Galvanizing protectionwithout the galvanizing plant
Cold spray zinc deposits a zinc layer of over 96% at ambient temperature. Apply it on site, on structures that are already erected, with a brush, roller or spray gun — no thermal deformation, no transport, no plant outage.
01 — Cold Spray Zinc
Why cold spray zinc replaces hot-dip galvanizing
Hot-dip galvanizing needs the part to travel to a plant, be dipped at 450 °C, and come back. Cold spray zinc is applied where the steel already is.
| Cold spray zinc (ZD96-1) | Hot-dip galvanizing | |
|---|---|---|
| Zinc content | ≥96% metallic zinc in dry film | ≥98% (molten bath) |
| Application temperature | Ambient (5–40 °C) | 450 °C molten zinc |
| Thermal deformation | None | Risk on thin / long members |
| Where applied | On site, on erected structures | Must travel to a plant |
| Plant outage | None | Dismantling and transport |
| Max component size | Unlimited | Limited by bath size |
| Surface repair | Repairable in place by brush or aerosol | Damaged coating bares the steel |
| Recoat / topcoat | Accepts full paint system | Requires specialised adhesion primer |
| Design life | 25 years (manufacturer figure) | 25–50 years depending on class |
| Colour | Zinc grey, or overcoat any RAL | Zinc grey only |
Technical note · 10 min read
Cold galvanizing vs hot-dip: the comparison most articles get wrong
Zinc mass per square metre, not thickness in microns, is what decides whether cold spray can replace hot-dip. The arithmetic, the boundary cases, and where the substitution fails.
Read the note →02 — Products
The coating system
One compatible system — from cold spray zinc through intermediate coats to topcoats, so you never mix incompatible chemistries on the same structure.
ZD96-1 Cold Spray Zinc
Standard type · ≥96% Zn
Technical data →ZD83-02 Zinc-Aluminium Coating
Single coat · silver metallic finish
Technical data →ZD6080 Epoxy Zinc-Rich Primer
Two-pack · ≥80% Zn in dry film
Technical data →ZD6180 Epoxy Primer for Galvanized Steel
Two-pack · bonds to galvanized zinc
Technical data →ZD6430 Aliphatic Polyurethane Topcoat
Two-pack · colour and gloss retention
Technical data →Zinc-rich Primers
Two-component high-solids epoxy zinc-rich and zinc-aluminium primers for cathodic protection on blast-cleaned steel.
Galvanized steel · SealerIntermediate Coats
Epoxy primers engineered for hot-dip galvanized surfaces and tie-coats between primer and topcoat.
Polyurethane · Metallic sealerTopcoats
Aliphatic polyurethane topcoats and metallic sealers for UV-stable colour and gloss retention over zinc-rich primers.
Low VOC · DTMWater-borne Coatings
Low-VOC water-borne acrylic direct-to-metal coatings for light to moderate corrosive environments.
03 — Projects
Projects
Cold spray zinc in service on bridges, wind towers, power infrastructure, port machinery and tanks.
Cross-sea cable-stayed bridge — steel box girder and tower
Marine atmosphere at C5-M. Cold spray zinc was applied as the base layer on the steel box girder and tower segments that could not be sent to a galvanizing bath, then sealed and finished with an aliphatic polyurethane topcoat. Application was carried out in the fabrication yard on completed segments, avoiding post-assembly touch-up over the water.
Offshore wind towers — internal and external protection
Salt spray and constant humidity at the coast. Tower sections received cold spray zinc on the external surface followed by an epoxy intermediate and a polyurethane topcoat; the internal surface used the same base with a lighter build. The single-component format removed mixing errors across multiple application crews working in parallel.
Transmission line lattice towers — field repair of galvanized steel
Galvanized lattice towers in a mountainous corridor had developed white rust and local red rust at bolt heads, weld seams and cut edges. Cold spray zinc was applied by brush and roller for in-place remediation without dismantling the towers or interrupting the line, restoring sacrificial protection at the damaged points.
04 — Ready stock
Stock in hand, packed the way it ships
Photographs taken in the warehouse we ship from in Shanghai — not renders. What you see is what gets loaded: pails strapped to pallets, a UN 1263 Class 3 label on every drum, racked stock waiting for the container booking.
Photographs taken at the warehouse in Shanghai. Marks and brand names on packaging belong to their respective owners.
05 — FAQ
Frequently asked questions
Can cold spray zinc replace hot-dip galvanizing?
For most C3 and C4 structures, yes. The dry film contains over 96% metallic zinc and protects steel the same way a galvanized coating does — the surrounding zinc becomes the anode when the coating is scratched to the steel. Hot-dip galvanizing still wins where the part fits a bath and the 25-year-plus life in C5 immersion is specified; cold spray zinc is the practical answer for large welded structures, repairs on site and anything that cannot be transported.
What surface preparation does it need?
Sa 2.5 to ISO 8501-1 with an angular profile of Rz 40–75 µm, and priming within four hours of blasting. The zinc bonds by mechanical and electrical contact, so a surface that is only wire-brushed leaves the sacrificial circuit open and the coating fails early. In repair work on existing galvanized steel, degrease, wash off soluble zinc salts with high-pressure fresh water, then abrade local rust before application.
How long does it last, and how many coats are needed?
The ZD96-1 system is specified for a 25-year design life in C3–C4 within a full coating system. In C3 environments the zinc can be used alone as a single coat at 60–80 µm; from C4 upward it is the base of a system — zinc, then an intermediate or sealer such as ZB18-12, then a polyurethane topcoat such as ZD6430 for colour and gloss retention.
Is it a dangerous good for shipping?
Yes. Solvent-borne grades ship as dangerous goods under UN transport regulations. We classify each SKU, issue the MSDS in the buyer's language and arrange the export packaging certificate needed for the booking, then ship from Shanghai or Ningbo on FOB, CFR, CIF or DAP terms.
How is it priced, and what is the minimum order?
Priced per litre delivered, not per drum list price, because the consumption per square metre is what drives project cost. Send the structure, the steel condition, the area and the corrosivity category and you get back a system, film builds and a delivered price. Orders start from one pallet for stock items; made-to-order batches follow the factory schedule.
Not sure which grade fits your environment?
Send us the structure, the steel condition and the corrosivity category (C2 to CX). We reply with a coating system, film builds and a delivered price.