal spraying is a technology, which protects and greatly extends the life of a wide variety of products in the most hostile environments and in situations where coatings are vital for longevity. The variety of metallised coatings is vast but can be broken down into two main categories. These include finishing coatings, such as anti-corrosion or decorative coatings, and engineering coatings such as wear resistant and thermal barrier coatings.

Metal spraying is carried out in a wide range of anti corrosion and engineering markets, including oil and gas, construction, petrochemical and marine. Corrosion is a major problem for these industries. There are four commonly used processes in thermal spraying; Flamespray, Arcspray, Plasma Spray and High Velocity Oxygen Fuel (HVOF), but only two of these, Flamespray and Arcspray are normally used for finishing coatings.

TSA

All methods of thermal spraying involve the projection of small molten particles onto a prepared surface where they adhere and form a continuous coating. To create the molten particles, a heat source, a spray material and an atomisation/projection method are required. Upon contact, the particles flatten onto the surface, freeze and mechanically bond, firstly onto the roughened substrate and then onto each other as the coating thickness is increased.

As the heat energy in the molten particles is small relative to the size of the sprayed component, the process imparts very little heat to the substrate. As the temperature increase of the coated parts is minimal, heat distortion is not normally experienced. This is a major advantage over hot-dipped galvanising.

In the Arcspray process, two electrically charged wires are driven and guided so that they converge at a point and form an arc. An air nozzle atomises the molten metal produced and projects it towards the work piece. The driving of the wires is typically either by air motor or electric motor and gearbox arrangement. The wires can be driven in three different ways, all which offer individual benefits.

Push only, where the wire is pushed from a drive unit to the pistol. Pull only, where the wire is pulled by a drive unit mounted in the pistol. Push/Pull, this method is obviously a combination of these two methods, where the wire is driven to and pulled from the pistol. Wire can typically be dispensed from portable MIG reels, coils or production packs (drums) depending on the application requirements.

TSA Flame

Flame or arc ?

This sounds like it should be an easily answered question, but, as with many engineering situations, a clear and precise answer is not available. In some instances, the coating properties achievable by one or the other processes does provide a simple answer. For example, arc sprayed aluminium has a bond strength that is approximately 2.5 times higher than flame sprayed aluminium. Other factors include deposit efficiency, ease of operation, safety/spray environment, changeover time, maintenance time and costs, coating finish and ease of automation.The above considerations give an insight into the wide range of variables when choosing which process to use. It is worth mentioning that a matter of personal or local market preference can also be added into the decision matrix.

Effectiveness of metallised coatings

Thermal Spraying is not a new process. It has proved itself to be extremely effective in the 90 years of its existence in all manner of applications ranging from coatings in gas turbines to corrosion protection on park benches. As a protective system for structural steelwork it is unsurpassed being the only system, recommended by International and European standards EN ISO 14713 as giving greater than 20 years to first maintenance in very aggressive environments such the marine splash zone (category lm2) as well as all other categories.

Norsok M501

Specialist Epoxy Paint Systems
M501 Norsok

With over 42 years in the preparation and application of wet paint systems we have experience in the processes and techniques of a wide range of paint products and their specific applications. Wet paint systems are employed for both anti corrosion protection and for cosmetic finish purposes from single coat primer applications to multi-coat two-pack systems. Hi-build two-pack system will offer long life corrosion protection in excess of 20 years in the harshest of environments.

We draw from an extensive range of paint manufactures producing polyurethane and epoxy systems that can provide protection in temperatures from -30°C up to 400°C from splash zone and immersed or sub-sea conditions to desert and aggressive industrial environments.

The NORSOK standard gives the requirements for the selection of coating materials, surface preparation, application procedures and inspection for protective coatings to be applied during the construction and installation of offshore installations and associated facilities. The standard covers paints, metallic coatings and application of spray-on passive fire protective coatings.

The aim of the NORSOK standard is to obtain a coating system, which ensures.



Our applicators are trained to the requirements of the Norsok M501 standard on various systems and have passed rigorous practical and theoretical testing to ensure specification compliance. Records are available for our operators and Inspectors giving the customer the confidence that the contract is dealt with by professionals and in a professional manner.
We have approvals for many major projects around the world and are the preferred suppliers to a number of OEMS in the UK.

We would be more than happy to discuss Project specific requirements.

Powder Coatings

Epoxy and polyester powder coatings baked on to prepared metalwork to provide a hard wearing decorative finish.

We offer effective coatings solutions for a wide range of applications, including furniture, automotive, IT, appliance, the architectural market and general industry.

Range of colours available from stock.

Powder coatings are used when a hard finish which is tougher than conventional paint is required. Basically anything capable of holding a small electrical charge can have powder applied to it. It is usually used for coating metals, however, newer technologies allow other materials such as MDF and even glass and ceramics to be coated using different coating methods.
Powder application is very simple. The powder is applied to an object using an electrostatic gun. Compressed air pushes the powder out of the gun, past an electrode which gives the powder a positive charge. The object being coated is grounded so the positive powder particles are attracted to it. When the object is completely covered, the ground is removed and the object is put into the oven to be baked. While in the oven, the powder goes through a chemical change where it becomes free flowing and forms a ‘skin’ around the object. After cooling, the powder is ‘set’ and forms a hard finish.
Powder can be applied to items kept inside; including washing machines and lighting and also to exterior items including architecture and fencing. Powders are capable of withstanding extreme environments, thanks to our intensive testing procedures. The levels of powder durability are dependant on the mix of ingredients used.

Powder Coat
Advantages of Powder Coatings