Galvanize It!

Seminar

American Galvanizing
Association
American Galvanizers Association
The American Galvanizers Association
(AGA) is a non-profit trade association
dedicated to serving the needs of after-
fabrication galvanizers, fabricators,
architects, specifiers, and engineers
The AGA provides technical support on
today's innovative applications and state-
of-the-art technological developments in
hot-dip galvanizing for corrosion control

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Continuing Education Credit

American Institute of Architects

Learning Units (HSW)

National Council of Examiners for

Engineering & Surveying
Professional Development Hours

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 Continuing Education

AIA/CES Policy on Endorsement: The

following program is registered with the
AIA/CES and does not include content that
may be deemed or construed to be an
approval, sponsorship, or endorsement of
any material of construction or any
method or manner of handling, using,
distributing, or dealing in any material or
product.
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 Continuing Education
The American Galvanizers Association has
met the standards and requirements of the
Registered Continuing Education Providers
Program. Credit earned upon completion
of this program will be reported to RCEPP.
A certificate of completion will be issued to
each participant. As such, it does not
include content that may be deemed or
construed to be an approval or
endorsement by NCEES or RCEPP.
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 Purpose of this Seminar
The purpose of this seminar is to
inform and educate architects,
engineers, and other specifiers about
hot-dip galvanized steel and how it
can address the growing corrosion
problem throughout North America.

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 Learning Objectives
At the end of this presentation you will be
able to:
• Recognize the corrosion issues confronting the
United States
• Describe how zinc coatings, specifically hot-dip
galvanizing, can protect against steel corrosion
• Incorporate sound corrosion protection into the
design of steel products that can significantly
decrease maintenance costs over the life of a
structure

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Tour of the City
The Corrosion Problem

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The Corrosion Problem

Bridge in Denver, CO

Bridge in Denver, CO

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The Corrosion Problem

Corroded Trolley

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The Corrosion Problem

Coors Field – Denver, CO

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The Corrosion Problem

Corroded Pier

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The Corrosion Problem

Williamsburg Bridge - New York City, NY

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 Corrosion Costs
NACE, CC Hazardous
Technologies, & • Public safety,
FHWA jointly property damage,
produced a report environmental
in 2001 detailing contamination
the costs of Natural Resources
corrosion • Waste production,
• $297 billion USD increased energy
annually consumption
• 3.1% of US GDP Public Outcry
(1998) • Traffic,
inconvenience
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The Solution: Hot-Dip
Galvanizing
Barrier Protection

Weathered Guardrail

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Cathodic Protection: Galvanic Series
ZINC - Anode
STEEL - Cathode
This arrangement of
metals determines what
metal will be the anode
and cathode when the two
are put in a electrolytic cell
(arrangement dependent
on salt water as
electrolyte).

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 Cathodic Protection
Exposed Steel
is Protected
Zinc Coating

Bare Steel

With a cathodically protective coating, such

as galvanized steel, damaged areas will be
protected by the surrounding zinc
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 HDG Process

Steel is dipped in a series of tanks including

solutions that remove impurities from the steel
surface. The galvanizing reaction only occurs on
perfectly clean steel.

The steel is inspected after galvanizing to ensure

conformance to the appropriate specifications.

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 Long-Lasting Zinc Protection
Barrier
Barrier
Cathodic
Zinc Patina

Long-lasting
Protection

Zinc Patina Cathodic

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 HDG Process: Surface Prep
Zinc-iron metallurgical
bond only occurs on
clean steel
Degreasing
• Removes dirt, oils,
organic residue
Pickling
• Removes mill scale and
oxides
Fluxing
Caustic cleaning
• Mild cleaning, provides
protective layer

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HDG Process: Galvanizing
Steel articles are
immersed in a bath of
molten zinc (≈ 830 0F)
> 98% pure zinc, minor
elements added for
coating properties (Al,
Bi, Ni)
Zinc bath removal Zinc reacts with iron in
the steel to form
galvanized coating.

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 HDG Process: Inspection
Steel articles are
inspected after
galvanizing to verify
conformance to
appropriate specs.
Surface defects easily
identified through
visual inspection.
Coating thickness
verified through
magnetic thickness
gauge readings.
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Hot-Dip Galvanized
Coating Properties
Metallurgical Bond

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Edge Protection

Same thickness at corner

Micrograph of galvanized edge

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 Additional Benefits of HDG
Complete Coverage

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 Additional Benefits of HDG
Variety of
sizes and
shapes

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 Additional Benefits of HDG
Availability

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 Galvanizing is Green
Zinc is 100% recyclable as is
the steel
• Properties of zinc do not
degrade w/ reprocessing
• Zinc is a natural element in the
Earth‟s crust
The longevity of galvanizing
means no additional energy
exerted or waste created
maintaining galvanized
structures
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Estimated Service Life of HDG

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Other Zinc Coatings for
Corrosion Protection
 Metallizing
Shop or in-field
application
Suitable for very
large pieces
Coating Properties:
• Thick coating
• Mechanical bond
• Less dense than
HDG zinc layers
• No interior coverage Metallizing Appliation

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 Zinc Rich Paint
Zinc Rich Paint Application
Metallic zinc dust
• Inorganic
• Organic
Barrier protection
Cathodic protection
• Limited
• Dependent on % Zn
Use salt spray data
to make
performance claims
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 Sheet Galvanized
Produced by a
continuous in-line
hot-dip process
• Coil-to-coil process
• 400-500 FPM
• “Air knives” remove
excess zinc
• Pure zinc with little
alloy layer
• Galvannealed (Zn-Fe) Sheet Steel of Continuous
• Galvalume (55% Al)
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 Sheet Galvanized
ASTM A653 – specify total coating weights,
most common G60 and G90
• Weights represent total coating weight for both
sides of the sheet

Coating Weight Coating

(ounces/sq. ft.) Thickness per
Side (mils)
G60 0.60 0.54
G90 0.90 0.81

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 Electroplated
Strip, sheet, or
small parts
• Smooth finish
• Slightly more
expensive than
sheet galvanized
Good formability
Paintable
Electroplating Application

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 Zinc (Mechanical) Plating
Similar to
electroplating
• used for fasteners
and small parts
Parts are tumbled
in drum with zinc
powder and glass
beads
Mechanical Plating Application
• mechanically
bonded zinc

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 Other Zinc Coatings

Metallizing Sheet Galvanized

Hot-Dip Galvanized

Zinc-Rich Paint
Electroplated

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Design & Fabrication
42
Materials Suitable for
Hot-Dip Galvanizing

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Hot-Dip Galvanized Fasteners
Hot-dip galvanized
fasteners are
recommended for
joining HDG structurals

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Steel Reactivity

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 Coating Appearance
Newly
Newly Galvanized
Galvanized
Dull Coating
No Spangle

Newly Newly
Galvanized Installed

Highly Spangle Shiny & Dull

Coating

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Combining Different Materials

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Weathering of Galvanized Steel

Photo taken: 12/18/02

Photo taken: 03/28/03

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 Dissimilar Thicknesses
Different thickness
• Zinc bath
temperature at
different times

Similar thickness
• Maintain original
shape

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Galvanizing Oversized Pieces

Progressive Dipping

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Material Handling

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Venting & Drainage
Vent

Drain

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Specifications &
Inspection
 ASTM Standards for Galvanizing
Galvanized Products
• ASTM A 123 – general
• ASTM A 153 – small parts
• ASTM A 767 – rebar
Supporting Specifications
• ASTM A 143 – embrittlement
• ASTM A 384 – distortion
• ASTM A 385 – high-quality coatings
• ASTM A 780 – repair
• ASTM D 6386 – surface prep for painting over

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 ASTM A 123
Standard Specification
for Zinc (Hot-Dip
Galvanized) Coatings
on Iron and Steel
Products
• Coating Thickness – material category and
steel thickness
• Finish – continuous, smooth, uniform
• Adherence – should be tightly adherent
through all expected uses of article
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 ASTM A 153
Standard Specification
for Zinc Coating (Hot-
Dip) on Iron and Steel
Hardware

• Coating Thickness – material category, steel

thickness, length
• Finish – continuous, smooth, uniform
• Adherence – should be tightly adherent
through all expected uses of article
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 ASTM A 767
Standard Specification
for Zinc-Coated
(Galvanized) Steel
Bars for Concrete
Reinforcement
• Coating Thickness – smooth or deformed (no
wire), bar size
• Chromating –prevent reaction between fresh
cement and recently galvanized material
• Bend Diameters – flaking and cracking due to
fabrication are not rejectable.
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 ASTM A 780
Standard Practice for Repair of Damaged
and Uncoated Areas of Hot-Dip
Galvanized Coatings

• Zinc-rich paint, zinc-based solder, or metallizing

• Zinc-rich paint - most common but must have certain
amounts of zinc dust as required by spec
• Zinc-based solder – good for small areas, closely
mirrors typical HDG coating appearance
• Metallizing – excellent corrosion protection

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Hot-Dip Galvanizing
Costs Less &
Lasts Longer
 Quantitative Analysis
Initial cost vs. Life-
cycle cost
• Based on 2006
galvanizing industry
survey -nationwide
• 2006 KTA-Tator paper
paint industry survey –
nationwide
• Standard mix of steel
products (structural,
tubing, plate)
• 10,000 ft2 project

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 www.galvanizingcost.com
Survey data organized in a database
Based on specific project data input
by the user, (job size & location,
coating type, expected service life,
etc.)
The web site automatically calculates
initial and life-cycle cost for the
specified paint systems and hot-dip
galvanizing
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 Initial Cost
Material
Shop cleaning labor
Shop application
Field labor

Pneumatic Bulk Trailers

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 Initial Cost ($/ft2)
Coating System $/ft2
Inorganic Zinc $1.31
Inorganic Zinc/Epoxy $2.09
Hot-Dip Galvanizing $1.92
Acrylic WB Primer/Acrylic WB
$2.51
Intermediate/Acrylic WB Topcoat
Inorganic Zinc Primer/
$3.07
H-B Epoxy/Acrylic Urethane

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 Life-cycle Cost
Maintenance on a „practical‟ (vs. ideal)
cycle - unique to each paint system, as
recommended by paint manufacturers
NACE Model for NFV and NPV
calculations
• 4% inflation
• 7% interest

Maintenance repaint at 5% rust in a

moderately industrial environment
30-Year Project Performance 64
 Life-Cycle Cost ($/ft2)
50-Year Project Performance
Coating System $/ft2
Hot-Dip Galvanizing $1.92
Inorganic Zinc $3.21
Inorganic Zinc/Epoxy $4.83
Inorganic Zinc Primer/
$6.43
H-B Epoxy/Acrylic Urethane
Acrylic WB Primer/Acrylic WB
$7.98
Intermediate/Acrylic WB Topcoat

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 What Does All of This Mean?
Coating System Cost
Hot-Dip Galvanizing $19,200
Inorganic Zinc $32,099
Inorganic Zinc/Epoxy $48,261
Inorganic Zinc Primer/
$64,302
H-B Epoxy/Acrylic Urethane

Acrylic WB Primer/Acrylic WB
$79,802
Intermediate/Acrylic WB Topcoat

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 Duplex Systems:
Painting & Powder Coating
Hot-Dip Galvanized Steel
 Why Paint a Perfectly Good
Galvanized Part?
Aesthetics
• Architects decision
Identification
Hostile
Environment to Zinc
Repair of Existing
Galvanized Articles
• Extended Life of the
Light Rail Station
Product

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 Galvanized Surface
Coating Condition
Newly Galvanized
Steel
Partially
Weathered
Galvanized Steel
Fully Weathered
Galvanized Steel
Painted Bridge Rail

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 Passivation Cycle
Time
0 – 48 hrs. 1

48 hrs. – 6 mo. 2

6 mo. – 2 yrs. 3

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Sweep Blasting

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Duplex System Layers

Fence Pole

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 Duplex System
Synergistic Effect
Paint Provides Barrier
for Galvanized Surface
Galvanized Coating
Provides Slow Corrosion
Under Paint
Paint Peeling due to
Corrosion is Minimized
Paint & Galvanizing
together have 1.5x to
2.5x Life of Individual Skaneateles Community Center
Lifetimes

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 Galvanized Steel
Project Applications
 Brooklyn Bridge
Date Galvanized
1999

Sector
Bridge &
Highway

Environment
Industrial

Location
New York, NY

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CALTRANS District 7 HQ
Date Galvanized
2004

Sector
Building &
Architecture

Environment
Urban

Location
Los Angeles, CA

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 The Cloud at Fashion Show Mall
Date Galvanized
2003

Sector
Building &
Architecture

Environment
Urban

Location
Las Vegas, NV

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 Harrisburg Airport
Transportation Facility
Date Galvanized
2004

Sector
Building &
Architecture

Environment
Urban

Location
Harrisburg, PA

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Cell Towers – Tree Application
Date Galvanized
2004

Sector
Electrical, Utility &
Communication

Environment
Rural

Location
California

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Leprino Foods
Date Galvanized
Unknown

Sector
Food & Agriculture

Environment
Rural

Location
Waverly, NY

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 Piers 1 & 21 Replacement
Date Galvanized
2002

Sector
Water & Marine

Environment
Marine

Location
Norfolk, VA

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