Salt spray

Salt spray testing

Salt spray testing is a standardised method for determining the quality of corrosion protection. It is an accelerated test whereby a 5% NaCl solution (salt water) is used to create a corrosive environment and parts are assessed periodically for appearance of rust and oxides. Essentially, the longer the timeframe before the appearance of corrosion, the better the coating protection.

We pride ourselves in providing our customers with the highest quality salt spray testing so they can be completely confident in our technology. Metavate work with Aerotech Laboratories Ltd who provide tests to British, European and American specifications:


ISO 9227:2007 (E)

BS EN 1670:1998 (in conjunction with performance rating method BS EN 10289:2001)

BS EN 248:2002 (E)

MIL-STD-810F Method 509.4


Below is an example of zinc phosphate treated plates (on the left) versus Plaforization treated plates (on the right). Both plates have been powdercoated following pretreatment and placed in the same salt spray environment. Plaforized parts withstood the environment over 500 hours longer than standard zinc phosphated parts, a shocking 64% increased corrosion protection!


Zinc phosphating + black powder coat

240 hours Zinc Phosphate

240 hours exposure

504 hours Zinc Phosphate

504 hours exposure

744 hours Zinc Phosphate

744 hours exposure

Zinc phosphating has now failed. Red corrosion to scribe extends 2-3mm, paint exfoliation to panel surface. Sample has been removed from the test.

Plaforization + black powder coat

240 hours plaforization

240 hours exposure

504 hours plaforization

504 hours exposure

744 hours Plaforization

744 hours exposure

1008 hours Plaforization

1008 hours exposure

1248 hours Plaforization

1248 hours exposure


We've calculated that in a year since changing over from our old conventional phosphating system, we've saved nearly £70k in chemical costs and labour

It sounded too good to be true but long term trials have proved the process works.

It’s the only process we’ve found that allows us to store cast steel and iron products without the worry of going rusty before assembly / painted.

We’ve seen lots of benefits - resolved storage issues, reduced utility costs, reduced water usage, carbon footprint AND our production time.

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