Metguard is tackling one of industry’s quietest sustainability challenges,corrosion. CEO Suyash Bihani talks innovation, impact, and what’s next for metal protection
How Metguard’s Metal Passivating Coating Works and How It Differs from Traditional Methods
Traditional corrosion prevention methods—such as galvanizing, cathodic protection, and barrier coatings—rely on clean, oxide-free metal surfaces for application. These methods aim to delay corrosion either by sacrificial protection (e.g., zinc-rich coatings) or by isolating the metal from corrosive elements (e.g., epoxy coatings). However, they often fail in real-world conditions, especially on heavy-duty or pre-corroded structures where oxides are already present.
Metguard takes a fundamentally different approach. Its coatings use a proprietary polymeric composition that forms an inert, impervious layer over the metal surface—even in the presence of existing oxides. “Instead of removing oxides, we work with them,” said Suyash Bihani, Co-Founder and CEO of Metguard. The technology integrates ferrous and non-ferrous oxides into the coating, forming a stable passivating layer that halts electrochemical activity at the source. This prevents metal dissolution, a common failure point for traditional coatings. “We eliminate the root cause of underfilm corrosion by immobilising the reactive species,” Bihani added.
Metguard’s Contribution to Sustainability
Corrosion is not just an engineering challenge, it is an environmental issue. Frequent replacement of corroded infrastructure leads to higher emissions, increased resource consumption, and manufacturing waste, contributing to carbon dioxide and acid gases. Additionally, extracting raw materials like ores and hydrocarbons depletes natural resources.
Metguard significantly extends the operational lifespan of metal structures, reducing the need for premature replacement. By minimising metal loss, it rehabilitates corroded infrastructure and reduces lifecycle emissions. Furthermore, its surface-tolerant nature eliminates the need for abrasive blasting and chemical pre-treatments, which pollute the environment. Metguard’s technology is free from toxic substances like lead, chromium compounds, halogens, and isocyanates, making it a cleaner and more sustainable alternative for corrosion protection.
Future Advancements and Expanding Impact
Suyash envisions Metguard expanding beyond metals: “Our vision goes beyond metals, aiming to develop next-generation coatings for concrete. We’re focused on advancing user-friendly formulations that align with global sustainability goals.”
Geographically, Metguard will focus on high-impact regions like the Middle East and North Africa (MENA), with plans to scale globally. Industries such as oil and gas, power, desalination plants, and heavy industry—where corrosion poses environmental and economic risks—are primary targets. “Strategic collaborations and investments in R&D will help us deliver advanced corrosion protection at scale,” Bihani stated.
Raising Awareness About Corrosion Prevention
Suyash explains, “We’re actively raising awareness by establishing a world-class application development centre, participating in industry forums, and collaborating with leading consultants to highlight the urgent need for sustainable corrosion prevention.”
The Science Behind Metal Passivation and Metguard’s Innovation
Metal passivation reduces or halts electrochemical activity on metal surfaces, specifically the anodic and cathodic reactions that lead to corrosion. Traditional methods, such as acid pickling and chromium-based primers, chemically react with freshly exposed metal. These inhibitors are not only environmentally harmful but also prone to failure under prolonged electrolyte exposure.
Metguard’s polymeric coatings, however, contain functional groups activated by electrolytes. These groups adsorb onto metal surfaces, even those with pre-existing oxides, forming a tightly bound, passivating layer. This “in situ” passivation eliminates the need for clean, active metal and invasive surface preparation. “Since the passivating layer becomes part of the coating, corrosion protection is maintained even with significantly thinner films,” Bihani explained.
Metguard’s Role in Addressing the Global Cost of Corrosion
The global cost of corrosion exceeds $6 trillion annually, driven by premature infrastructure failure and the need for costly repairs or replacements. Metguard addresses these inefficiencies by slowing structural degradation, extending asset lifespans, and reducing maintenance intervals. This translates into substantial cost savings and reduced material waste.
Metguard is not just a protective coating—it’s a long-term value proposition that reduces lifecycle emissions and enhances the economics of infrastructure.
Economic Benefits of Metguard Over Traditional Methods
Metguard offers significant cost advantages over conventional corrosion protection systems. “First and foremost, our technology extends the life cycle of metal structures, reducing the need for premature replacement or scrappage,” said Bihani. Its surface-tolerant nature allows for minimal surface preparation, eliminating costly grit blasting or chemical pre-treatment steps.
Metguard coatings are quick to cure, reducing application downtime and speeding up project timelines. “This combination of long-term durability, ease of application, and reduced maintenance requirements translates into the lowest overall lifecycle cost of protection,” Bihani explained. When used with cathodic protection systems for submerged or buried structures, Metguard can lower material and energy costs. “In aggressive environments like oil and gas, Metguard can even replace galvanising, offering a cleaner and more cost-effective alternative,” he added.
Challenges Faced as a Startup and Addressing Them
Suyash reflects, “As a startup, we face scepticism and inertia. Many industry players are heavily invested in traditional methods, making it hard for new technologies to gain traction. Trust in legacy systems, despite their limitations, often outweighs openness to innovation.”
To overcome this, Metguard focuses on real-world performance by conducting pilot trials, providing third-party test results, and collaborating with stakeholders. “Inclusion in the Mohammed Bin Rashid Innovation Fund (MBRIF) has strengthened our credibility,” said Bihani. Through persistent engagement and transparent data sharing, Metguard is gradually breaking down resistance and gaining momentum for a new standard in corrosion protection.
