Aichi (Aichi Prefecture)
Technical Case Studies
Rust, one of the most popular
Rust, like black leather, is one of the most popular designs and is popular overseas. In recent years, rust has become popular in Japan as well, with owners and designers requesting rusted surfaces for large walls and interiors. The popular rust design offers a wide range of possibilities for expression. At the end of 2022, AICHI METALS completed a showroom with a meeting room and photography studio. Here, we have created a huge iron rust wall, creating an overwhelming presence. At the same time, this wall is an experiment for our company. When it is this large, we can examine how it changes and deteriorates depending on the base material, both superficially and internally.
Rust repair
In fact, about two months after installation, the wall cracked due to thermal expansion caused by the sun and temperature changes. The biggest challenge was that the VeroMetal coating did not add any strength. As the surface treatment alone was not enough, the treatment of the base material was changed, the combination of materials was re-examined and finally a proprietary material was developed to complete the solution. We were able to sublimate this methodology to the point where we could offer it as a deliverable to a wide range of users.
Prepare rust for natural rust colour
VeroMetal and thermal spray coatings are rusted by polishing and scientific decoration, and then enjoy a unique ageing effect in the environment in which they are installed. Once decorated with the agent, the rusting process is accelerated by exposure to water and air. The initial rusting is done by hand, but the rest of the surface is exposed to rain and wind and settles down to its natural rust colour over time. Exposure to rain and wind gives the surface a variety of different looks. However, this is different from the paint peeling off. The steel reacts. That reaction changes with each passing day. Where it eventually arrives depends on the environment. This is how it becomes the one and only rust wall.
