The nuclear industry is being urged to accelerate its shift from traditional electroplating to modern zinc flake coatings.
Experts say this move could significantly reduce contamination risks, cut maintenance downtime and improve long‑term safety.
Surface coating specialist Anotec, part of the Anochrome Group, is becoming increasingly active in the nuclear industry, coating bolts, seals, o-rings and gaskets used on nuclear flasks at some of the largest sites in the country.
Mark Smith, Assistant General Manager at Anotec, said zinc flake was quickly becoming the go-to corrosion protection method ahead of the formerly favoured electroplating process.
He said: “Zinc flake coatings are better for the environment since they do not contain the same levels of hazardous chemicals – such as hexavalent chromium – as electroplating.
“Nuclear supply chains face extremely strict scrutiny when it comes to contamination risk, so the environmental benefits are certainly a key factor in the switch to zinc flake.
“However, the change is not solely environmental, with many other benefits that are encouraging specifiers to opt for zinc flake finishes.”
Unlike electroplating, zinc flake has no risk of hydrogen embrittlement, which is seen as a massive benefit.
Maintenance may also be reduced by using zinc flake – and Mark said the cost is likely to be comparable.
“In a sector where even a tiny fastener failure could have massive consequences, having no risk of hydrogen embrittlement is huge,” said Mark.
“Maintenance in nuclear is costly, complex and potentially dangerous. Zinc flake offers exceptional protection, which ultimately means less lifetime intervention.
“There are still some misconceptions that zinc flake is much more expensive than electroplating, but that’s not generally the case, particularly when you factor in the long-term benefits.”
Zinc flake coatings can be applied either as a standalone solution or in combination with a range of topcoats. They protect parts from rust even after mechanical damages, such as stone chipping, thanks to its self-healing properties.
Anotec uses manual, automatic and robotic techniques to produce high-quality spray coatings, anodising and aluminium passivation, thermal diffusion and electromagnetic compatibility coatings (EMC) for several industry sectors including automotive, industrial, aerospace, wind energy, rail, defence, nuclear, petrochemical and marine.