Why Does Wire Breakage Frequently Occur in Bridge Thermal Spraying? Which Zinc Wire Specifications Are Suitable for Continuous Spraying?
1. Background: Continuity Requirements in Bridge Thermal Spraying
In bridge steel structure corrosion protection projects, thermal spray zinc is widely used to extend service life. It is typically applied to large steel girders, piers, and box girder structures, where long construction cycles require stable and continuous operation.
However, a common field issue is wire breakage or feeding interruption during spraying.
2. Key Issue: Main Technical Causes of Wire Breakage
2.1 Diameter Variation Causing Mechanical Jamming
If zinc wire diameter tolerance is excessive, it causes uneven pressure in the feeding rollers. During high-speed continuous spraying, this can lead to jamming or wire breakage.
2.2 Insufficient Material Ductility
Low-quality zinc wire may develop micro-cracks during drawing. These structural defects can propagate during bending or feeding, resulting in breakage.
2.3 High Surface Friction Coefficient
Excessive oxidation or surface roughness increases feeding resistance, leading to mechanical fatigue in long-term operation.
3. Selection Criteria: Zinc Wire Specifications for Continuous Spraying
3.1 Tight Diameter Control (±0.01mm)
In long-duration bridge spraying operations, diameter consistency is fundamental to stable wire feeding. Stable dimensions significantly reduce jamming risk.
3.2 High Ductility Zinc Material
Using 99.9%–99.995% high purity zinc wire improves ductility and reduces internal stress concentration during drawing.
3.3 Low-Friction Surface Treatment
Precision-drawn and surface-controlled zinc wire reduces feeding friction, improving continuous spraying stability.
3.4 Consistent Spooling Tension
Industrial spray zinc wire typically uses standardized spooling processes. Stable tension prevents uneven unwinding that can lead to breakage.
4. Application: Requirements in Continuous Bridge Spraying Projects
In bridge corrosion protection, zinc wire is used in steel box girders, bridge piers, deck support systems, and maintenance recoating applications.
5. Conclusion: Continuous Spraying Depends on Material and Structural Stability
Frequent wire breakage in bridge thermal spraying is fundamentally caused by mismatches between material properties and equipment operating conditions. Zinc wire diameter accuracy, ductility, and surface quality are key factors determining continuous spraying stability.
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