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About us – After Fabrication Hot Dip Galvanizing
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Prevention of Corrosion
When iron is extracted from its ore, a This manual is designed to assist designers,
fundamental tendency of nature is abruptly specifiers, materials engineers, consultants,
reversed. Unless protected, iron and steel and fabricators to protect and improve their
will corrode in most environments, slowly steel products. All important aspects of the
returning to their natural state. galvanizing process and the properties and
applications of galvanized coatings are
Corrosion prevention is an essential factor
covered. Sections detail the design and
in the economic utilisation of steel.
specification of galvanized products,
Provision of the appropriate protective
fabrication methods including bolting and
coating can bring initial savings plus
welding, and the painting of galvanized
substantial economies in service, due to
steel surfaces.
reduction or elimination of maintenance and
lost service time, and by deferring the Great effort has been made to make this
replacement date of structures and manual accurate and up-to-date, but
equipment. responsibility is not accepted for any loss,
damage or other consequence resulting
In suitable applications, galvanizing
from its use.
provides ideal corrosion protection for steel
– no other coating matches galvanizing’s
unique combination of low first cost,
ease of inspection for coating quality,
durability, predictable performance, low
maintenance, and resistance to abrasion
and mechanical damage.
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About us
The Galvanizers Association of Australia Education We have developed a range of Design,
(GAA) comprises the leading galvanizing Venting & Transport Safety charts to assist
The GAA provides a range of education
companies throughout Australia, New all members of the industry to design,
services on hot dip galvanizing to engineers,
Zealand and parts of Asia. manufacture and transport their fabricated
architects, specifiers, students and other
articles in the most economical and
GAA is an Industry Association established interested parties.
safe manner.
in 1963 to represent galvanizing companies
The sessions include general information
and to provide technical consulting services
provided to groups and individuals on Professional Assistance
on a not for profit basis.
process, corrosion protection, specification,
design and benefits. More specific training Professional engineering, corrosion and
The Association’s objectives are to provide
on aspects of HDG for specific needs is also galvanizing experts within the GAA are
the highest standards in design and quality
available for small groups and ‘one-on-one’. available to industry, fabricators and
of galvanized products and to assist
specifiers alike.
consumers achieve the economics inherent
The GAA maintains registration with key
in the correct design and application of Our work includes review of proposed
industry bodies to enable professionals to
galvanized products. designs, analysis of issues, and assistance
earn CPD points through their attendance at
training sessions. We also provide regular in specifications, including
We provide free technical publications and
higher education lectures around Australia. recommendations on corrosion categories.
practical assistance on all aspects of
design, application, process, bolting, Most services are available at no cost to
welding and painting of galvanized steel. Publications industry, fabricators and specifiers
The GAA has a range of publications, including Further information is readily available from
Industry Size this one available to interested people. the GAA or any of the leading galvanizers
There are 38 hot dip galvanizing plants listed in our members’ directory which can
Our website (www.gaa.com.au) provides a
operating in all States of Australia, including be found at www.gaa.com.au
significant amount of technical advice to
regional areas.
fabricators and specifiers and is regularly
The industry directly employs approximately updated with new case studies and
industry news. Contact:
3,000 people and has a capacity to process
around 750,000 tonnes of steel annually. Level 5, 124 Exhibition Street
The GAA also publishes two editions per
annum of ‘Galvanize!’ which is designed to Melbourne 3000 Victoria.
Industry Serviced bring interesting case studies and other Phone: +61 3 9654 1266
The hot dip galvanizing industry touches technical information to people interested in Fax: +61 3 9654 1136
most parts of Australian society and is hot dip galvanizing. Email: gaa@gaa.com.au
widely used in the infrastructure, Technical Papers are produced by GAA’s Web: www.gaa.com.au
commercial, mining, agriculture, recreation qualified staff and other industry
and housing markets. professionals on current topics relating to
corrosion or aspects of galvanizing. These
are available from the website or by
contacting the GAA directly.
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Table 2. Requirements for coating thickness and mass for articles that are
centrifuged
The thickness of the galvanized coating shall first be tested by the purchaser/designer at the
galvanizer’s works, using an approved magnetic measuring device. In the event of any dispute,
an independent test shall be carried out in accordance with AS/NZS 4680, Appendix G.
2 Surface Finish
The galvanized coating shall be continuous, adherent, as smooth and evenly distributed as
possible, and free from any defect that is detrimental to the stated end use of the coated
article. On silicon killed steels, the coating may be dull grey, which is acceptable provided
the coating is sound and continuous (See Note 3). Any reparation is to be carried out as per
Clause 8 of AS/NZS 4680.
The integrity of the coating shall be determined by visual inspection and coating thickness
measurements. Where slip factors are required to enable high strength friction grip bolting,
where shown, these shall be obtained after galvanizing by suitable mechanical treatment of
the faying surfaces.
Where a paint finish is to be applied to the galvanized coating, all spikes shall be removed
and all edges shall be free from lumps and runs. (See Note 4).
3 Adhesion
The galvanized coating shall be sufficiently adherent to withstand normal handling during
transport and erection.
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contents
Metallurgy of
galvanizing
Hot Dip Galvanizing –
Process, Applications,
Properties
Mechanical properties
of galvanized steels
Corrosion rates of
steel and zinc
Protective life of
galvanized coatings
Performance in various
environments
Bimetallic corrosion
Galvanized coatings
for buildings and
structural steel
Reliability of coatings
for steel
other CHAPTERS
2 Design, specification, inspection of galvanized products
3 Galvanized steel reinforcement for concrete
4 Bolting galvanized steel
5 Welding galvanized steel
case 6 Painting galvanized steel
studies
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4. The galvanized coating is subject to 12. ‘Duplex’ coatings of galvanizing-plus- Each cell comprises a positive electron-
corrosion at a predictably slow rate, paint are often the most economic producing anode and a negative cathode.
between one-seventeenth and one- solution to the problem of protecting Negatively charged electrons flow from
eightieth that of steel, depending on steel in highly corrosive environments. anode to cathode. The loss of electrons
the environment to which it is exposed. Such systems provide a synergistic converts some atoms of the anode to
5. Galvanizing’s cathodic protection for effect in which the life of the combined positively charged ions which in turn react
steel ensures that small areas of the coatings exceeds the total life of the with negatively charged ions in the
base steel exposed through severe two coatings if they were used alone. electrolyte. This reaction between anode
impacts or abrasion, are protected See ‘Painting galvanized steel’. and electrolyte causes disintegration and
from corrosion by the surrounding corrosion of the anode metal. There is no
galvanized coating. Cathodic protection corrosion of the cathode metal.
6. An inherent advantage of the process is Metallic zinc is anodic to steel as indicated Galvanic series of metals in a sea
that a standard minimum coating by the galvanic series of metals. See water electrolyte
thickness is applied. ‘Galvanic corrosion of galvanized
7. During galvanizing the work is coatings in contact with other metals’. The table below shows a series of metals
completely immersed in molten zinc and arranged in order of electrochemical activity
the entire surface is coated, even In the presence of an electrolyte, the anodic in a sea water electrolyte. Metals high in
recesses and returns which often zinc coating on a galvanized article corrodes the scale provide cathodic or sacrificial
cannot be coated using other processes. preferentially to the cathodic steel basis protection to the metals below them.
If required, internal surfaces of vessels metal, preventing corrosion of small areas Zinc therefore protects steel.
and containers can be coated which may be exposed through accidental
simultaneously. See ‘Design’ damage to the coating. The cathodic or
8. Galvanized coatings are virtually sacrificial protection continues for as long
‘self-inspecting’ because the reaction as some of the galvanized coating remains.
between steel and molten zinc in the A simple description of the phenomenon of
galvanizing bath does not occur unless corrosion of steel is given on following
the steel surface is chemically clean. pages as background for the explanation of
Therefore a galvanized coating which cathodic protection. The scale indicates that magnesium,
appears sound and continuous is sound aluminium and cadmium should also protect
and continuous. See ‘Metallurgy of The nature of corrosion steel. In most normal applications
galvanizing’ and ‘Inspection of magnesium is highly reactive and is too
galvanized products’. Corrosion is basically an electrochemical
rapidly consumed. Aluminium forms a
process. It occurs because of differences in
9. Galvanizing is a highly versatile process. resistant oxide coating and its effectiveness
electrical potential which exist between
Items ranging from small fasteners and in providing cathodic protection is limited.
dissimilar metals in contact or between
threaded components, up to massive Cadmium provides the same cathodic
small areas on a metal surface in the
structural members can be coated. protection for steel as zinc but its
presence of an electrolyte.
See ‘Galvanizing’ and ‘Design’. applications are limited for technical,
10. The mechanical properties of commonly Differences in potential on a metal surface economic and environmental reasons.
galvanized steels are not significantly can be caused by:
affected by galvanizing. See 1. Variations in composition
‘Mechanical properties of
2. Presence of impurities
galvanized steels’.
3. Uneven internal stresses
11. Galvanizing provides outstanding
corrosion performance in a wide range 4. A non-uniform environment
of environments. See ‘Performance in The environment may be a damp
various environments’. atmosphere, surface moisture, or liquid in
which the metal is immersed. All serve as
electrolytes allowing formation of small
electrolytic cells at the metal surface, with
resulting corrosion.
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Corrosion of steel The positively charged iron ions of the The anode and cathode areas on a piece of
anode attract and react with negatively steel are actually microscopic. When
Differences in electrical potential are
charged hydroxyl ions in the electrolyte to greatly magnified the surface might appear
caused on surface areas of exposed steel
form iron oxide or rust. Negatively charged as the mosaic of anodes and cathodes
by non-uniformity of surface composition,
electrons react at the cathode surface with visualised here, all electrically connected by
by surface moisture or by the electrolyte in
positively charged hydrogen ions in the the underlying steel. Corrosion occurs in the
which it is immersed. Small electrolytic
electrolyte to form hydrogen gas. anode areas.
cells are formed comprising anodes and
cathodes. One such cell is shown
diagrammatically.
Under suitable conditions corrosion occurs As anode areas corrode new material of
at the rate of billions of complete reactions different composition and structure is
every second and soon results in a layer of exposed. This results in changes in
As the result of differences in electrical rust appearing over the surface of the electrical potentials, causing anodes and
potential within the cell, negatively charged anode area. cathodes to exchange roles, though not all
electrons flow from anode to cathode and at once, and areas previously uncorroded
iron atoms in the anode area are converted are now attacked. These processes may
to positively charged ions. continue until the steel is entirely
consumed.
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The mechanism of cathodic At the cathode surface, negatively charged Most organic coatings and paint films
electrons attract and react with positively depend on their sealing ability and in some
protection charged hydrogen ions from the electrolyte, cases anti-corrosive inhibitive pigments to
When zinc and steel are in contact in an liberating hydrogen gas. There is no protect steel from corrosion. They offer
electrolyte, differences in electrical chemical reaction between the steel little or no protection to bare steel exposed
potential develop and an electrolytic cell cathode and the electrolyte. This by failure, damage or discontinuity in the
is formed. Zinc is more electrochemically phenomenon which prevents corrosion of coating film. Corrosion starts and spreads
active than steel, as shown in the galvanic the cathode, is known as cathodic rapidly beneath the coating.
series on page 9. The zinc therefore protection. The positively charged zinc ions
becomes the anode for all the steel, at the anode surface react with negatively
preventing the formation of small anodic charged hydroxyl ions from the electrolyte
and cathodic areas on the steel surface. and zinc is slowly consumed, providing
sacrificial protection for the steel.
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techniques. Large galvanizing baths, in PAINT AND OIL REMOVED RUST AND MILL SCALE REMOVED STEEL GALVANIZED QUENCHED TO COOL
http://youtu.be/c2J07n5hSbs
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As indicated the total coating mass on The structure of the galvanized coating and
heavier steel sections normally contains a the relative thickness of its zinc-iron alloy
minimum of 600 grams of zinc per square layers have little or no effect on the
metre of surface area, (g/m2) equivalent to protective life of the coating. Protective life
about 85 µm thickness. As illustrated depends on total coating mass.
below, coating thickness is slightly greater
On most commonly galvanized steels, the
at corners.
relatively pure outer zinc layer of the
galvanized coating solidifies to give the
typical bright zinc crystal or ‘spangle’ finish.
Certain steel compositions may cause the
zinc-iron alloy layer to grow through to the
surface of the galvanized coating producing
a matt grey finish sometimes known as
‘grey bar’, as discussed below under
‘Composition of steel’ and under “Dull
grey coating”. There is negligible
difference between the protective lives
Galvanized coatings are slightly thicker at provided by each coating.
corners and edges as shown, an important
advantage over most organic coatings which thin
out in these critical areas.
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11
barrier protection in two ways: firstly, the
2 NOT YET FAILED
10
4
9
8
galvanized layer provides a protective
7
6
2
3
4
5
physical envelope around the steel;
secondly, the galvanized layer also develops
Zinc coating life, years
2
5
4
a protective patina on its surface upon
4 1 Sherardized
3 4
5 2 Zinc plated
3 Zinc plated and chromate The barrier protection qualities of
2
1
1
5
2
5 passivated
4 Hot dip galvanized exposure to the environment. This is made galvanized steel are also enhanced by the
up of insoluble zinc oxides, hydroxides,
5 Zinc sprayed
0
300 600 900 1200 fact that it is immune to ultraviolet
carbonates and basic zinc salts depending radiation and thus will not degrade on
Note. These test results were obtained in an extremely on the nature of the environment. Once the exposure to Australia’s harsh environment.
corrosive environment, and should not be taken as a patina stabilises, it reduces the exposure of Most other corrosion protection coatings
guide to coating life for applications under normal the base galvanized steel to the will degrade on exposure to solar radiation.
conditions. environment, thus considerably slowing This is usually one of the key limiting
the corrosion process. This patina factors to the performance of such
regenerates itself after damage by very coatings.
slowly consuming the zinc outer coating.
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125µm
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Most natural waters contain sufficient The addition to the galvanized coating of a Galvanized coatings are used in
dissolved salts to prevent initial attack and suitable paint system is recommended in refrigeration equipment circulating brine
galvanized tanks and equipment give areas of severe sea water exposure, solutions treated with sodium dichromate
excellent service. particularly in the splash zone. Such duplex inhibitor.
systems provide the best available
Effect of water temperature. In cold
protective coating for steel in sea water.
water of normal composition galvanized
Suitable paint coating systems are listed in
coatings are most effective and the rate of
‘Painting galvanized steel’.
consumption of the coating is very low. This
has resulted in almost universal use of
Corrosion rate
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Compatibility of galvanized coatings with various media Galvanized coatings perform extremely well
Compatibility of galvanized coatings with various media is summarised in the table below. by comparison with other protective
Further specific information is available from the Galvanizers Association of Australia. coatings for steel in the severely corrosive
conditions prevailing in most sewage
Compatibility of galvanized coatings with various media treatment operations. As a result galvanized
steel is used extensively in sewage
Aerosol propellants excellent treatment plants throughout the world.
Acid solutions weak, cold quiescent fair
strong not recommended In contact with building
Alcohols anhydrous good materials
water mixtures not recommended
beverages not recommended
Alkaline solutions up to pH 12.5 fair
strong not recommended
Carbon tetrachloride excellent
Cleaning solvents chlorofluorocarbon excellent
Detergents inhibited good
Diesel oil sulphur free excellent
Fuel oil sulphur free excellent
Gas* towns, natural, propane, excellent
butane
Glycerine excellent
Inks printing excellent Galvanized coatings give invaluable
aqueous writing not recommended protection to steel used in all sections of
Insecticides dry excellent the building industry. The slight etching
in solution not recommended action upon galvanizing by mortar, concrete
Lubricants mineral, acid free excellent and plaster ceases after setting.
organic not recommended When galvanized steel products and
Paraffin excellent fasteners are installed in direct contact
with unseasoned timber it may be
Perchlorethylene excellent necessary to protect them by the
Refrigerants chlorofluorocarbon excellent application of suitable paint.
Sewage excellent Care should be taken that galvanized
Soaps good products are stored and transported
under dry ventilated conditions as
Timber preservatives: discussed above.
Copper-chromium-arsenic, freshly treated poor
After drying is completed excellent
Boron excellent
Trichlorethylene excellent
*Chromate passivation is recommended because moisture may be present.
Galvanized lintels
Sewage treatment
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Bimetallic corrosion
Prevention of bimetallic corrosion in a highly corrosive coastal environment. The stainless steel wire is
electrically isolated from the hot dip galvanized balustrade.
Bimetallic or electrolytic corrosion with Galvanized surfaces in Copper and copper alloys
resulting rapid consumption of the zinc
coating is likely if a galvanized article is
contact Bimetallic corrosion requires electrical
For maximum corrosion resistance under contact in the presence of an electrolyte
installed in contact with brass or copper,
conditions of extreme humidity, overlapping and cannot occur in the absence of these
particularly in a moist environment. Contact
galvanized surfaces should be isolated from factors. However, run-off water from copper
between aluminium, cadmium and
each other by the application of an surfaces frequently contains small
galvanized surfaces is normally satisfactory.
inhibitive jointing compound such as quantities of dissolved copper, sufficient
Bimetallic corrosion occurs for the same Dulux Foster C1 Mastic or equivalent. to cause attack and rapid deterioration of
electrochemical reasons as those by Alternatively a suitable paint may be used. zinc coatings through chemical deposition
which zinc provides cathodic protection Galvanized surfaces in contact with other of copper.
for steel but the rate of consumption of materials may also require isolation. Where use of copper or brass together with
zinc coatings by galvanic corrosion may
Galvanized members in contact with galvanized steel in the presence of an
be extremely high.
aluminium conductors may require the use electrolyte cannot be avoided, precautions
A guide to compatibility of metals and of an electrical conductive compound at should be taken to prevent electrical
alloys in contact is given in the table on the joint faces to repel moisture and inhibit contact between the dissimilar metals.
next page. corrosion. Galvanizers Association of Joint faces should be insulated using non-
Australia can provide further information conducting gaskets or mastics and
on this. connections should be made with insulating
grommet-type fasteners. The design should
be arranged so that water flows from the
galvanized surface onto the brass or copper
surface and not the reverse.
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Key
1 A Very good 2 A None 3 A Very Low
B Good B Little B Low
C Poor C High C High
D Very poor D Very High D Very High
* R. Thomas, 1980 (modified).
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contents
Galvanizing
fundamentals
Size and shape
Design, Specification &
Inspection Of Galvanized
Products
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fundamentals
surface of the steel is perfectly clean.
drawing board. No matter what corrosion
Good design ensures this will occur.
protection system is used, it must be
• The hot dip galvanized coating will not
Hot dip galvanizing is an immersion process factored into the design of the product.
form unless the zinc can intimately
where steel sections and fabrications Once the decision has been made to use contact the steel surface
undergo the following operations: hot dip galvanizing to provide corrosion • The hot dip galvanized coating will not
1. Hot caustic degreasing (removal of protection for steel, the design engineer form unless the steel is heated to about
oil, organic materials, selected mill should ensure that the pieces can be 440oC
primers and paint) suitably fabricated for high quality • Steel items to be processed must fit
galvanizing. Adopting the following design into the preparation tanks and
2. Hydrochloric acid pickling (removal
practices will ensure the safety of galvanizing bath. This is not limited to
of rust and mill scale)
galvanizing personnel, reduce coating cost, the physical vessel dimensions but that
3. Rinsing (removal of pickling acid and produce optimum quality galvanizing.
residues) space which results from double end
4. Prefluxing in zinc ammonium It must be remembered that the process dipping techniques, which normally
chloride solution (surface involves dipping in molten metal at 450°C meet the permissible road transport
conditioning) and this can have effects on the material dimensions
5. Hot dip galvanizing (at 450-460°C) being processed or can be extremely Double end or depth dipping is a term used
hazardous to workers if there is any danger to describe the process of galvanizing an
6. Quenching (passivation of the zinc
of molten metal being thrown out of the item which is longer or deeper than
surface to prevent early oxidation)
bath. Molten zinc and all processing available bath dimensions. In this procedure
7. Surface clean up & inspection. solutions must be able to enter and drain
(eg. deburring) the item is lowered into the bath so that
from fabrications without difficulty and this half or more of its length or depth is
may require additional holes for venting immersed in the zinc bath. When the zinc
and draining. coating has been achieved, the item is
SURFACE FLUXED
If you have additional questions regarding raised from the bath and adjusted in
PAINT AND OIL REMOVED RUST AND MILL SCALE REMOVED STEEL GALVANIZED QUENCHED TO COOL
design requirements, your galvanizer or the handling so that the ungalvanized part can
Galvanizers Association of Australia can be immersed in the bath. It should be noted
provide the desired information. that in this procedure an overlap of zinc
coating will occur and this may have to be
Hot dip galvanizing is a self inspecting addressed in the case of visually obvious
process that relies heavily on proper design structural elements that require an
of the steelwork to achieve a quality result. aesthetic finish.
HOT CAUSTIC HYDROCHLORIC WATER HOT ZAC ZINC QUENCH
DEGREASING ACID PICKLING RINSE PREFLUX BATH
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Note: A directory listing the dimensions of all galvanizing baths operated by GAA members is available on the
website www.gaa.com.au
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As illustrated, design must allow for pickle Internal baffles in tanks should be cropped Hollow structurals and
acids, fluxes and molten zinc to enter, fill on the bottom and top or provided with
and flow upwards through the enclosed suitable drainage holes to permit free flow
fabricated columns
space and out through an opening at the of molten zinc and air venting. Access Closed sections must never be included in
highest point so that no air is trapped as ports, bosses and openings should be tubular fabrications. Vent holes at least
the article is immersed. The design must finished flush inside. 50% of internal diameter or diagonal
also provide for complete drainage of both dimension and a minimum of 10 mm
Openings should finish flush inside and diameter should be provided by the
interior and exterior details during
should be positioned so that all pickle acid fabricator at locations agreed with the
withdrawal.
and molten zinc can be drained out during galvanizer.
A vent hole of equal dimensions should be the galvanizing operation.
provided diagonally opposite the filling hole
to allow the escape of enclosed air and to
facilitate draining.
Tanks and closed vessels should have at
least one filling/draining hole with a vent
diagonally opposite.
All welded sections in fabricated pipe work
should be interconnected with open tee or
mitre joints. Alternatively each closed
section must be provided with a vent hole
of not less than 10 mm diameter. Pipe ends
or flanges should always be left open, or
provided with removable vent plugs.
Closing of unwanted vent holes.
Small vent holes which are necessary for
galvanizing but not wanted in the finished
job may be closed by hammering in lead
plugs after galvanizing and filing off flush
with surrounding surfaces, or by the use of
threaded plugs. Threads may need
re-tapping after galvanizing.
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NOTE: Water, process solutions and molten zinc 1. Avoid designs which require double-end
enter hollow sections during fabrication or during dipping to fit into the galvanizing bath.
the galvanizing process. If the drain holes are not
located at the lowest point on both sides in the It is preferable to build assemblies and
fabrication: sub-assemblies in suitable modules so
that they can be immersed quickly and
• Process chemicals will be trapped
fully in a single dip.
internally and cause an explosion hazard
when immersed in the molten zinc 2. Use symmetrical sections in preference
• Zinc will be trapped internally and will
to angles or channels.
freeze in the undrained area. This may 3. Use sections of near equal thickness at
In welded structures venting holes must be joints.
interfere with assembly, it will add to inserted at all junctions. The holes must
the weight of the item in service and it 4. Bend members to the largest acceptable
enable the zinc to run in and out freely. radii.
is a waste of zinc which adds to the Closed tubes incur the risk of explosion!
cost of galvanizing. 5. Accurately preform parts to avoid force
or restraint during joining.
6. Continuously weld joints if possible
using balanced welding techniques to
reduce uneven thermal stresses.
Balanced, staggered welding is
permissible. For staggered welding of
material of 3 mm and lighter, weld
centres should be closer than 100 mm.
7. Design castings to conform to the rules
listed under Materials suitable for
galvanizing – Castings. Large grey
iron castings should always be
normalised by the fabricator and then
abrasive blast cleaned prior to
galvanizing.
Advice on design to minimise distortion is
Inwardly projecting pipe connections available from the galvanizer.
prevent containers from being completely Note: GAA Advisory Note GEN 13/1 – “Distortion
emptied of zinc and flux. Locate pipe becoming a diminishing event”
connections near corners and diagonally. is available on the GAA website.
It will also be easier for the zinc to run out
if the pipe connections are not too small.
On large containers lifting eyes should be
applied for easier handling.
Vent and drain holes must be located as
close to the high and low points of the
hollow section as possible to prevent air Dimensional stability
locks, entrapment of pre-treatment In certain cases, fabricated assemblies may Use of symmetrical sections minimises
chemicals and zinc puddling. be liable to loss of shape at galvanizing distortion during galvanizing. Avoid
temperatures due to the release of stresses combinations of thick and thin materials.
induced during manufacture of the steel and Such designs should preferably have the
in subsequent fabricating operations. These items galvanized separately and then bolted
stresses may be compounded by bad design together.
incorporating unequal thicknesses or non-
symmetrical sections. Observance of the
following recommendations will improve
dimensional stability:
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Clearance for moving parts Galvanized threads Handling parts for galvanizing
Moving parts such as drop handles, When assemblies to be galvanized Parts may require suspension holes if there
hinges, shackles and shafts must incorporate threaded components, the is no convenient point to attach a jig or
incorporate minimum radial clearances tolerance normally allowed on internal hook. No special requirements apply if the
as detailed below: threads must be increased to provide for the work can be handled by chains, baskets,
thickness of the galvanized coating on tongs or racks. Your galvanizer will advise of
Shaft or spindle size Minimum radial external threads. Standard practice is to tap necessary provision to suit the handling
clearance nuts oversize after galvanizing, according to equipment available.
Up to 10 mm diameter 1.0 mm figures in the table under Oversize tapping
allowances for galvanized nuts (listed in Large pipe sections, open top tanks and
10 to 30 mm diameter 2.0 mm the Bolting galvanized steel section). similar structures may require cross stays to
maintain the shape of the article during
Over 30 mm diameter 2.5 mm handling and galvanizing.
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Design for maximum corrosion Educational seminar on hot Galvanizing design aids
protection dip galvanizing for corrosion As an aid to designers and specifiers, the
Galvanized coatings provide outstanding protection Association publishes and distributes free
corrosion protection for steel. Treatment of of charge the colour wall chart ‘Design for
GAA technical staff are available for
design details in accordance with good Galvanizing’ and ‘Safety in Venting for
in-house seminars and discussions on
corrosion design practice as discussed Galvanizing’.
“Hot Dip Galvanizing for Corrosion
below will further increase the life of protection”. These sessions will assist you Contact GAA, Level 5, 124 Exhibition Street,
galvanized steel fabrications. to understand the galvanizing process, Melbourne, Victoria 3000.
Many of the design requirements for good specifications and grades of galvanizing. Phone +61 3 9654 1266
galvanizing detailed earlier, such as the or email gaa@gaa.com.au
The seminars and discussions can be
provision of flush-finished internal flanges tailored to specific areas as required.
in tanks and vessels will also ensure good
drainage in service and optimum corrosion The GAA maintains registration with key
resistance. industry bodies to enable professionals to
earn CPD Points through their attendance at
Fabricated assemblies should be designed training sessions.
to eliminate undrained areas which will
collect water and sediment in service, If you would like more information or to
producing localised corrosion pockets. request a seminar presented by GAA
The following rules should be followed: technical personnel, please contact the GAA
by phoning +61 3 9654 1266.
1. Use butt welds in preference to lap
welds.
2. Where lap welds are used face joints
downwards to avoid collection of
moisture and sediment.
3. Avoid use of horizontal boxed sections,
ledges, seams and flat undrained areas.
4. Use rounded internal corners rather than
squared corners in vessels and
containers to avoid build up of
sediment.
5. Design to eliminate crevices and
unnecessary openings.
6. Avoid contact of galvanized surfaces
with brass or copper as discussed under
‘Bimetallic corrosion’.
7. Provide ventilation where possible in
condensation areas.
8. Under conditions of extreme humidity
use an inhibitive jointing compound
between contacting galvanized surfaces
such as roof overlaps.
9. Provide maintenance access where
anticipated service life of certain
components is less than that of the
complete structure.
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despatch to the are designed to show what is acceptable when delivering small items through to large
items. Each State has a different poster due to varying legislation in regards to truck
galvanizer
overhang limits. By adhering to the legislation it ensures the safety of the galvanizing plant
personnel, the truck drivers and the public. For a copy of the poster for your State please
contact GAA.
Fabricated assemblies, castings and other
components for galvanizing should be
inspected before despatch to the galvanizer
to ensure that the following points conform
to design requirements detailed earlier. This
Transportation Load Safety
may avoid costly rectification and delays at
Transporting a Load to the Galvanizer Chain of Responsibility
the galvanizing plant. WhAT IS not ACCEPTABLE? What is the Chain of Responsibility?
It comprises all personnel, including Directors,
Managers, Operators, Schedulers, Receivers,
Size and shape. Check that work is Packers, Loaders and Drivers, working together
suitably sized and dimensioned for the Large open mesh bins are
unsuitable for the transporting
Plastic rubbish bins are
unsuitable for the transporting
Re-used drums are unsafe.
It is impossible to use the
Dangerous goods label still
shown
to ensure that:
handling and galvanizing facilities of the
of smaller items. of heavy steel items. The side correct lifting equipment.
of the bin splits open.
• all loads are packed safely and securely
• the total weight is within the carrying capacity
selected galvanizer. It may be too late to
make changes to the design, but it is costly
WhAT IS ACCEPTABLE? of the vehicle
• the dimensions of the load are within the legal
load dimensions of the vehicle
to despatch work which the galvanizer • all vehicles used for this purpose are in safe
working condition.
cannot process. Small items are kept secure in
the correct size mesh stillage.
Solid metal bins can
accommodate the weight of
steel items, are easily
Steel items should be suitably
and securely strapped
(and/or wrapped) when being
Ensure the work leaving your
premises is suitably contained.
Legal action can be taken against individuals along the chain of responsibility.
transported and can improve transported on pallets. Whole corporations can also be held legally responsible as well as the
manual handling procedures.
directors of the corporation.
Structural steel. Check that bending, TRuCk oveRhanG LimiTS
• Forward projection limit: – 1.2m from front of the vehicle
punching and shearing have been carried • Side projection limit: – 150mm either side of a vehicle
• Overall width for a vehicle and any load is 2.5m
• Maximum rear overhang is 3.7m or 60% of the wheelbase, whichever is the
under Embrittlement.
Flag dimension must be at least 450mm x 450mm
For further information see your local transport authority.
The National Transport Commission (NTC) has worked with all State road agencies including the Copies of this legislation can be accessed by visiting www.legislation.sa.gov.au
Department for Transport, Energy and Infrastructure, police agencies and industry representatives This amending legislation known as the Statutes Amendment (Road Transport Compliance and
to develop model national compliance and enforcement legislation. The result was the National Enforcement) Act 2006 came into force on Monday 30 April 2007 affecting all businesses that
Road Transport Reform (Compliance and Enforcement) Bill. A copy of the C&E Bill can be found at
Satisfactory galvanizing
operate or use heavy vehicle road transport. The new legislation is designed to encourage safe
the National Transport Commission’s website www.ntc.gov.au work practices and fairness across the total transport task, where everyone takes appropriate
www.gaa.com.au In 2006, the South Australian Parliament passed amending legislation to bring these model
national compliance and enforcement provisions into State law involving amendments to the:
responsibility for the way goods are moved on our roads.
Road Traffic Act 1961, Motor Vehicles Act 1959, Summary Offences Act 1953.
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contents
Galvanized steel
reinforcement
Corrosion of
Galvanized Steel
Reinforcement for Concrete
reinforcement
Factors determining
the durability of
reinforcement
Corrosion protection
provided by galvanizing
Economics of galvanized
reinforcement in
concrete
Bond strength of
concrete to galvanized
reinforcing bars
Specification and
installation of galvanized
reinforcement
Welding galvanized
steel reinforcement
other CHAPTERS
1 Hot dip galvanizing – Process, applications, properties
2 Design, specification, inspection of galvanized products
4 Bolting galvanized steel
5 Welding galvanized steel
case 6 Painting galvanized steel
studies
forward >
Chapter 3 – Galvanized steel reinforcement for concrete
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Quality of concrete
In preventing corrosion of reinforcement,
Cracks in concrete
The type and size of cracks have an
Corrosion
the most critical property of concrete is
permeability. The degree of permeability
important influence on durability of
concrete. Cracks caused by shrinkage or protection
determines the extent and rate of the
diffusion of chloride ions and carbon
thermal stresses may contribute
significantly to reinforcement corrosion, provided by
galvanizing
dioxide through the concrete. Permeability particularly when they run parallel to
is a function of mix design, compaction reinforcing bars and are close to the
and curing: concrete surface.
Mix design. To achieve low permeability, In areas where the reinforcement may be
Crack widths of less than 0.1 mm are exposed accidentally due to thin or porous
concrete must be dense, with a good bond generally regarded as not causing
between aggregate and cement paste. concrete, cracking, or damage to the
significant corrosion risk, provided cover is concrete, the galvanized coating provides
These desirable characteristics can be adequate and the structure is not exposed
obtained by using good quality materials, extended protection. Since the corrosion
to highly corrosive environments. Flexural product of zinc occupies a smaller volume
with an adequate portland cement content, cracks are not generally a problem as they
a low water/cement ratio, and small sized, than the corrosion products of iron, any
decrease in width from a maximum at the small degree of corrosion which may
well graded aggregates. surface and become narrower at the level occur to the galvanized coating causes
Compaction. Proper compaction of of the reinforcing steel. little or no disruption to the surrounding
concrete is of vital importance in concrete mass.
minimising permeability. Problems are Surface treatment of concrete
likely to arise when placing and vibrating Studies were made at the Structural
techniques are incorrect, slump is too low, In the production of architectural finishes Engineering Materials Laboratory,
reinforcement is congested, or form shapes the concrete surface is sometimes washed University of California, Berkeley California,
are not conducive to the necessary flow of or treated to expose the aggregate. These of the effects of corrosion on reinforced
concrete during placement. practices are not recommended if there is concrete test prisms.
any possibility of aggressive chemicals such
Curing. Proper curing of concrete is as acids or salts being left behind to Prisms 300 x 100 x 100 mm were axially –
essential to achieve low permeability, as permeate the concrete. reinforced with 19 mm diameter galvanized
the continued hydration of the cement or black steel bars. A 12.5 mm deep notch
increases the volume of the gel and hence Etching, washing and mechanical concrete was cut at the mid section of each prism to
decreases pore spaces and blocks surface finishing may also result in loss of enforce formation of a crack at the notch
capillaries. Proper field curing must be the valuable cement-rich paste which forms should corrosion products exert sufficient
provided for. the surface layer of the concrete, reducing disruptive stresses. Prisms were placed in
carbonation resistance and depth of cover. loading frames and the steel reinforcing
Depth of Cover bars stressed to 140 MPa. Prisms were
Lack of concrete cover for reinforcement Reaction between galvanized then subjected to alternate immersion/
has been identified as a major problem coatings and concrete drying cycles in a 4% NaCl solution.
associated with ‘failures’ in high rise
buildings.* In a survey of 95 Sydney During initial contact of galvanized
buildings ranging in height from 5 to 36 reinforcement with wet concrete, the outer
storeys and aged between 2 and 17 years, zinc layers of the galvanized coating react
the average depth of concrete cover at sites to form stable insoluble zinc salts. Attack
where spalling occurred was 5.45mm. ceases as the concrete hardens and the
The maximum depth of cover at any failure galvanized coating remains intact.
point was 18 mm compared with
recommended covers to AS 3600 ‘Concrete
structures’ in the range 25 – 30 mm,
depending on the type of member.
* Marosszeky, M and Sade, D (1986).
“Concrete durability – the problem of reinforcement
corrosion and improving workmanship”.
Building Research Centre, University of NSW.
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Acknowledgement
Edited and updated June 2005 by Building
Knowledge.
Work involved in developing these
recommendations was performed by
Pasminco Metals-Sulphide, in association
with Reinforcing Products, BHP Steel Rod
and Bar Division, supported by International
Lead Zinc Research Organisation, Research
Triangle Park, North Carolina, USA.
contents
Influence of the
galvanized coating on
design
Galvanized commercial
grade bolts
Tightening procedures
for high strength
structural bolts
Inspection of high
strength bolted joints other CHAPTERS
1 Hot dip galvanizing – Process, applications, properties
Flush spliced structural 2 Design, specification, inspection of galvanized products
joints in galvanized steel 3 Galvanized steel reinforcement for concrete
5 Welding galvanized steel
case 6 Painting galvanized steel
studies
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These requirements dictate that in practice Requirements for coating thickness and mass for articles that are centrifuged
one of four types of zinc coating will be
suitable: Thickness of articles Local coating Average coating Average coating
(all components thickness minimum thickness minimum mass minimum
1. Galvanizing including castings) µm µm g/m2
2. Zinc plating mm
3. Sherardising
<8 25 35 250
4. Mechanical plating
>8 40 55 390
Galvanizing Note: 1. For requirements for threaded fasteners refer to AS 1214
The galvanizing of fasteners produces a 2. 1 g/m2 coating mass = 0.14µm coating thickness
heavy coating of zinc ideally suitable for
long-term outdoor exposure. The coating is Oversize tapping allowances for galvanized nuts
applied by the immersion of clean, prepared
steel items in molten zinc. The resulting To accommodate the relatively thick galvanized coating on external threads, it is usual to
zinc coating is metallurgically bonded to the galvanize bolts of standard thread dimensions, and to tap nuts oversize after galvanizing.
basis steel, and consists of a succession of AS 1214 ‘Hot dip galvanized coatings on threaded fasteners’ specifies the following
zinc-iron alloy layers and an outer zinc layer. oversize tapping allowances on internal threads:
To ensure that nut stripping strength is adequate after oversize tapping, galvanized high
strength nuts are manufactured from steel with a higher specified hardness than standard
high strength nuts, as discussed under ‘Galvanized high strength nuts’.
Galvanized high strength bolts and nuts must be provided with a supplementary lubricant
coating for satisfactory bolt tightening. See ‘Influence of the galvanized coating on
design’.
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Friction type joints subject to Where: Joints subject to shear force only
shear, and combined shear V*sf = design shear force on the bolt in Bearing type joints subject to shear force
and tension. the plane of the interfaces only, and which are less than 500 mm long
in the direction of the applied shear force,
High strength hexagon head bolts are used N*tf = design tensile force on the bolt shall be proportioned so that the shear
as described under ‘Galvanized high force on any bolt does not exceed the
strength structural bolts’. Ø = capacity factor
maximum permissible shear force,
Vsf = nominal shear capacity of the bolt permitted by the table.
Shear joints
Ntf = nominal tensile capacity of the bolt For joints greater than 500 mm long refer to
In joints subject to shear only in the plane
of the friction faces the number of high clause 9.3.2.1 of AS 4100.
strength bolts and their disposition should Bearing type joints subject to
Joints subject to shear and tensile
be such that the resulting load at any bolt shear and combined shear forces
position does not exceed the value: and tension
Bearing type joints subject to shear and
Slip factor* x number of x minimum In bearing type joints, design follows tensile forces shall be proportioned so that
effective bolt conventional practice based on allowable the tensile force on any bolt does not
interfaces tension tension, shear and bearing values as exceed that permitted by the Parabolic
*Slip factor is the coefficient of friction on the mating specified in AS 4100. Design of a joint as Interaction Equation of AS 4100 (Rule
surfaces and can be defined as the ratio of the shear bearing type infers that some slip into 9.3.2.3)
force between two plies required to produce slip, to bearing may take place.
( )( )
the force clamping the plies together.
AS 4100 specifies that shear or moment V*f 2
N*tf 2
+ < 1.0
AS 4100 provides that the slip factor for connections subject to stress reversal, or ØVf ØNtf
clean as-rolled steel surfaces shall be taken where slip would not be acceptable shall
as 0.35. When protective coatings are be designed as friction type joints. Bearing Where:
present on mating surfaces, AS 4100 type joints must be designed in accordance
specifies that the slip factor applied in Ø = capacity factor
with AS 4100 using the allowable forces
design must be that of the protective detailed in the table below. Provided joint Vf = nominal bolt shear capacity
coatings, based on test evidence as surfaces are free from oil, dirt, loose scale,
discussed under ‘Slip factors of Ntf = nominal tensile capacity of the bolt
loose rust, burrs or defects which would
galvanized coatings’. prevent solid seating, AS 4100 permits the
use of applied coatings without change in
Joints subject to external tension in design values.
addition to shear
An externally applied tension in the Maximum permissible applied forces using metric bolts to AS 1252
direction of the bolt axis reduces the
effective clamping action of the bolt. To Diameter Maximum permissible Maximum permissible applied forces
allow for this effect, the Interaction of bolt, tension: Friction type and bearing type joints, kN
Equation of AS 4100 (Rule 9.3.3.3) mm bearing type joints Shear note (1) Bearing on
V*sf
ØVsf
+
)( )
N*tf
ØNtf
< 1.0 Threaded
portion
Unthreaded
portion
projected
area
The installation and tightening of a high strength structural bolt/nut assembly is at least as
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contents
Welding galvanized
steel
GMA welding
Welding Galvanized Steel
galvanized steel
Manual metal
arc welding
galvanized steel
Physical properties
of arc welds in
galvanized steel
GTA brazing
galvanized steel
Oxyacetylene welding
galvanized steel
Reconditioning
weld-damaged
surfaces
Welding fumes
other CHAPTERS
1 Hot dip galvanizing – Process, applications, properties
2 Design, specification, inspection of galvanized products
3 Galvanized steel reinforcement for concrete
4 Bolting galvanized steel
case 6 Painting galvanized steel
studies
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properties except in loss of fatigue strength large enough relative to plate thickness to
which can be avoided as discussed 92.6
fail by fatigue from the toe of the weld in
under ‘Effect of porosity on fatigue the same manner as in uncoated steel, the
strength’, below. 77.2
presence of porosity in the weld does not
reduce the fatigue strength of the joint.
Properties of sound welds in 61.8
104 2 3 4 5 105 2 3 4 5 106 2 3 4 5
Where the dimensions of a weld are just
galvanized steel Endurance, cycles Uncoated plate
large enough to cause fatigue failure from
Galvanized plate the toe in a sound weld, a weld containing
General properties porosity at the root may fail preferentially
When welding conditions are chosen to give SN curves showing results of fatigue tests through the throat of the weld.
sound welds in galvanized steel, the tensile, on cruciform joints. CO2 short circuiting
GMA welds on 13mm uncoated and Cracking
bend and charpy impact properties are
equivalent to those of welds in uncoated galvanized Lloyds Grade A steel, AWS Intergranular cracking of fillet welds
steel. Tests showed that the presence of A5.18:ER70S-2 filler metal. EN Gregory, containing porosity, sometimes referred
zinc at the levels occurring in the weld ‘The mechanical properties of welds in to as zinc penetrator cracking, does not
metal does not affect tensile, bend or zinc coated steel’ significantly affect the strength of
impact properties. non-critical joints. For more critical stressed
Properties of welds applications however, it is advisable to
Fracture toughness carry out procedural tests on material
containing porosity and samples.
Crack opening displacement (COD)
measurements and drop weight tests General effects
established that fracture toughness Porosity will occur in certain joint designs in
properties of welds are unaffected by the galvanized steel, depending on coating
presence of galvanized coatings. thickness, due to volatilisation of the zinc
coating and entrapment of gas in the weld.
The type of joint affects pore formation
since gases cannot readily escape from tee
joints and lap joints or from butt joints in
thick materials. In the case of butt joints, a
vee edge preparation or provision of a gap
between square edges facilitates the
escape of gases, minimising porosity.
Pore formation is also influenced by the
thickness of the galvanized coating relative
to the steel base.
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Welding fumes
Arc and oxyacetylene welding
In the arc welding or oxyacetylene welding
of galvanized steel, provision must be made
for control of welding fumes when planning
procedures. Due to the relatively low
melting point of zinc a proportion of the
coating is volatilised and given off as a
white zinc oxide fume. The presence of any
fume evolved is obvious and this permits
simple observation of the efficiency of the
ventilation or extraction system.
When welding is carried out in accordance
with normal industrial practice with GMA welding Plasma cutting of galvanized steel
provision for adequate ventilation and air Welding fume extraction guns for GMA Plasma cutting using compressed air as the
circulation, the non-toxic zinc fumes will welding galvanized steel are available from cutting gas allows high speed cutting of
cause no inconvenience. If adequate major welding equipment suppliers. These galvanized steels in thicknesses from 0.5 to
ventilation is not available, supplementary guns are very effective in removing weld 10 mm, with reduced distortion. The high
ventilation using air extraction equipment or fumes and have negligible effect on cutting speed and concentrated arc results
forced air circulating equipment, should weld quality. in very limited coating damage and minimal
be provided. fume generation.
GMA welding tests were conducted by the
Although welding fumes from galvanized Welding Institute, Cambridge, England for
steel are not toxic, operators welding in a International Lead Zinc Research
confined space should always be provided Organisation Inc. Using CO2 shielding gas at
with suitable respirators to minimise a flow rate of 15 L/min, a horizontal-vertical
possible discomfort. Fume development and fillet weld in 6 mm thick batch galvanized
consequent coating damage may often be steel was free from porosity. Tests with the
minimized with certain joint designs in flat same CO2 flow rate and the fume extractor
sheet by the use of copper chill bars. The in operation produced a fillet field on the
chill bars are used as a backing strip or same plate sample containing only two
clamped on the weld side of the joint to small pores in 150 mm of weld, showing
absorb some of the heat generated that disturbance of the shielding gas is
during welding. extremely small.
contents
Painting objectives
Decorative painting
The Effect of
Microclimates
Surface preparation
Painting systems
Appendix 1
Typical paints
Sample specification
Corrosivity Environment:
A Quick Guide
Bibliography
other CHAPTERS
1 Hot dip galvanizing – Process, applications, properties
2 Design, specification, inspection of galvanized products
3 Galvanized steel reinforcement for concrete
4 Bolting galvanized steel
case 5 Welding galvanized steel
studies
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Galvanizers Association of Australia The painting of hot dip galvanized steel is an orthodox and well-proven
In collaboration with Don Bartlett practice in outdoor environments, both in Australia (AS/NZS 46801) and
(CTI Consultants) internationally2. However, there are examples of early failures of paints
Edition 2 over galvanizing due to incorrect specifications and poor practice. This
May 2012 Guide aims to avoid such failures by directing specifiers and applicators
to the paint systems, surface preparation and application practices that
will provide a durable paint finish over galvanizing in a broad range of
service conditions.
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While good painting practices and Decorative painting It is important to note that because these
generic products for the various exposure paint systems are quite thin, typically 70 to
In outdoor service, remote from the coastal
conditions have been nominated, this 120 µm for a three coat system, the zinc
fringe and isolated from areas of severe
does not preclude the possibility of other profile and localised areas of increased zinc
industrial pollution, hot dip galvanizing is
paints and methodologies also performing thickness, such as at edges, may be visible
inherently durable. This contrasts with
satisfactorily. However, in selecting in the finish, much in the same way as the
paints and other organic materials, which
alternative products, specifiers are urged grain is visible in painted timber. While this
are degraded by solar radiation. Therefore,
to select products only from those with would rarely be a problem higher build
in most conditions of atmospheric exposure,
verified records of satisfactory long-term paints can be used as part of the painting
little is to be gained from painting
performance in equivalent or more severe specification.
galvanizing with a coating thickness more
service conditions.
than 300 g/m2 (42 µm) unless aesthetic or While acknowledging the lesser user
This document is a general guide only colour considerations are important. requirements of conventional (DIY)
and requires strict compliance with the decorative paints, strict adherence to the
In benign internal situations, and
individual paint manufacturers detailed appropriate surface preparation and prime
particularly conditions of extreme impact or
application instructions for each coat specification are a key to reliability
hard wear, unless a change in colour or
proprietary product. in all situations when painting over
gloss is considered necessary, galvanizing
galvanizing.
is usually best left unpainted.
Painting Objectives The paint systems detailed under Service
A great deal of galvanizing is painted on a
Reasons for painting galvanized steel requirement 1 & 2, on page 90, are
casual basis, with conventional latex or
are primarily: essentially decorative paint systems.
suitably primed solvent-based alkyd paint3.
• Decorative - to create an aesthetic Choice of this primer is crucial and requires
colour and gloss or provide an a clear recommendation from the paint Painting for enhanced
identifying colour. manufacturer. In particular, the use of an durability
• Enhanced durability - to increase alkyd primer in direct contact with the Hot dip galvanizing is inherently very
service life. galvanizing risks delamination of the paint durable, so there will rarely be a need to
• Wider chemical resistance – in a due to its saponification. paint over it to achieve the intended service
situation where galvanizing alone may life. Indeed, in higher corrosivity zones
be vulnerable, such as outside the pH (C3 to C5) painting galvanized steel can
range of 6 to 12. actually accelerate corrosion of the zinc
substrate and reduce the overall service life
of the article from the expected galvanized-
only life unless a judiciously selected,
uniformly applied, high build paint
system is applied and the integrity of
that paint system is maintained through
its service life.
Nevertheless, in circumstances where the
galvanized coating is slowly being attacked
by a corrosive environment, the application
of a suitable coating which insulates the
zinc from that environment can prolong the
life of the galvanized coating. Therefore, in
severe coastal and industrial service
environments, the painting of galvanizing
can significantly extend service life. Even in
quite benign outdoor service conditions
where galvanizing might last for many
decades, it can be prudent to paint areas
which are sheltered from the cleansing
influence of rain to extend the service life
Reverie - Dandenong, Victoria of the structure even further.
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Primer being applied over galvanizing to EG Whitlam Pool frame structure in preparation for
decorative coat
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Painting Systems
The following pages provide guidance on paint systems suitable for use in industrial and commercial situations under six different “service
requirements” as follows:
Service Requirement 1 Low corrosivity conditions & medium term service
Service Requirement 2 Low corrosivity conditions & high resistance to wear & trafficking/long term service.
Service Requirement 3 Medium corrosivity conditions & high resistance to wear & trafficking/long term service.
Service Requirement 4 High corrosivity conditions & high resistance to wear & trafficking/long term service.
Service Requirement 5 Very high corrosivity conditions & high resistance to wear & trafficking/long term service.
Service Requirement 6 Specific industrial chemical or solvent exposure.
Notes
• Service life: The paint systems listed in this guide provide for either medium or long term service lives, which are typically 5 to 10
years or 10 to 15 years respectively, for a maintenance repainting cycle to retain aesthetic performance.
• The corrosivity condition assessment is based upon the guidelines of ISO 92239, which essentially relate corrosivity in terms of
distance from the seacoast and need careful interpretation. ”Corrosivity Environment – A Quick Guide” (page 95) provides assistance on
choosing the corrosivity environment.
ISO 9223 is preferred over AS/NZS 23128 for reference to corrosivity categories as AS/NZS 2312 is under review at the time of writing
and ISO 9223 includes the new extreme corrosivity category CX.
AS 431210 provides excellent guidance for the determination of the general Australian macro environment with respect to corrosivity
zones, but care should be taken when dealing with very high to extreme corrosivity locations (CX) because AS 4312 has not yet been
modified to take the extreme zone into account. Otherwise, the corrosivity zones are the same as listed in ISO 9223.
The GAA has no paint system recommendation for category CX at the time of preparation of this guide.
• Application should be strictly in accordance with the paint manufacturer’s written instructions and the relevant recommendations of
AS/NZS 2311 in the case of Service Requirement 1 and to AS/NZS 2312 in the case of Service Requirements 2 to 6.
• For all but Very Low and Low Corrosivity Service Requirements it is recommended that a brush applied stripe coat be applied to
corners, welds and other sharp edges to ensure full thickness coverage. Indeed, for High and Very High Corrosivity Conditions it is
critical. This is because, unlike galvanizing, paint tends to shrink away from sharp edges.
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Service requirement 1
C1 very low & C2 low corrosivity conditions (note 1)
Medium term service (note 2)
Decorative finish
1 coat of 100% Acrylic Gloss 1 coat of 100% Acrylic Gloss
Clean 1 coat of Latex Primer (to AS
> > Latex (to AS 3730.10 or APAS > Latex (to AS 3730.10 or APAS
Degrease 3730.15 or APAS 00134)
0280/1) 0280/1)
Note 1 ISO 9223 Corrosion Categories C1 (Very Low) and C2 (Low). These locations range from more than 50km from a surf
beach down to about 1 km from quiescent seawater. It also includes Category C (Medium) locations, provided the
structure is totally exposed to the cleansing influence of rainwater or is subject to an appropriate regular hosing with
fresh water, as unwashed areas in Category C can be quite corrosive.
Note 2 Typically 5 to 10 years maintenance repainting cycle to retain aesthetic performance.
Note 3 For enhanced resistance to wear and trafficking and staining adopt “Service Requirement 3”.
Note 4 Flat, Low Gloss and Semi-Gloss 100% acrylic latex finishes may be also options, as aesthetics demand.
Note 5 Application should be strictly in accordance with the paint manufacturer’s written instructions and consistent with
the relevant recommendations of AS/NZS 2311 “Guide to the painting of buildings”
Service requirement 2
C1 very low & C2 low corrosivity conditions (note 1)
Long term service (note 2)
Decorative finish
Minimum System DFT 175 µm
Clean 1 coat of 2 pack inhibitive epoxy primer – 2 coats of 2 pack polyurethane or 2 pack acrylic
> >
Degrease minimum DFT 75 µm – minimum DFT 50 µm/coat
Note 1 ISO 9223 Corrosion Categories C1 (Very Low) and C2 (Low). These locations range from more than 50km from a surf
beach down to about 1km from quiescent seawater. It also includes Category C3 (Medium) locations, provided the
structure is totally exposed to the cleansing influence of rainwater or is subject to an appropriate, regular hosing
with fresh water, as unwashed areas in Category C3 can be quite corrosive.
Note 2 Typically 10 to 15 years maintenance repainting cycle to retain aesthetic performance.
Note 3 For enhanced resistance to wear and trafficking or staining adopt “Service Requirement 3”.
Note 4 Powder Coatings covered under Service Requirement 3 are also appropriate.
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Service requirement 3
C3 medium corrosivity conditions (note 1)
High resistance to wear & trafficking/long term service (note 2 & 3)
Decorative finish
Paint
Minimum System DFT 175 µm
Clean 1 coat of 2 pack inhibitive epoxy 2 coats of 2 pack polyurethane or 2 pack
> Brush Blast > >
Degrease primer – minimum DFT 75 µm acrylic – minimum DFT 50 μm/coat
Industrial finish
Minimum System DFT 225 µm
Clean 1 coat of 2 pack inhibitive epoxy 1 coat of high build 2 pack epoxy –
> Brush Blast > >
Degrease primer – minimum DFT 75 µm minimum DFT 150 μm
Powder Coating
Clean, coat and cure in accordance with the powder coating manufacturers written instructions using the appropriate
polyester powder coating to a cured thickness of not less than 70 µm.
Note 1 ISO 9223 Corrosion Category C3 (Medium). These locations range from more than 1 km from a surf beach and down
to about 100 metres from quiescent seawater, except in tropical locations where Service Requirement 4 is more
appropriate. It also includes Category C4 (High) locations, provided the structure is totally exposed to the cleansing
influence of rainwater or is subject to an appropriate, regular hosing with fresh water, as unwashed areas in
Category C4 can be very highly corrosive.
Note 2 Wear & trafficking is defined as surfaces subject to mild abrasion and scuffing, such as occurring in public
thoroughfares, kitchens and other work areas.
Note 3 Typically 10 to 15 years maintenance repainting cycle to retain aesthetic performance.
Note 4 For enhanced performance or in the more corrosive areas within the Category C3 zone a higher minimum total cured
film thickness may be required.
Service requirement 4
C4 high corrosivity conditions (note 1)
High resistance to wear & trafficking/long term service (note 2)
Decorative Finish
Minimum System DFT 350 µm
Clean 2 coats of high build of 2 pack 2 coats of 2 pack polyurethane or 2 pack acrylic
> Brush Blast > >
Degrease epoxy – minimum DFT 250 µm – minimum DFT 50 µm/coat
Industrial Finish
Minimum System DFT 350 µm
Clean
> Brush Blast > 3 coats 2 pack high build MIO epoxy
Degrease
Note 1 ISO 9223 Corrosion Category C4 (High). These include locations more than 300 metres from surf and down to the
seashore in quiescent seawater, tropical coastal service and indoor swimming pools.
Note 2 Wear & Trafficking is defined as surfaces subject to mild abrasion and scuffing, such as occurring in public
thoroughfares, kitchens and other work areas.
Note 3 Typically 10 to 15 years maintenance repainting cycle to retain aesthetic performance.
Note 4 Where decorative finish is not required polyurethane or acrylic may be replaced by a further coat of high build 2 pack
epoxy of equivalent thickness.
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Service requirement 5
C5 very high corrosivity conditions (note 1)
High resistance to wear & trafficking/long term service (note 2 & 3)
Decorative Finish
Minimum System DFT 400 µm
1 coat of inhibitive 1 or more coats of high 2 coats of 2 pack polyurethane
Clean
> Brush Blast > 2 pack epoxy primer – > build 2 pack epoxy – > or acrylic – minimum DFT
Degrease
minimum DFT 75 µm minimum DFT 225 µm 50 µm/coat
Industrial Finish
Minimum System DFT 400 µm
1 coat of inhibitive
Clean
> Brush Blast > 2 pack epoxy primer – > 3 or more coats 2 pack high build MIO epoxy
Degrease
minimum DFT 75 µm
Note 1 ISO 9223 Corrosion Categories C5 (Very High). These locations are offshore and on the beachfront in regions of rough
seas and surf. It also applies in a few aggressive industrial areas.
Note 2 Wear & Trafficking is defined as surfaces subject to mild abrasion and scuffing, such as occurring in public
thoroughfares, kitchens and other work areas.
Note 3 Typically 10 to 15 years maintenance repainting cycle to retain aesthetic performance.
Note 4 Polyurethane finish preferred unless OH&S considerations prohibit isocyanates.
Note 5 Alternatives to galvanizing should be considered, particularly in wear and tear conditions.
Service requirement 6
Specific industrial chemical or solvent exposure (note 1)
Typical Minimum System DFT 400 µm
1 coat of inhibitive 2 pack
Clean Finish coat subject to manufacturer’s
> Brush Blast > epoxy primer – minimum >
Degrease technical advice
DFT 75 µm
Note 1 While the requirements for surface cleaning and brush blasting are mandatory, the specific paint system and its total
system thickness are dependent upon the type and concentration of the chemical/solvents exposure and the
manufacturer’s advice.
Note 2 Typically 10 to 15 years maintenance repainting cycle to retain aesthetic performance.
Note 3 Typically polyurethanes are specified for resistance to acids and organic solvents and epoxies for resistance to
alkalis. Where strong acid or alkali contact is envisaged, alternative construction materials should be considered.
Note 4 Alternatives to galvanizing should be considered, particularly in acid or alkali conditions.
Typical Paints
Several paint suppliers are able to offer solutions to the Service Requirements. The GAA has not offered a listing of suitable paints/
suppliers due to regular formula, brand and ownership changes in the paint industry. The GAA recommend direct contact with the paint
companies for information on current product availability and suitability. In particular, it is important to establish that the manufacturer
provides examples that the particular formulation has been used successfully on galvanized steel.
www.gaa.com.au
Sample specification
The following provides guidelines for 1. Introduction 3. Technical Requirements –
preparing an appropriate specification for
painting galvanizing. Specific projects may 1.1 Purpose Coatings
need to encompass additional requirements This Specification defines the technical 3.1 General
not included in this generalised requirements for surface preparation and (i) Surface preparation treatments,
specification and Section 12 of AS/NZS application of protective coatings that have inspection and testing and health and
2312 provides additional advice. been hot-dip galvanized in accordance with safety shall comply with statutory
Note: For powder coating, while the general AS/NZS 4680. It does not cover powder requirements and the guidelines of
specification format would be appropriate, the technical coatings, which requires specific AS/NZS 2311 or AS/NZS 2312 as
requirements, notably surface preparation and recommendations regarding surface appropriate.
application and cure conditions will be considerably preparation and coating system selection,
different and need to be consistent with the guidelines (ii) All cutting, welding and other physical
of the specific powder coating manufacturer. application and cure. working of the metal shall be
(accurately describe location and scope of completed before surface preparation
items to be painted) and these shall be completed off-site,
except for repairs made necessary
1.2 Definitions/Glossary of Terms because of damage during transport,
For a glossary of paint and painting terms, storage and construction.
refer to AS 2310. (iii) All paint forming part of the one paint
system shall be from the same paint
2. Reference Documents manufacturer.
(iv) No paint shall be used after the
The following documents have been expiration of its shelf life or its pot life
referred to in this Specification: and all paint shall be mixed, thinned as
2.1 Standards/Codes appropriate and applied in strict
accordance with the manufacturer’s
AS 1627 Metal finishing - written instructions.
Preparation and pre- (v) Apply the first (prime) coat to the
treatment of steel surfaces clean, dry surface as soon as
AS 1627.4 Part 4: Abrasive blast practicable after it has been prepared
cleaning (Note: Not relevant for coating.
for Service Requirement 1) (vi) Coating application shall only proceed
AS 2310 Glossary of paint & painting when the surface temperature is
terms greater than 15°C and at least
AS 3894 Site testing of protective 3°C above the dew point of the
coatings surrounding air.
AS/NZS 2311 Guide to the painting of (vii) Coating application procedures and the
buildings (Note: Not time elapsed between coats shall be
relevant for Service consistent with this specification and
Requirements strictly in accordance with the
2 to 6) manufacturer’s written
AS/NZS 2312 Guide to the protection of recommendations.
iron and steel against (viii) Where repairs to the coated finish
exterior atmospheric are necessary and permitted by the
corrosion Project Manager, they shall be carried
AS/NZS 4680 Hot-dip galvanized (zinc) out using the system approved by the
coatings on fabricated manufacturers of the original system,
articles and to a standard which will not
compromise the protective performance
of the overall coating system.
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(ix) The Project Manager reserves the right 3.2 Surface Preparation 3.3 Painting
to check each and every stage of the (i) The first coat of paint shall be applied
(i) Remove any oil, grease or wax in
coating process to determine the to the clean, dry prepared surface as
accordance with the relevant method
cleanliness of surfaces, degree of cure, soon as practicable after it has been
described in AS 1627 Part 1.
adhesion, time between application prepared for coating and at least
and coating thickness, colour gloss and (ii) Remove all dirt, dust, water-soluble
salts and other contaminants by within 4 hours. Immediately prior to
finish. When tested in accordance with coating, the surface shall be air
AS 3894.3 each coat and the total appropriate methods consistent with
the requirements of AS 1627. blasted or dusted off to remove any
coating thickness shall be not less than surface dust.
the specified minimum. (iii) Remove or smooth out all sharp edges,
dags, weld spatter and laminations in (ii) For Corrosivity Zones C5 and CX, or
(x) After the completion of all painting where otherwise nominated by the
works, all equipment and materials a manner that such physical
imperfections in the galvanized surface Project Manager, all edges and corners
used in painting activities and all paint shall be first stripe coated with prime
debris shall be removed from the site, shall not thwart the even build up of
the subsequent paint system. coat, prior to application of one full
which shall be restored to its original prime coat.
condition. (iv) (Service Requirements 3 to 6 only)
Lightly (brush or whip) blast all (iii) The prime coat shall be ……….:
galvanized steel using a soft abrasive, Refer systems detailed in Section 4.
such as limestone or aluminium (Detail at least product name and
magnesium silicate in a manner that minimum dry film thickness)
profiles the surface without removing a (iv) As soon as practicable after the
significant amount of zinc from the minimum recoat time for the primer,
surface. apply …..
Refer systems detailed in Section 4.
(Detail at least the product name, the
minimum dry film thickness for each
coat to be applied and the minimum
total dry film thickness of the paint
system and colour/ gloss of final finish)
The final finish shall be smooth and
uniform in colour and gloss consistent
with best industry practice for the
products specified.
(v) Damage or other defects in the coating
system shall be feathered back to a
smooth transition and patch repaired
with the same products to not less
than the specified dry film thickness.
www.gaa.com.au
No
Are you within a temperate or subtropical zone with an atmospheric environment consisting of very high
pollution (90 μg/m3 < SO2 ≤ 250 μg/m3) &/or significant effect of chlorides, e.g. industrial areas, jetties & other Very High
Yes
offshore structures, within a few hundred metres of the ocean & sheltered positions on the coastline? Corrosivity
Are you in a space with very high frequency of condensation &/or with high pollution from production process, C5
e.g. mines, caverns for industrial purposes, unventilated sheds in subtropical & tropical zones?
No
Are you in a temperate zone with an atmospheric environment consisting of high pollution (30 μg/m3 < SO2 ≤
90 μg/m3) or substantial effect of chlorides, e.g. less than two kilometres from polluted urban areas, industrial
areas or between a few hundred metres & a kilometre of the ocean or within one hundred metres of sheltered High
coastal areas without spray of salt water? Yes
Corrosivity
Are you in a subtropical or tropical zone with an atmosphere with medium pollution? C4
Are you in a space with high frequency of condensation & high pollution from a production process,
e.g. industrial processing plants, swimming pools?
No
Are you in a temperate zone with an atmospheric environment with medium pollution (5 μg/m3 < SO2 ≤ 30 μg/
m3) or some effect of chlorides, e.g. urban areas, between a kilometre & twenty to fifty kilometres (depending
on winds & topography) from the ocean, or within one hundred metres of sheltered coastal areas with low Medium
deposition of chlorides? Yes
Corrosivity
Are you in a subtropical or tropical zone with an atmosphere with low pollution? C3
Are you in a space with moderate frequency of condensation & moderate pollution from production process,
e.g. food-processing plants, laundries, breweries, dairies?
No
Are you in a temperate zone with an atmospheric environment with low pollution (SO2 < 5 μg/m3), e.g. rural
areas, small towns? Low
Yes
Are you in a dry zone with an atmospheric environment with short time of wetness, e.g. desert areas? Corrosivity
Are you in an unheated & un-air-conditioned space with varying temperature & relative humidity with low C2
frequency of condensation & low pollution, e.g. storage rooms or buildings, sport halls?
No
Are you in a dry zone with an atmospheric environment with very low pollution & time of wetness,
e.g. certain deserts? Yes Very Low
Corrosivity
Are you in a dry, continually heated or air-conditioned space with low relative humidity & insignificant pollution,
C1
e.g. offices, schools, museums?
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Bibliography
1. Australian/New Zealand Standard AS/
NZS 4680:2006 Hot-dip galvanized (zinc) This Guide is intended to keep readers abreast of current issues and developments in
coatings on fabricated articles. the field of galvanizing. The Galvanizers Association of Australia has made every effort
2. ISO 1461-2009 Hot dip galvanized to ensure that the information provided is accurate, however its accuracy, reliability or
coatings on fabricated iron and steel completeness is not guaranteed. Any advice given, information provided or procedures
articles - Specifications and test recommended by GAA represent its best solutions based on its information and
methods research, however may be based on assumptions which while reasonable, may not be
applicable to all environments and potential fields of application. Due and proper
3. Australian/New Zealand Standard AS/
consideration has been given to all information provided but no warranty is made
NZS 2311:2000 Guide to the painting of
regarding the accuracy or reliability of either the information contained in this
buildings.
publication or any specific recommendation made to the recipient. Comments made are
4. Thomson G., “Paint over Galvanizing” of a general nature only and are not intended to be relied upon or to be used as a
Galvanizers Association of Australia, substitute for professional advice. GAA and its employees disclaim all liability and
Melbourne 2001. responsibility for any direct or indirect loss or damage which may be suffered by the
5. ISO 14713-1-2009 Zinc coatings - recipient through relying on anything contained or omitted in this publication.
Guidelines and recommendations for the
protection against corrosion of iron So long as no alterations are made unless approved, you are invited to reproduce the
6. Bartlett D J “Paint Finishes over information contained in this advice provided acknowledgement is given that GAA is
Galvanizing, Why Do They Fail?” the source.
Presented to ACA Conference, Melb.
Nov. 2003.
7. Slunder C. J. and W.K. Boyd “Zinc and
its Corrosion resistance”, Int. Lead Zinc
Research NY 2nd Edn. 1983.
8. Australia/New Zealand Standard AS/
NZS 2312:2002 “Guide to the protection
of structural steel against atmospheric
corrosion by the use of protective
coatings.
9. ISO 9223-2012 Corrosion of metals and
alloys — Corrosivity of atmospheres —
Classification, determination and
estimation.
10. AS 4312-2008 Atmospheric corrosivity
zones in Australia
11. Australian Standard AS 1627 Metal
Finishing - Preparation and pre-
treatment of surfaces.
12. Smith L. M. “Cleaning and Painting
Galvanized Steel”, 51-55, JPCL 18, April
2001.
13. “Sweep Blasting Hot Dip Galvanizing”
Galvanizers Association of Australia,
Advisory Note GEN/1/1, March 2012.
• Tropical Environments
• Coastal Environments
• Resources
• Sustainability
• Durability &
Sustainability
• Stadiums
• Carparks
• Swimming pools
• Galvanized
Reinforcement
• Bridges
• Water Treatment
• Architecture
• Safety Chart
other CHAPTERS
1 Hot dip galvanizing – Process, applications, properties
2 Design, specification, inspection of galvanized products
3 Galvanized steel reinforcement for concrete
4 Bolting galvanized steel
5 Welding galvanized steel
6 Painting galvanized steel
71
Associate of International Zinc Association
Winner
Hartway Galvanizers
Naval Base for
The Brockman 4 Project
“Green with Envy”
Special commendations
Korvest Galvanisers for
‘Manuele Engineers Steel
Facade Building’
and
Australian Professional
Galvanizing Pty Ltd for
‘Redlynch Indoor Sports
Stadium – Futsal ‘
The winner of the Sorel Award 2011 for Industry Innovation was announced at the
Galvanizers Association of Australia’s Annual Conference last October. The award
was presented to:
SPECIAL COMMENDATIONS
Korvest Galvanisers for ‘Manuele Engineers Steel Facade Building’
Manuele Engineers Steel Facade Building, North Plympton from the same steel supplier. With a “meccano” type construction of the
South Australia - Korvest Galvanisers facade required in order to bring the various components together, very tight
tolerances were involved. This was reduced to several millimetres to
Manuele Engineers had previously used hot dip galvanizing with success on
accommodate a number of the in-fill panels which are able to be hydraulically
the steel facade of their Clovelly Park SA office and wanted to make a
rotated. This, of course, required close attention to the method of fabrication,
similar, but more prominent, statement about the business they are in by
as well as dipping technique during the hot dip galvanizing process.
showcasing intricate steel fabrication, enhanced by contrasting hot dip
galvanized in-fill panels against a painted RHS support frame. The critical nature of this project highlights the need for early collaboration
between the stakeholders; from the architect to fabricator to hot dip galvanizers.
Here is a project that combines the complemented aesthetics of hot dip
Teamwork again was the key.
galvanized steel with a painted frame. The metallic nature of the galvanized
steel contrasts well against the dark gloss painted RHS frame. The The judges commented that both entries display great innovation in achieving
durability and maintenance free nature of hot dip galvanizing on very the architect’s design. Close collaboration with the stakeholders ensured the
complex and intricate fabrications will continue to enhance the surrounding vision of the buildings were a success. The Manuele Engineers Building
environment long into the future by preventing unsightly rust staining. highlights successfully the melding of galvanizing with paint to produce a
striking visual statement. The Fustal Stadium showcases a dynamic structure
As an architectural feature of the steel facade, it was imperative the finish
complementing the tropical landscape.
was consistent, requiring selection of domestic equivalent steel chemistry
Note: The artwork cannot be scaled.
Note: All components must be printed.
70
galvanize February 2011
HOT DIP GALVANIZED REINFORCING
STEEL FOR CONCRETE STRUCTURES
In this issue
Introduction – An added
insurance against corrosion
Reinforcement corrosion:
cause and effect
Protecting reinforcement
by galvanizing
Performance of galvanized
reinforcement concrete
Galvanized reinforcement
applications
Some FAQ’s AN ADDED INSURANCE AGAINST CORROSION
Further information on In coastal or chemical environments, or where extra durability and security is required,
galvanized reinforcement the practice of hot dip galvanizing steel reinforcement in concrete is now a well-proven
safeguard against corrosion.
The maxim that “prevention is better than cure” finds no greater example than the use
of hot dip galvanized reinforcement with a history of usage extending over 50 years.
Despite the increased usage of steel, concrete remains the most widely used construction material in the world today.
Whilst it is universally understood that exposed steel structures are vulnerable to corrosion, less well appreciated is that
steel reinforcement in concrete is also similarly susceptible under certain conditions and that this can have serious
consequences. The fact that reinforcement is embedded within the concrete and is therefore hidden from view renders
the corrosion problem all the more insidious. Often by the time the first tell-tale signs such as cracking or rust staining at
Editorial the concrete surface become visible, corrosion is in all likelihood already well advanced. Concrete remediation or use of
Mike Ainsley corrosion mitigation systems to halt further destructive deterioration can often be rendered difficult, if not impossible, by
Prepared by
Galvanizers Association of Australia Story continued on page 2
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structures, some in service for 30-40 years. These surveys have been very Telephone (03) 96
Facsimile (03) 96
thorough, even to the point of periodic extraction of sample cores from • high risk structures in corrosive environments Email gaa@gaa
Web www.gaa
structures for detailed examination. The references later cited under • immersed or buried structures subject to groundwater effects or chloride
“Further Information” should be consulted for in-depth information on presence (reclaimed land)
performance evaluations. • containment structures subject to prolonged contact with water or structures
Key measures of performance are serviceability and durability. Serviceability subject to extended periods of wetness
relates to the reinforcement’s ability to fulfil its intended function of • high visibility architectural facades and lightweight precast panels for
imparting strength to the structure over its service life. Relevant factors buildings. For these types of applications the avoidance of unsightly
here are that galvanizing has been proven to have no adverse effect on staining caused by rust “weeping” from corroding reinforcement is a
reinforcement’s inherent strength nor on the bond strength with concrete. In major concern.
fact, the evidence shows bond strength can be significantly higher with The benefits of galvanized reinforcement are globally recognized and many
galvanized reinforcement. In regard to durability, galvanized reinforcement examples exist around the world where it has been successfully used in a
appreciably extends the service life of the concrete structure by delaying variety of applications. Examples include:
the time for corrosion initiation by a factor of 4-5 times that of unprotected
reinforcement under similar conditions. • seawalls, jetties, pontoons and offshore structures
• coastal bridges and roads (crash barriers, paving)
• building construction, especially in coastal areas (exterior cladding,
balconies, balustrades, external staircases, porches, foundations)
• industrial sites such as chemical plants, water and sewerage treatment plants
• cooling towers
• tunnel structures both underground and submerged
• critical support structures (columns, beams, poles).
Some examples of prominent structures utilizing galvanized reinforcement
are featured in this article.
Some FAQ’s
Q. Does galvanized reinforcement need to be handled differently to ordinary bare steel reinforcement during the concreting process?
A. No.
Q. Can I use galvanized reinforcement in conjunction with bare steel reinforcement?
A. Yes. In fact, it may only be considered necessary to use galvanized steel in the more critical locations of a structure where there is a higher risk of corrosion
or where the consequences of corrosion could have particularly serious consequences.
Q. Do compliance standards exist for galvanized reinforcement?
A. Yes. In Australia and New Zealand galvanizing of reinforcement falls under the AS/NZS Standard 4680:2006 “Hot–dip galvanized (zinc) coatings on
fabricated ferrous articles”. In other countries (eg. USA and some European countries) a product-specific standard exists.
Q. How does galvanized compare to (fusion bonded) epoxy coated reinforcement?
A. Galvanized compares very favourably. Being soft, epoxy coatings are easily prone to damage, requiring extreme care be taken at all stages of storage and
installation, since corrosion at even minor areas of damage will progressively spread beneath the surrounding coating. In contrast, no special precautions
are necessary for handling galvanized reinforcement due to its excellent damage resistance. Even if localized damage occurs zinc’s cathodic protection will
prevent corrosion from spreading. A further important distinction is that studies of reinforcement’s bond strength to concrete has shown this to be generally
lower for epoxy coated, and certainly more variable, than galvanized. Significantly, in view of its superior performance, some infrastructural authorities
responsible for marine structures (in the USA) have now opted to use galvanized in preference to epoxy coated reinforcement.
ISBN:008044511X Reinforced concrete is one of the most widely used modern materials of construction. It is comparatively cheap,
Hardback readily available, and suitable for a variety of building and construction applications.
320 Pages This reference provides a detailed resource covering all aspects of this important material. Both serviceability and
$225 durability aspects are well covered, with all the information needed to maximise the life of buildings constructed
from it.
Containing an up-to-date and comprehensive collection of technical information and data from world-renowned
authors, it will be a valuable source of reference for academics, researchers, students, designers, specifiers,
fabricators and other professionals alike.
69
galvanize December 2009
SYDNEY DESALINATION PLANT
SHORING UP THE FUTURE
In this issue
Sydney Desalination
Plant
Powering Up The
Green Way
Nuts and Bolts of the
Structural Side
Beating Corrosion –
How Did They Do It? The population in most urban centres of Australia is increasing. Sydney is no different
Australian Made for and its population is expected to increase by 30-40% over the next 30 years. The
Australian Conditions! prolonged drought and the predicted changes to the global climate have resulted in
diminished rainfall and a subsequent reduction in the level of water in our dams. This
has meant that authorities need to look at alternative methods of securing the supply of
Education Revolution –
water to the public, industry and agriculture.
Australian Hot Dip
Galvanized Steel Not The Sydney Desalination Plant was designed to protect the future of the region by ensuring the supply of water without
impinging on other natural water sources. The location of the plant in a coastal area, and the nature of the process it is
Left in the Shade required to handle, means that corrosion protection is a significant feature of the design. Sydney Water needed to build a
structure that was durable, but kept the future maintenance costs to a minimum.
The Sydney Desalination Plant will initially supply 15% of Sydney’s water requirements by producing 250 million litres of
water a day. Sydney Water has also looked to the future by ensuring that the plant can be easily scaled up to produce
Editorial
500 million litres a day when and if this is required.
Emmanuel Pimentel
Prepared by Story continued on page 2
Galvanizers Association of Australia
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Australian Made for Australian Both Alfasi and the galvanizer showed that local product and local industry
are able to meet the demanding and exacting requirement of challenging and
Conditions iconic infrastructure projects.
As the galvanizer was a member of the GAA, they had access to all the
An important aspect of the structural steel in the reverse osmosis plant is technical support and other services that are provided as part of their
that it was sourced, fabricated and galvanized in Australia. The capability of membership. Customers of GAA members also have access to this valuable
the local steel industry coupled with the ingenuity and coordination skills of resource and this provides them with the security of knowing that their
Alfasi Steel Constructions and the galvanizer meant that the project was suppliers have access to all of the latest up to date technical information. ItLevel 5, 124 Exhibition S
able to proceed smoothly. The access of all the stakeholders to each other Melbourne Victoria 3000 Aus
can be disappointing when projects have problems with imported product Telephone (03) 9654
played a significant part in the success of the project. Facsimile (03) 9654
only to find that there is a lack of support and then experts such as the GAA Email gaa@gaa.co
Using a local supplier also made sense to Alfasi. “The galvanizer would are expected to assist in remediation and/or design modifications. Members Web www.gaa.co
come and pick up the steel once a day from the workshop during normal contributing to the GAA provide funding for research, technical services,
times. However, if things got really busy or deadlines were tight, then they education and work in other areas. This shouldn’t be dismissed lightly by
would come twice a day. Occasionally, one day turnaround was required and those involved in large infrastructure projects.
we always found that their people were happy to help out. We could send Now in Sydney, they can all drink to that for well into the future!
our transport there ready to pick up the steel for Sydney and they would
make sure it was ready for us.”
Project team:
The GAA found that everything went smoothly with these Australian Client: Sydney Water
companies dealing with each other and supplying a major local infrastructure
Project Management: Blue Water JV
project. Of particular interest was the fact that employees found that it gave
Structural Engineering: SKM/Maunsell (AECOM) JV
them something tangible to be proud of and say, ‘we did that’. The hot dip
Steel Fabrication: Alfasi Steel Constructions
galvanizing industry prides itself on its service and the project showed what
Australian industry can do when it’s given the opportunity. KERMAC Welding and Engineering
New World Engineering
Silo Constructions
S & L Steel
Coating: Australian Hot Dip Galvanized Steel
Acknowledgements
Alfasi Steel Constructions
Australian Steel Institute
Blue Water JV
EDUCATION REVOLUTION
Australian Hot Dip Galvanized Steel not left in the shade
Hot dip galvanized steel has long been a staple building material for schools “It gives you confidence to be able to give a warranty,” says David. “We
and educational facilities. Its use has recently been increased due to the galvanize every job we do after fabrication.”
government’s Education Revolution upgrade program and galvanize will Hot dip galvanized steel also has the advantage of a long history of use in
feature case studies in the future to show designers the versatility of this schools, is easy to handle, is robust enough to handle transportation and is
proven material. able to be erected under most climatic and site conditions. “Some of our jobs
Australian Shadola are an Australian company specializing in the provision involve larger steel components and quantities compared to most in our
of shade structures and weather canopies and a significant part of their work industry as we use RHS members, not C and Z purlins.” Hot dip galvanizing
involves educational facilities. All of their structures are engineered and allows David to meet his specific requirements of quality and durability. “By
structurally certified, including wind ratings above 130 km/h. using RHS our product is very robust.”
Australian Shadola’s structures need to meet both the aesthetic and durability
requirements of educational facilities. Their flexibility in construction and use
is also important. Shadola specializes in modular design so that work may be
done in stages as both needs and finances dictate.
The fact that steelwork is in schools means it has to be robust enough to
undergo the sort of punishment that schoolchildren can mete out, but also
have minimal maintenance costs as education funding is always at a
premium and subject to many competing needs.
David Scrivens, Manager of Australian Shadola, insists that all of his steel is
after fabrication hot dip galvanized and he relies on its durability, reliability
and quality to provide him with an Australian-made premium product. Also,
importantly for structures designed to protect children from the sun, hot dip
galvanizing is itself immune to the effects of the sun and UV. Zinc doesn’t
only work in sunscreen to protect the human body from the sun – it also
protects steel!
Note: The artwork cannot be scaled.
Note: All components must be printed.
As the Education Revolution and the development of schools gets into full
swing, the need to provide Australian children with facilities that protect
them from the sun and the elements is of utmost importance. Thanks to the
likes of Australian Shadola, local hot dip galvanized steel will be increasingly
used to provide a safe, low maintenance and robust structural material.
Hot dip galvanized steel may provide much-needed shade, but as the
toughest and most economical material of choice in educational facilities, it
need not stay there!
Acknowledgements
David Scrivens – Manager, Australian Shadola
St. Michaels, Baulkham Hills
68
galvanize May 2009
rebuildinG a coMMunity
mIDLAnD rEDEvELoPmEnT AnD
WooDbrIDgE LAkEs – mIDLAnD, WA
In this issue
Introduction – The
Importance of History
to the Future
Midland: The Historical
Heart and Soul of the WA
Railway Industry
Midland Redevelopment
Authority – The Beginning
ThE ImPorTAnCE of hIsTory To ThE fUTUrE
History and the past: most would acknowledge their importance. The importance of
Woodbridge Lakes and the the past is that what has been done previously can be seen and its success easily
Coal Dam measured. It may seem obvious to look to the past before doing things now or
planning for the future and the built environment is no different.
Don’t Forget Sustainability
and the Environment! However, often lessons are not learnt from the past and we can fall into the trap of using a material unproven in real life
just because it is “new”. Just as in our everyday lives, we look to the newest thing, the latest thing, the “in” thing. This is
not necessarily a negative prospect as it encourages innovation, but just because something is old, doesn’t mean it cannot
The use of Galvanized be used in innovative and exciting ways and still provide the security that can only be achieved by long-term proven past
Steel in Woodbridge Lakes performance.
and the Midland Area Galvanized steel is an “old” material being used in ever-increasingly modern and innovative ways. Engineers, architects and
specifiers are realizing that the proven performance, durability and sustainability of galvanized steel give them greater
flexibility in their designs because they have the security of proven performance.
Galvanizing has been in existence for around 170 years and it has been used in Australia for almost as long. There are
galvanized telegraph poles in far north Queensland that are around 130 years old and they are still in such good condition
that some cheeky locals often take them down and use them for other structural applications – the ultimate in recycling.
“Recycling” and “sustainability” may be new buzz words for many materials and in many industries, but in galvanizing it is
par for the course. Both steel and zinc (the components of galvanized steel) are 100% recyclable. It is not a well-known fact,
Editorial but zinc is one of the few materials that can be recycled indefinitely without any loss of superior performance qualities.
Emmanuel Pimentel Approximately 30% of the zinc produced globally comes from recycling. The only reason this figure isn’t higher is because
Prepared by
Galvanizers Association of Australia Story continued on page 2
reADING.
FrOM SO yOu CAN reTurN TO CONTINue
NOTe THe PAGe THAT yOu Were LINKING
The Coal Dam is a large reservoir of about 1 ha that was originally built in The design guidelines also ensure that the character and history of the
about 1895. In 1947, the Coal Dam started to be used as a convenient Railway Workshops heritage area is acknowledged. These guidelines
underwater storage area for the Collie coal that was used as fuel for steam encourage the use of materials that complement the area’s history.
locomotives. Once mined, Collie coal can deteriorate quickly in the ESD is not restricted to Woodbridge Lakes, the whole Midland
atmosphere and become highly combustible, making it a volatile material to Redevelopment is looked at in this way. “Part of the big picture is to make
store safely. In fact, legend has it that Collie coal was first discovered by a the town centre a mixed-use walkable environment,” says Annelise
stockman, George Marsh, in 1883. At the end of a long day minding sheep Safstrom. “That way we reduce dependence on driving within the town and
along the Collie River, he was getting ready to prepare dinner. To help we can reduce traffic and emissions while maximizing the community feel.”
support some of his cooking utensils next to the fire, he used some black
“stones” that were lying around when, much to his surprise, they caught fire!
The proximity of the Coal Dam to the Railway Workshops made it a
convenient storage facility for the coal. It could be kept underwater safely for
The use of Galvanized Steel
as long as needed, and then extracted for use as required. With the decline
of steam locomotives, the dam was eventually decommissioned as a storage
in Woodbridge Lakes and the
facility in 1971 and it was then used to capture and store effluent wastewater
from the Railway workshop.
Midland Area
The remediation of the Coal Dam was obviously one of the main priorities It makes sense that in a community dominated by the Midland Railway
and challenges facing the MRA. After being used for various industrial Workshops that an iconic Australian utilitarian and durable material such as
activities over 90 years, the Coal Dam was severely contaminated with a galvanized steel is used extensively throughout the built environment around
variety of materials including coal dust, sludge and hydrocarbons. The the Coal Dam and Woodbridge Lakes. Galvanized steel is a common sight
contaminants were dredged from the dam and its natural catchment is now throughout Australia’s landscape and it fits in well with the “bushy” feel of
supplemented by bore water which has had a positive impact on the water the whole precinct. Many old trees were retained and it gives the recently
quality. The dam also collects stormwater runoff from the Woodbridge Lakes regenerated area an established appearance.
subdivision and the water is used for irrigation purposes. The Coal Dam is Chris Byrne, a Landscape Architect with Urbis, says, “Given the finish and
now a thriving wetland with various water birds and tortoises calling it appearance of galvanized steel, it was really the only option as it fits in well
home. It is also part of an aesthetically pleasing area with surrounding parks with the history and uses of the site.”
and bush land where residents can enjoy the outdoors and meet for
barbeques and picnics. Story continued on back page
Top: Railway tracks in the Coal Dam Above: Galvanized steel viewing platform
The boardwalk that runs around the Coal Dam is made up entirely of
galvanized steel and timber and fits in well with the aesthetics of the area. Conclusion
In some areas, the galvanized columns and structural steel are actually in the The Woodbridge Lakes development and the regeneration of the Midland
Coal Dam itself so a building material with superior corrosion resistance is Railway Workshops area show how visionary thinking and community
the only option to realize the vision of the designers. involvement can produce successful results. An area that had become
Again, Chris Byrne says that, “We were thinking long-term and trying to tie depressed over the closing of the workshops and the attendant unemployment
in the aesthetics of the site with the permanence of galvanized steel. Using and loss of economic input is being revived through innovative planning and
other materials would have detracted from our vision or not provided the feel design. In fact, the region is one of the fastest growing areas in Australia.
we wanted for the area.” Woodbridge Lakes now has houses valued in the million dollar bracket. This
has helped to change the perception of Midland and creates a momentum to
The fact that most of the steelwork is in public areas means that it needs to help continue the redevelopment of the region.
be robust as it is in constant contact with users of the facilities. Galvanized
steel is actually harder than the base steel it protects so the designers can The creation of the built environment is not just about structures – it’s about
be sure that the steelwork is getting the best possible protection for the people and helping them to feel comfortable and secure. The Midland
longest amount of time. Also, because galvanized steel is a building material Redevelopment achieves this in an impressive way.
where the protective coating is an alloy of the base steel and therefore Whoever said you couldn’t teach an old dog new tricks has obviously
metallurgically bonded to it, there is no risk of the coating being removed by never used Australian galvanized steel or taken a walk around the
impact or abrasion and flaking off into the water. This is an important impressive development at Woodbridge Lakes. That’s why galvanized
consideration not only for reducing the maintenance burden, but also steel and Woodbridge Lakes work so well together – they both have a
because the dam now provides a habitat for various wildlife. rich history, but they also have a bright future.
There are other innovative uses of galvanized steel besides practical
structural applications. Not quite in the Woodbridge Lakes development, but Awards
scattered around the Railway Workshops precinct are several interesting Landscape Design and Irrigation 2006
artworks, many of them using galvanized steel. Local artist Kath Wheatley Awards of Excellence
was commissioned to produce public art for the precinct and she struck upon
the idea of street signs that look like people. Many of the materials used in Australian Institute of Landscape Architects
creating the galvanized “people” were actually appropriated from the • Category: Public Open Space Design
Workshops themselves, a neat twist on recycling and preserving the history Awarded to Tract (now Urbis) for Coal Dam Park
of the area.
Note: The artwork cannot be scaled.
Note: All components must be printed.
Acknowledgements
Annelise Safstrom – Director Planning, Midland Redevelopment Authority
Chris Byrne – Director & Registered Landscape Architect, Urbis
Susanne Roberts – Roberts Thorn Consulting
For further information on the Midland Redevelopment please visit:
www.mra.wa.gov.au
67
Hot Dip GalvanizinG anD
rocket science
galvanize august 2008
Corrosion control has a
big part to play in making
sure that assets provide
a satisfactory return on
their investment to the
community. Durability and
low maintenance mean that
financial reserves are not
expended unnecessarily
and to the detriment
of future investment.
Also, durability is a key
component of sustainability
– the longer an asset lasts,
then the less natural
resources and energy are
required to replace it.
READING.
FROM SO YOU CAN RETURN TO CONTINUE
NOTE THE PAGE THAT YOU WERE LINKING
The Leaning Tower provides a magnificent view across the vast coastal plain
Behind the Leaning Tower
BUTTON TO RETURN TO PREVIOUS PAGE.
BUT UNLIKE A WEBSITE THERE IS NO BACK
from the sea to the Darling Scarp. At the top of the tower there is a platform TO OTHER PAGES WITHIN THE DOCUMENT
of Gingin
that allows visitors and students to repeat Galileo’s ground breaking free fall
THIS INTERACTIVE CD ALLOWS YOU TO LINK
INTERACTIVE CD
experiments from the top of the Leaning Tower of Pisa and to allow studies of A GUIDE TO USING THIS
impact craters caused by their falling objects. Galileo’s experiments not only
uncovered the key universal nature of gravity but also represented the first true The Leaning Tower of Gingin was designed to provide
use of scientific observation to determine the truth behind natural phenomena.
a structure to replicate the feel of Galileo’s testing
The Leaning Tower is the central part of an interactive education experience
on the iconic Leaning Tower of Pisa 400 years ago.
which focuses on gravity, meteorite impacts and the history and formation of
the Earth. The aim of this experience is to excite students about science Of course, Gingin tower’s “lean” of almost 15º was
(especially students in the age range 8-15) and help turn around the declining intentional, as opposed to that of its Italian namesake,
interest in science, technology and innovation related careers. which leans at a mere 5º! Level 5, 124 Exhibitio
Melbourne Victoria 3000 A
Telephone (03) 965
The design development of the Leaning Tower and its construction was a Facsimile (03) 965
major team effort between a number of organizations that donated time, The inclination of the tower means that the structure had to be designed to Email gaa@gaa.
Web www.gaa.
money, expertise and materials. Hatch Associates and United Group cope with a permanent and complex spectrum of stresses in the steel
Resources donated engineering and design services throughout conceptual members. United Group began seriously working on the design and ultimate
phase to detail design. United Group Resources undertook all design drafting construction of the structure about five years ago and has donated most of
work and prepared the shop detail drawings for steelwork fabrication. United the engineering design and project management for the tower.
Group Resources also donated services for the project management, GAA members from the WA State Chapter had no hesitation in offering to
(planning and costing) and construction of the Project. Mr Jon Birman, CE of donate all of the hot dip galvanizing to such an iconic and worthwhile
United Group Resources provided the project coordination for the tower and project. GAA members felt that Australian companies should put something
organised the industry contributions to the project. The Galvanizers into the project to contribute to the work that had already been undertaken
Association of Australia was also represented on the project by its WA State by the other people involved in the project. Not only did GAA members
Chapter members. All of the GAA WA State Chapter members donated their provide the hot dip galvanizing, but another member, OneSteel Australian
services free of charge and are proud to be Australian companies supporting Tube Mills, also contributed a significant amount of the tubular structural
Australian science and education. steel used in the tower.
The tower is made up of approximately 100 tonnes of steel and the base
contains approximately 300 cubic metres of concrete (about 750 tonnes).
The design and detailing of the structure, and its individual structural
components, provided some unique challenges. The triangular plan
arrangement combined with the 14.8º inclination of the tower introduced
deceptively complex geometry and meant that many of the components at
different levels were unique. This complexity also meant that beams at each
level and supporting the viewing platforms had horizontal flanges to support
the floor plate with webs which are inclined.
United Group Resources used the Tekla Structures (X-Steel) shop detailing
software package to ensure that each component would be properly shop
detailed, regardless of the complexity of the geometry. The seamless
integration of engineering design and shop detailing is a significant feature
A view from the top of the Leaning Tower
of United Group Resources’ workflows and project delivery techniques.
These methodologies remove inefficient contractual interfaces and
dramatically improve cost effectiveness and fabrication/construction
efficiency for the downstream stakeholders. The result was that the Tower
was erected easily and with a minimum of effort and disruption to the
operation of the Centre. The construction phase too had its challenges – it’s
not easy to erect a structure which is leaning and constantly trying to fall
over. Gravity always works, especially when building a Leaning Tower!
office and related amenities and a shop where books, science toys,
posters and souvenirs are on sale.
Besides the Leaning Tower of Gingin, other buildings and areas for
exploration and learning include the Southern Cross Cosmos Centre,
Cosmology Gallery and the Zadco Telescope Dome.
66
galvanize may 2008
GalvanizeD steel on the coast
BaCk to thE FuturE
Use of plastic inserts prevents dissimilar corrosion between stainless steel and
galvanized steel in coastal environment
Geelong Carousel Pavilion Bridge rail at Grassy Creek on Great Ocean Road (24 years old)
case stuDies
CaSE Study 4:
Port of Botany Light towers at dP World terminal
Conclusion
Galvanized steel has a long history of use on the Australian coastline.
The requirements for the corrosion protection of steel will continue to
increase due to the nature of the general “seachange” in society and the
fact that most of Australia’s population and industry is located in coastal
environments. In the overwhelming amount of cases examined, galvanized
steel has performed at least to or above expectations. Much of this can
be attributed to the fact that the use of galvanized steel by experienced
engineers and specifiers means that detailing and corrosion protection
are taken into account in the design of structures. However, much
historical “proof of performance” has been passed down by practitioners
without any specific detailing of the reasons why it actually works and
its use in many applications has become a “cultural” norm rather than a
scientifically based process.
It would appear that, in some instances, standards may have
underestimated the performance of galvanized steel in coastal
environments. Case studies and documented evidence are required so
that a scientific basis for the successful and economic use of materials
such as galvanized steel can be presented to show that they are an
option as a construction material in some of the harshest environments.
This will require further work on both an exposition and recording of the
condition of practical structures over their life cycle and also how this
relates to theoretical performance.
Note: The artwork cannot be scaled.
Note: All components must be printed.
Port of Botany light tower being examined (27 years old) The GAA is currently conducting the next stage of the study which will
provide a closer examination of the galvanizing thicknesses and corrosion
The DP World terminal is located in Botany Bay. Depending on wind levels, by-products. It is hoped this provides further insight in the performance
water agitation and other factors, then the corrosivity environment may be of galvanized steel in such environments. Galvanize readers will be
classed as either a C: Medium to AS/NZS 2312 (C3 ISO 9223) or D: High (C4 provided with the results.
ISO 9223). During the time of the inspections, the wind was very strong
coming off the bay and there was considerable spray indicating that for acknowledgements
certain weather conditions there would be periods where the environment Catherine Blaine – James Rose Consulting (Sydney)
approaches that of an E-M Very High Marine (C5 ISO 9223). Greg Cullen – Vic Roads (Geelong)
Geelong Council and Carousel Management
The coating appeared to be in good condition considering its exposure Portland Discovery Centre Management and Staff
environment and age of 27 years. All of the thickness measurements were
above what would be required by Australian Standards for a new installation
(AS/NZS 4680).
Based on the conventionally accepted corrosion rates for zinc and taking into
account the lowest measured thicknesses for each tower, it was conservatively
determined that the remaining life of the coating was approaching at least
20 to 25 years.
63
galvanize January 2006
HOT DIP GALVANIZING
AESTHETICS AND PERFORMANCE FOR AN INNOVATIVE NEW SCULPTURE
galvanize
54April 2001
GALVANIZING IN A
MARINE ENVIRONMENT
In this issue
Channel Island Power Station,
Darwin Harbour, Northern Territory
Christies Beach High School,
South Australia
Galvanized Fasteners adapted
from an article by Frank T Budge,
F&P Consultants
International Zinc Association
Industry Support
The growth of the City of Darwin heralds increasing Australian links with South East Asia and has brought with it the need for development of
infrastructure in similar coastal tropical climatic conditions. This South East Asian link has been highlighted by the development of oil and gas
resources in the Timor Gap, with significant expansion of this activity now on the move. Likewise the progressive increase in the Defence Force
presence in the North has added to infrastructure and urban expansion. This growing port city was given further impetus recently as the base for
Australian and United Nations involvement in East Timor and the many support facilities involved. A continuing growth in the need for electricity has
been addressed by the recent installation of an ice thermal storage system at the Channel Island Power Station operated by the Territory Government’s
Power and Water Authority. The project was a cooperation of Baltimore Aircoil Australia Pty Limited, White Refrigeration and Tafair.
Cost The capital cost of the ice thermal storage system and the associated inlet air-cooling plant was
approximately 70% of that of an additional generating unit to provide a similar increase to power station
capacity. Steel structures are a substantial part of the installation at this marine location. Major units of
steel items include: Freezer Coils
Structural Steel
Roof Purlins After-Fabrication Galvanizing was selected on economic grounds and to withstand the greater risk of
Pipe Work condensation on steel work, due to the cooler temperatures around the ice tank and on general proof of
performance at similar locations around Darwin. Finally as added security, the steel reinforcement of the
ice tank was galvanized to ensure very long service life. The galvanizing work involved several companies
and was sourced from Northern Territory, Queensland, New South Wales and South Australia.
History This significant high school redevelopment was undertaken to consolidate two existing campuses and to provide up to date facilities to cater for
current education trends and the growing number of students in Adelaide’s southern suburbs.
From an aesthetic point of view, there is inherent lasting respectability in the appearance of clean,
natural metal, as well as levels of durability well beyond that offered by applied synthetic materials
which demand regular maintenance. The clever architectural solutions and approach to material
selection evident at Christies Beach High School has resulted in a campus which expresses a quiet
dignity underlining its education purpose and suggesting a campus of substance.”
56
AND THE ENVIRONMENT Special Feature
EPA Victoria/GAA Partnership
Carousel Pavilion
57
galvanize August 2002
BRIDGES IN ASIA
Recent vigorous economic growth in South East Asia has redistributed population and
expanded industry and infrastructure building.
Development of rural and remote regions required innovative engineering solutions to gain
right of way to new land for extractive purposes, industry, urban development and the critical
arteries of commerce – roads.
In countries where, historically, seaports and rivers were the main outlets, roads and bridges emerged Chung Cheng Overpass
to provide heavy load capability and more reliable and productive transport.
In this respect steel bridges were found well suited to the pace of development and challenging
terrain. Offsite completion, orthodox freight to site and relatively simple erection were invaluable aids
to the rapid expansion of the time.
The use of steel in bridge construction is not new, and knowledge of the manufacture and behaviour of this
material is well understood where advancing design use of steel has resulted in economical and
aesthetically pleasing bridge structures. Steel offers particular advantages in that it can be shop
fabricated, under controlled conditions, to almost any desired cross sectional geometry to meet the
specific strength requirement at each site, often at completely undeveloped locations.
However corrosion prevention is one essential factor in the economic utilisation of steel where
provision of the appropriate protective coating can influence initial and whole of life cost, eliminate
maintenance and lost service time, and defer the replacement date of structures.
A wide variety of products have been used for this purpose, however, many bridges require permanent
maintenance teams to sustain adequate steel protection.
In most environments, after-fabrication galvanizing provides very suitable corrosion protection for steel
and has a range of coating characteristics which make it unique. These include an alloy hardness
greater than mild steel, a self-inspecting process discipline and predictable life directly proportional to
its heavy coating thickness. These result in a surface alloy with competitive cost, resistance to severe
impact, extended service life and in turn reliability for use in engineering calculations.
This issue of ‘galvanize!’ features the widespread use of hot dip galvanized steel bridges in the
development of a number of South East Asian countries. Twenty-five years on, these are a tribute to
many people and to the value of galvanized steel.
Taiwan
behind the bridge
The Ma Tsao Bridge in Mount Yang Ming, North Taiwan, the earliest bridge to utilize after-fabrication hot dip
galvanized steel, was opened in 1992. From then on, approximately 30 000 tonnes of steel and around 30–40
bridges have been hot dip galvanized. The most representative of these bridges are the Chung Cheng
Overpass and the Linkou Bridge. There are now approximately 25 000 tonnes of bridges under construction
which are the result of work by the galvanizing industry, with government and academia, in presenting proof
of service of the hot dip galvanizing process, where security, low cost and reliability were crucial factors.
Indonesia - Cambodia
Malaysia - Myanmar - Laos
Transfield-MBK Steel Bridging Systems
Organisation
An outstanding infrastructure bridge achievement throughout the region was the introduction in 1980 of the
Transfield prefabricated bridge systems.
Transfield Constructions were the provider of the Transfield MBK bridging system throughout the South East
Asia region. This included Transfield’s Joint Venture Company in Indonesia, P.T. Trans-Bakrie.
Clients included Government contracts, local authorities and private companies. In flow-on contracts,
Double-Lane Permanent Span A-Class Truss
Transfield-MBK designed and supplied steelwork for a 235 metre double lane suspension bridge over the
Mamberamo River in Irian Jaya and a Twin Suspension Bridge over the Barito River in South Kalimantan (each
420.5 metres in length with a 60 metre deck top truss bridge at the Banjarmasin End).
The original series of these bridges were fabricated and galvanized at Transfield Galvanizing - Seven Hills Plant
Sydney, but were progressively manufactured by the developing fabrication and galvanizing industry in Asia.
Update
As an update to these case histories we can report further bridge announcements
in South East Asia.
Twelve Provinces Bridge Replacement Project
The Indonesian Ministry of Settlement and Regional Infrastructure has just awarded the
“Twelve Provinces Bridge Replacement Project” to the Trans Bakrie-DSD Joint Operation.
This contract comprises the supply of 73 bridge spans which will be erected in 12 separate
provinces of Sumatra and Java.
Trans Bakrie won this tender with a modified design, by Cardno MBK, to the AASHTO
LRFD Bridge Code. The proven principles of the Transfield-MBK bridging system remained
unchanged.
Trans Bakrie’s partner is DSD Dillinger Stahlbau, an established German contracting
company that is part of the MAN and Ferrostahl Groups.
Eastern Indonesia Region Transport Project –
Procurement of Steel Bridging
Trans Bakrie has just received formal award of the IBRD (World Bank) funded steel bridge
supply contract from the Ministry of Settlement and Regional Infrastructure.
This important project named the “Eastern Indonesia Region Transport Project – Procurement
of Steel Bridging” is for the design, fabrication and supply of 77 spans of bridging ranging
from 40m to 100m in length. Total weight of supply is 9150 tonnes and these bridges are all
destined to be erected in Eastern Indonesia over a large geographic area from Central
Kalimantan to Irian Jaya.
The same Cardno MBK design will be used and all fabrication and galvanizing will be
carried out at Trans Bakrie’s Sumuranja facility. Completion date is January 2003.
GAA records its thanks for the history and data in this issue to
Richard Woods – Cardno MBK Consulting Engineers, Sydney, NSW
Tony Caristo – Transfield Pty Ltd
George Walker – P.T.Trans Bakrie – Indonesia
Pasminco Metals
Galvanizing Association of Taiwan (ROC) and many GAA International Associate Members
in Asia
Editorial
George Thomson
ABN 60 004 579 828 Rosemary Scott
We provide information, publications, films and assistance on all aspects of design, performance and applications of hot dip galvanizing. Chairman of GAA
124 Exhibition Street Melbourne Victoria 3000 Telephone 03 9654 1266 Facsimile 03 9654 1136 Andrew Bohn
Email gaa@gaa.com.au Web page www.gaa.com.au
60
Associate of International Zinc Association
In this issue Petrochemicals in their various forms are represented in a wide range of industry, domestic and luxury goods
Galvanizing as an Architectural such as clothing, containers, decorative products, toys, vehicles, building materials and many other utility
Finish (refer back page) items. In addition to traditional plastics and fibre, petrochemicals have become an important component of
electronics, aerospace and other high technology industries.
The rationale for this industry development in Taiwan arose from the land scarcity, dense population and the
need for an economic vehicle to accommodate these characteristics.
300,000 tonnes of In this respect petrochemicals matched the available resources well as it offered accelerated employment
galvanized steel has growth and value added product opportunities, while occupying relatively little land.
been used in this Initially however an acute shortage of basic petrochemicals in Taiwan had impeded development of this logical
downstream activity.
industry development
To this end a major petrochemical plant was designed by the Formosa Plastics Group and a search for a suitable
site undertaken. After wide community debate the project was located in Yunlin County on a vast land
Client
reclamation site on the west coast of Taiwan.
Formosa Plastics Group
This vast project has had a major impact on Taiwan’s development and has been called “the locomotive of
Editorial national economic growth.”
George Thomson
Rosemary Scott Location – “Head of the windstorm and end of the water flow”
Prepared by The Mailiao and Haifong zones that hold No 6 Cracking Plant extend from the Chuoshui River estuary, nearly
Galvanizers Association of Australia 8km north on the coast and approximately 4km seaward, with large areas of the site below sea level for much
of the time.
Editors wish to thank the following for
their generous assistance in preparing Design included geological considerations and strengthening for the security and safety of the refinery
this case study. foundations.
• Formosa Plastics Group
• Taiwan Galvanizers Association
Co-Generation Plant
This unit provides electricity, steam, hyperpure and
industrial water, nitrogen, oxygen and compressed air
for use throughout the plants. A further 500 T/H boiler
is being installed to guarantee the supply of steam.
65
galvanize May 2007
GALVANIZED STEEL
BUILDING THE FUTURE: WATER SUSTAINABILITY DURABILITY ECONOMICS
Archimedean screws carrying sewage to milliscreening plant Galvanized pipes carrying air to aeration tanks
A key part of its strategy is not only the use of recycled water as part of a This waste contains mainly paper pulp and vegetable matter. Once it is
sustainable plan for the future, but it must also be commercially viable. separated, it is transported off site to a waste disposal facility.
Recycled water is considered a valuable resource and part of responsible
The remaining effluent then flows to the facility’s selector tanks and is mixed
management of water as a finite resource.
with recirculated “liquor” (activated sludge) from the aeration tanks. This
About 55 megalitres of sewage is treated at the Black Rock water “liquor” is rich in the bacteria that digests the sewage.
reclamation plant daily. Approximately 99.5% of this sewage is water. The
These tanks work on a four-hour cycle, staggered by one hour. Air is pumped
balance is made up of bacteria, organic fats, solids and various chemicals.
via hot dip galvanized pipes into the tanks for two hours to encourage the
This sewage comes from both domestic and non-domestic sources.
growth of the bacteria so they can do their work. The aeration then stops and
When the sewage arrives at the treatment plant, it is lifted to the milliscreening the sludge is allowed to settle for one hour. At the end of the process, the
facility via large Archimedean screws. These Archimedean screws produce the water left in the decanting tank is suitable for agricultural and horticultural
required pressure to continue through the treatment process. purposes.
The sewage first passes through a coarse screen and then progresses to the
milliscreening plant. The milliscreens have fine apertures of only 3mm. An Environmentally Good IDEA
During this process, solids are removed from the water. The process implemented by the Black Rock water reclamation plant is
appropriately called IDEA: Intermittently Decanted Extended Aeration.
It uses a natural biological process rather than chemicals. It removes
pollutants from the sewage in a simple, cost-effective and sustainable
manner. The bacteria use organics in the sewage as a food source and no
environmentally harmful chemicals are required. These bacteria are
constantly monitored to make sure they are the “good” bacteria and that
they are there in the required numbers.
Corrosion Protection
Water reclamation plants are highly corrosive environments and only the
most robust materials can survive. The Black Rock water reclamation plant
judiciously uses a mix of hot dip galvanized steel, stainless steel and
aluminium to achieve maximum durability and economic efficiencies.
The actual process of aerating the tanks means the pipework can not only
come into contact with sewage, but also has the impacts of salt air, and high
temperatures caused by the friction of the aeration process. All of these
factors not only cause corrosion, but also accelerate corrosion. The incoming
untreated sewage can contain and generate hydrogen sulphide (H2S). Long-
term case studies from the United States of America have shown hot dip
galvanizing performs very well in environments with high levels of H2S in the
atmosphere, such as in close proximity to sedimentation or aeration tanks. Aeration tank – note Bass Strait in the background
All of the main piping that delivers the heated air to the aeration tanks is hot
dip galvanized due to its resistance to corrosion and ability to withstand the
heat generated by the process. Where the steelwork is required to be
Conclusion
immersed in the tanks, then stainless steel is utilised. This is achieved by Water recycling is an increasing part of securing Australia’s future.
joining the stainless steel pipe to the galvanized steel pipe just above the Sustainability and economics demand only the most environmentally-friendly
surface of the sewage using rubber couplings, which separate the two and durable materials should be considered for such projects.
different types of metals to prevent bimetallic corrosion. Barwon Water has engineered the Black Rock water reclamation plant to
Gratings, chains, railings and various other steel furniture are also hot dip ensure it has the least impact possible on the surrounding environment and
galvanized. Most of this steelwork has been installed for around 10 years this has meant ruling out the use of materials and processes that are not only
and is performing well and above expectations. Some of the hot dip costly to use, but can cause further problems when they degrade.
galvanized steel in the milliscreening and pressing plant has been installed The successful implementation and operation of the plant using a judicious
for more than 15 years and has performed well. This includes electrical cable selection of hot dip galvanized steel, stainless steel and aluminium has
trays, structural steel, gratings, platforms and enclosures. The steelwork in ensured the facility has a relatively trouble-free life without impacting on its
direct contact with the fluid in the aeration tanks is stainless steel. sensitive environs.
In addition to the normal harsh environment of a water reclamation plant, the
Black Rock water reclamation plant’s corrosivity levels are further increased
by the fact that it is located on the coast. The combination of a water
reclamation plant in a high chloride environment means only the most robust
and corrosive resistant materials will survive.
The harsh conditions are further exacerbated by the fact that the local
birdlife appear to find the tanks used in the process an attractive
environment. Unfortunately, they are not toilet-trained with much of their
waste ending up on the steelwork and this can also be very corrosive! Hot
dip galvanizing is a significant part of the solution used by Barwon Water
and it is meeting the challenge of durability and corrosion resistance.
Engineers, asset owners and operators have long been at the forefront “Sustainability” means meeting our current needs without compromising
Note: The artwork cannot be scaled.
Note: All components must be printed.
in demanding that their designs be economical, durable and the ability of future generations to meet their own needs. This can be
environmentally responsible. To these important criteria has also applied to businesses to mean that the structures that are put in place
recently been added the idea of sustainability. The implementation of today should be cost effective, relatively maintenance free and not place
such economical, durable and environmentally responsible designs a financial burden on their future operations.
requires sustainable materials that are accessible, simple to apply and After-fabrication hot dip galvanizing has long been recognized as
retain their protective integrity over a long period of time. After- providing superior corrosion protection in most conditions. It is also now
fabrication hot dip galvanizing has been used to protect steel for over being recognized as an environmentally friendly corrosion protection
170 years. During this time, it has been used to protect almost every technology based on the measures of sustainability, durability and life
type of steel structure and fabrication used in the built environment and cycle assessment. Galvanized steel has an inherent environmental
infrastructure industries. advantage in that its two components, steel and zinc, are recyclable. Not
The Galvanizers Association of Australia and its members believe that content in the fact that after-fabrication hot dip galvanizing is superior
sustainability should be a major consideration of all industries and that to other corrosion protection technologies, the Australian galvanizing
their performance should be measured in these terms. Galvanizing has a industry has continued to invest in its process to ensure that a
long, proud and successful track record and this is expanding due to the sustainable corrosion protection system is produced in an equally
ease of use of galvanized steel and the technical support available sustainable manner.
through the Association. The Association’s technical staff are constantly working on monitoring
It has been acknowledged in Australia and around the world that and developing case studies that give specifiers reliable information on
sustainability needs to be an integral factor in the process of design and the performance of galvanized steel in their particular applications. All
construction, a “core function” in the modern parlance. However, members of the Galvanizers Association of Australia have access to
sustainability must be financially viable if it is to be embraced by their technical staff, technical materials and case studies from Australia
business. It is only when businesses and projects are both profitable and and around the world. If you need further information or advice on any
sustainable that their true value to the community is realised. aspect of hot dip galvanizing or corrosion protection, then please contact
our technical staff for assistance.
58
galvanize April 2003
WORSLEY ALUMINA
EXPANSIONPROJECT
64
galvanize October 2006
GALVANIZED STEEL
ENVIRONMENTAL SENSITIVITY AND PERFORMANCE
In this issue Architectual engineering and landscape designers are great innovators.
Innovative designs require materials and protection technologies that are
Lake Vasto, versatile and sensitive to all environments, yet are durable and minimise the
need for ongoing maintenance. After-fabrication hot dip galvanizing technology
Western Australia has been used to protect steel for over 170 years. In fact, hot dip galvanizing
has been used to protect almost every type of steel structure and fabrication
imaginable. In Australia, there are examples of hot dip galvanizing that have
The Australian Garden, managed to survive in the harshest conditions for 130 years.
Victoria As our cities become denser and expand, the selection of materials for use in
the built environment will require innovative and sensitive design that should
not only be aesthetically pleasing, but will also need to withstand the rigours of
Editorial everyday use by those in the community. Designers are beginning to appreciate
Emmanuel Pimentel the fact that galvanized steel is a material with superior corrosion resistance,
abrasion resistance and environmentally friendly qualities. Australian Garden, Cranbourne VIC
Prepared by
Galvanizers Association of Australia When designers opt for the superior durability of hot dip galvanized steel,
they are using a natural material with aesthetic and protective capabilities
that maximises the use of public capital and space. The vision of inspired
designers can be realised without compromising their environmental integrity.
In this issue of galvanize!, we look at two case studies separated by 3,500km,
but similar in their efforts to promote environmental awareness and
responsibility.
Lake Vasto is named after Perth’s Sister City, Vasto, a port city on Italy’s
Adriatic Coast. The lake was opened in 2004 by the Lord Mayor of Perth,
Dr. Peter Nattrass, and the Mayor of Vasto, Dr. Filippo Pietrocola.
Lake Vasto has a key role to play in a more environmentally friendly
irrigation system for foreshore parks and reserves in Perth. It is filled with
water collected from a 300m deep artesian supply beneath Langley Park.
This water is then used to irrigate most of the City of Perth’s 70 hectares
of foreshore parkland.
A key contributor to maintaining its environmental friendliness while
improving aesthetics is a new water treatment and pumping facility that
reduces the level of iron staining on surrounding footpaths and buildings
– an unsightly consequence of using bore water for irrigation in an
urban setting.
The benefits of the systems are not only environmental and aesthetic,
they are also economic and raise efficiency. This is achieved through an
automated, in-ground irrigation system that replaces inefficient and
labour-intensive travelling irrigators and above-ground hoses. “I like the raw quality. It’s simple to use and I haven’t had any problems
The City of Perth also had a vision to make the area visually appealing with it.”
and to promote its use to the public. Part of this involved the design and The virtual elimination of maintenance costs through the use of
construction of a boardwalk along the shores of the lake. The boardwalk galvanized steel also appeals to designers. Stuart says that one of the
was constructed by combining timber and galvanized steel, two natural, main advantages is that, “Galvanizing is very durable. There is no damage
durable and earthy materials. to the coating during transport and installation like there is with other
The boardwalk was designed by landscape architect, Stuart Pullyblank coatings such as powder coating and paint.”
of TRACT in Perth. Stuart often uses natural and robust materials such Environmental and visual concerns were also an issue since this was a
as galvanized steel in his work. He said that choosing galvanized steel waterway. “Once in use,” says Stuart, “And in this particular application,
was easy. we couldn’t afford a coating that falls or chips off into the water.”
“Galvanized steel is tough and durable in public traffic situations, but
warm enough that people accept its presence.”
59 THE ARCHITECTURAL
galvanize INTEGRATION OF CAR PARKS
October 2003 The modern car park provides the transition from personal to public transport. These transport hubs link car use
to anything from pedestrian thoroughfares to flying. Inner city dwelling is also a growing factor in the need to
park cars more efficiently. “Galvanize” case studies in this issue highlight the architectural achievements
evolving from upgrading strictly utility structures to unobtrusive and functional civic buildings.
61
galvanize March 2005
INDOOR SWIMMING POOLS
In this issue
Aquatics: Growth of indoor
swimming pools.
Westpac Call Centre
Editorial
George Thomson
Rosemary Scott
Prepared by
Galvanizers Association of Australia
Maintenance Community
Pool maintenance includes ensuring Mr Peter Smith, Associate Director
water quality, services to the public of Prior + Cheney Architects
and fabric preservation, all within a summarises by saying, “swimming
high level of surface wear and facilities require highly detailed
impact. The need for maintenance research to offer a large community
derives not only from these segment maximum utility and
conditions but also the degradation fulfilment from this enjoyable
of organic paint coatings by UV activity.”
radiation. This company, whose work is now
Galvanizing is immune to UV, has featured in galvanize!, has been
outstanding abrasion resistance and designing aquatic facilities for over
good evidence of over 30 years to 18 years and has produced many
first maintenance. examples of steel frame structures
used in a striking and attractive
manner.
Even in Australia’s climate, such
Queanbeyan Aquatic Centre, NSW
facilities have become an invaluable
aid to our good health and athletic
aspirations and have achieved
increasingly wide appeal.
62
galvanize August 2005
GALVANIZED REINFORCEMENT
In this issue
Galvanized Reinforcement
in Major Infrastructure
Engineering
Industry Environmental
Leadership Project
Editorial
George Thomson
Rosemary Scott
Prepared by
Galvanizers Association of Australia
52
galvanize
March 2000
GRANDARBOUR
SOUTHBANKBRISBANEQUEENSLAND
It is said that many of our cities have succumbed to functional concrete jungle design. Social reformers working
to reverse this world trend will be impressed by the ingenuity of the South Bank Corporation in Queensland, which
has provided clear direction for some inspired architectural work, bringing the vision and rhythm of the Australian
Hinterland into the heart of the City of Brisbane. It is refreshing to see the commercial growth of this vibrant city,
accompanied by matching concern for its people and the environment.
Master Plan
Denton Corker Marshall
The master plan of the expo site and some adjoining neighbourhood, comprises approximately
43 hectares along the Brisbane River, directly opposite the central business district.
In addition to the Brisbane Convention and Exhibition Centre, South Bank features an
international hotel, high quality corporate office development, selected academic facilities,
residential apartments and a range of restaurants, retail outlets, a swimming lagoon with
its own beach and a tropical arbour linking the entire development.
Parkland
The 17 hectare South Bank Parklands stretches along one kilometre of the river bank, where
further development includes placement of tropical rainforest trees, surrounding open green
spaces of ground vegetation; a soothing contrast to city activity.
Vision
The success of the development has arisen from the adage that enthusiasm is infectious.
In this case, it has also been innovative and inspired.
A cooperative team of experts have created a city development equal to any in the region,
with an admirable balance of community consideration, appropriate function, environmental
concern and aesthetic appeal.
Even yet, the project is not considered closed, where clearly opportunity is being provided
for further development for the future growth of the area.
HBANKBRISBANEQUEENSLAND
Modular components
The height of the posts (10m) meant that they would have to be in parts
for ease of transportation and assembly. A kit of parts, made up of a
small range of components was the solution. The posts were divided
into 3 unequal lengths - Base, Neck and Head. 3 variants were devised
for each part (A, B, C) resulting in a total of only 9 different components.
Any Base component could be connected to any Neck and any Neck with
any Head. They could also be rotated 180 degrees. This allowed for a
possible 108 different permutations for the post profiles, varying from
10m high gently undulating to head height expressively curving. Computer Model
The complexity and non-linear nature of the project meant that
traditional documentation techniques would be insufficient.
Advanced Computer Aided Design for all stages including design,
documentation and construction was utilised. The entire Arbour was
simulated as a full scale 3D computer model, from which all plans,
elevations and sections were extracted.
Specially written computer programmes analysed the CAD model
and automatically generated schedules for the Arbour setout and
post components.
Finishes
Hot dip galvanizing was selected as the finish for the posts. Corten
steel (a pre-rusted finish) had been considered in the early stages, but
concerns over run-off staining of the path (and pedestrians) negated its
use. Furthermore its rusty brown colour would give the impression that
the posts were imitating trees. The Arbour, while being organic, was
clearly to be a man-made insertion into the landscape, not an imitation
of nature. The grey metallic finish of the hot dip galvanizing provided
the desired artificiality and industrial ruggedness, in addition to a low
level of maintenance.“
GAA would like to thank Denton Corker Marshall and South Bank
Corporation for their assistance in preparing this case study.
Masterplanner and Architect Denton Corker Marshall Client South Bank Corporation Master Architect John Simpson Landscape Architect Gillespies Australia
Project Manager Resource Co-ordination Partnership Structural & Civil Engineer Connell Wagner Lighting Consultant Barry Webb & Associates
Main Contractor Walter Construction Group Steel Fabrication Sub-Contractor Schmider Engineering Group
55
galvanize November 2001
FEDERATIONSQUAREMELBOURNE
The essence of the city, it is said, is embraced in the architecture of Federation Square. Whether
defined as encompassing the basic nature, or an indispensable quality, much of it is to be found in
these visionary structures. Melbourne has been nominated the world’s most liveable city and has
now gained a futuristic precinct, which defines both its appeal and its welcome.
Taking the city to the river The Atrium from Flinders Street
Vision “Federation Square is one of the most ambitious and complex projects ever undertaken in Victoria.
It is a complete new city block, the first ever to physically connect the central business district with the Yarra
River. Situated at the heart of central Melbourne, Federation Square will be a fusion of arts and events,
leisure, hospitality and promenading.”
Federation Square Management – The State Government of Victoria has established a management company, Federation
Square Management Pty Ltd, to act as client and director of the project and run Federation Square in perpetuity on a commercial
basis. The company comprises of a board of three directors, its management team and staff.
DESIGN: Federation Square’s design is the product of an international architectural competition won in July 1997 by Lab
architecture studio of London in association with Bates Smart Architecture of Melbourne. Atelier One were appointed
Project Structural Engineers. The judging panel said of the winning design: “It draws its inspiration from the unique
characteristics of Melbourne’s arcades and laneways, and transforms these elements into a new form of organization,
celebrating the city. The design will invite pedestrians to explore a complex and urban linkage of open and closed spaces,
a set of different amenities brought together in the architectural equivalent of Federation”
FEDERATIONSQUAREMELBOURNE
As Federation Square Management describes, “The area is designed with extensive flow, integrating activities
across the site, and forming links within it, as well as with the Yarra River, Arts Centre, Southgate and the Central
Business District. Federation Square’s architectural intent is to generate visual harmony for the site while
maintaining differences between its civic, cultural and commercial buildings. The approach creates distinctions
through a high degree of surface and material variation. The creative use of the ‘pin wheel’ triangular grid, in which
every panel is exactly the same size with only the orientation changing, as the modular basis for this system allows
both façade cladding and frame shapes to be treated in a continually changing visually dynamic way. On the main
buildings three cladding materials have been used – sandstone, zinc and glass.
Forming a north-south link from Flinders Street to the Yarra River, the Atrium
is a large, high volume public thoroughfare and covered meeting space. This
glass-enclosed galleria provides a sheltered extension of the Plaza, and acts
as the forecourt to the National Gallery of Victoria: Australian Art. Open at
the northern end, the Atrium allows 24-hour access across Federation
Square linking the city to the river. The southern half of the Atrium steps
down from the elevated level of the riverside promenade, and has been
designed to operate as a casual chamber amphitheatre, with an acoustic
tuned interior. The open-frame structure of the Atrium has been developed
using parts of the same triangular geometry as the facades, but forms a
three-dimensional framing system, glazed both inside and outside. The
7,500m2 Plaza has been designed as the new civic focus for Melbourne,
capable of holding about 10,000 people. The Plaza will be paved with
sandstone from the Kimberley region of Western Australia, featuring
striking reds, maroons, purple and gold surfaces. Federation Square utilises
an environmentally sensitive building design. Innovative air-conditioning has
been integrated within the building design to achieve significant, long term
cost savings. Underneath the Plaza, traditional passive cooling technologies
on a large scale eliminate the need for energy-hungry air-conditioning for
the glazed Atrium.”
Part of a liveable city
GAA would like to thank the following companies for their assistance and
content: Federation Square Management Pty Ltd, Lab + Bates Smart Pty Ltd
and Riband Steel Pty Ltd.
Steel structures and window spaces
forward >
New Safety in Venting for Galvanizing A1 Poster available from GAA, email gaa@gaa.com.au
chapter start
Vessels and hollow
VENT AND DRAIN REQUIREMENTS sections, including those
FOR GATES AND FENCING in small diameter tubular
fabrications, MUST be
< back
vented to atmosphere for
the safety of galvanizing
personnel and to prevent
possible damage to the
article. At galvanizing
temperatures, moisture
trapped in closed
sections is converted
rapidly to superheated
steam, generating
explosive forces unless
vented.
www.gaa.com.au
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