In-Situ Service
Boiler Tubes Coating
In-situ thermal spray coating of boiler tubes inside operating power plants, cement plants, paper mills, and oil refineries — preventing high-temperature coal ash erosion and sulfidation.
About Thermal Spray Engineering
DISCOVER OUR STORY
Leading Thermal Spray & Industrial Surface Engineering Company
Welcome to Thermal Spray Engineering Established in 2007 in Ahmedabad, Gujarat, we have grown into India's most trusted source for advanced thermal spraying, surface engineering, and industrial anti-corrosion coating services.
Our cutting-edge Thermal Spray Coating and industrial painting solutions are engineered to significantly extend the operational lifespan of industrial assets while reducing maintenance costs. We serve key industries including Power Plants, Steel, Oil & Gas, Refineries, Cement, Chemical, and Offshore Marine across India.
Advanced Technology
HVOF, Twin Wire Arc & Flame Spray systems.
ISO Certified
Strict adherence to international coating standards.
Our Specializations
Thermal Spray Coating Services & Solutions
Comprehensive surface engineering services covering boiler tube protection, corrosion coatings, wear-resistant hardfacing, in-situ grinding, blasting, and industrial painting.
In-Situ Service
HVOF / TWAS
Thermal Spray Process
Full range of thermal spray processes including High Velocity Oxy-Fuel (HVOF), Twin Wire Arc Spray (TWAS), Flame Wire Spray, and Flame Powder Spray for all industrial applications.
Corrosion Barrier
Thermal Spray Aluminium (TSA) Coating
Highly reliable thermal spray aluminium coatings for marine, pipeline, offshore, and industrial applications in India — providing long-term sacrificial corrosion protection.
Why Partner With Us
Why Choose Thermal Spray Engineering TECHNO SERVICES?
Locally Trusted & Experienced
Operating since 2007 with hundreds of successful thermal spray projects across power, steel, and chemical plants in India.
Provide Quality Service
Strict quality management ensuring consistent coating thickness, bond strength, and microstructural integrity on every project.
One Stop Solution
From initial surface preparation, grit blasting, alloy thermal spraying, to final in-situ grinding and quality testing — under one roof.
Customized Approach
Tailored alloy chemistry and spraying parameters specifically selected for your operating temperature and chemical environment.
ISO Certified
All our thermal spray processes and quality inspection procedures comply with international ISO and industry-specific standards.
Best Customer Service
Rapid response field crews with 24/7 support for emergency boiler shutdown repairs and tight plant maintenance turnarounds.
Engineering Excellence
Thermal Spraying Capabilities & Processes
Our thermal spray processes involve heating metallic or ceramic alloy materials to a molten or semi-molten state and propelling them at high velocity onto prepared substrate surfaces.
Thermal Spray Process
Advanced surface engineering technique that deposits finely divided molten or semi-molten metallic, cermet, or ceramic particles at supersonic velocities onto prepared substrates to deliver exceptional wear and corrosion resistance.
High Velocity Oxy-Fuel (HVOF)
Supersonic combustion spray producing extremely dense coatings (>99% density) with low oxide content and superior bond strength (>70 MPa). Ideal for wear plates, valve seats, and turbine components.
Twin Wire Arc Spray – TWAS System
Uses an electric arc between two consumable wire electrodes to deliver rapid high deposition of aluminium (TSA) and zinc (TSZ) coatings for large-area corrosion protection.
Flame Wire Spray Process
Economical oxy-acetylene or propane combustion wire spray process for dimensional restoration, bearing journals, and corrosion barrier application on industrial shafts and machinery.
Flame Powder Spray Process
Precision combustion spray utilizing alloy powders to rebuild worn machine components, deposit ceramic thermal barriers, and restore shaft dimensions with minimal substrate heating.
Key Technical Advantages
Zero Substrate Distortion: Cold process maintains component temperature below 150°C.
Extended Component Life: Improves wear life by up to 5x versus bare metal surfaces.
In-Situ Application: Mobile spray equipment enables on-site execution inside boilers and plant environments.
Wide Material Range: Carbides, Stainless Steel, Aluminium, Zinc, Inconel, Stellite, and ceramic alloys.
All Industry Certifications: Coatings tested to ASTM, AWS, and customer-specific standards.
Need technical support for your plant equipment? Contact our engineering team for custom alloy selection and coating specification.
Applications & Sectors
Industries We Serve
Power & Generation
Protecting thermal power plant boiler tubes, superheaters, coal pulverizers, and hydro turbine components against severe erosion, oxidation, and sulphur attack.
Steel Industries
Hardfacing hot/cold rolling mill rolls, continuous caster rolls, sink rolls, and furnace components subject to extreme thermal and mechanical stress.
Oil & Gas
TSA coatings for offshore oil rigs, subsea pipelines, pressure vessels, storage tanks, and valve components in harsh marine environments.
Petrochemicals & Refineries
Surface engineering for catalytic cracking units, heat exchanger tube sheets, high-temperature pumps, and gas processing vessels.
Pulp & Paper Mills
Corrosion and wear protection for paper mill digesters, yankee dryers, press rolls, and black liquor recovery boiler tubes.
Cement Plant And Collieries
Carbide spray coatings for high-pressure fan blades, raw mill rollers, clinker crushers, and coal washing and handling equipment.
Offshore & Marine
Thermal spray aluminium (TSA) for marine vessel hulls, splash zones, sea water piping systems, and offshore deck equipment.
Chemical Industry
Anti-corrosion protective coatings for chemical reactors, acid storage tanks, agitators, condenser tubes, and fertilizer plant processing units.
Others & General Industries
Custom thermal spray and hardfacing solutions for gearboxes, shafts, hydraulic rams, and heavy industrial manufacturing machinery.
TRUSTED BY INDUSTRY LEADERS
Our Esteemed Clients & Industrial Partners
HAVE QUESTIONS?
Frequently Asked Questions
Explore authoritative engineering answers regarding our thermal spray coatings, turnaround times, and on-site deployment capabilities.
Thermal spray coating is an industrial surface engineering process where molten or semi-molten coating materials (metals, ceramics, carbides, or alloys) are propelled at high velocity onto a prepared substrate to form a tough, bonded protective layer against wear, erosion, and corrosion.
We specialize in High Velocity Oxy-Fuel (HVOF), Twin Wire Arc Spray (TWAS), Flame Wire Spray, Flame Powder Spray, and In-Situ Grinding across power plants, refineries, cement mills, and chemical industries.
Yes, Thermal Spray Engineering operates fully portable mobile rigs capable of complete 24/7 in-situ execution for boiler water walls, rotary kilns, storage tanks, chimneys, and paper mill rolls without component dismantling.
No. One of the main advantages of thermal spraying over conventional welding is that substrate temperatures typically remain below 150°C to 200°C, completely eliminating metallurgical distortion, stress cracking, and structural warping.
We regularly serve power generation plants, steel mills, cement & collieries, oil & gas processing, petrochemical refineries, chemical manufacturing, pulp & paper mills, and marine & offshore installations.