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November 23, 2019  Steel Pole Design / Technical Articles

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Corrosion protection and nish are important Technical Articles
considerations when designing a line using steel Steel Pole Design

structures. The most commonly used corrosion Pinoy Inhinyero

protection and nish options used for steel poles Philippine Electrical
Code
include (1) paint and coating systems, (2) galvanizing, (3)
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weathering steel, and (4) metalizing.
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For comprehensive information regarding these

protections, refer to ASCE/SEI 48-11 Design of Steel Blog Stats
Transmission Pole Structures.
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Table of Contents 

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1. Paint and Coating Systems Significant
Changes to
A large variety of paint and coating systems are available
Philippine
that not only provide corrosion protection for the
Electrical Code
underlying steel but also o er a choice of color.
(PEC) 2017
Edition
Above-Grade Protection
For above-grade corrosion protection of steel Sag-Tension
poles, superior paint system use zinc-rich primer. Spreadsheet Free
These types of primers offer cathodic protection. Calculator (Even
Below-Grade Protection Elevation)

For the embedded portion of steel structures, a

What is Ruling
thick coating of polyurethane or epoxy material Span?
provides significant protection.
Additional protection us a welded steel ground Sample
Calculation of Sag
sleeve that should extend 2-4ft above and below
and Tension of
the grade line.
Transmission Line
- Even Elevation
2. Galvanizing
Philippine
Galvanizing, in the context of transmission structures, Electrical Code
generally refers to the hot-dip process. This process
involves the immersion of the section into a bath of Subscribe to Blog
molten zinc. via Email

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Hot-dip galvanizing has been an economical means of
address to subscribe
corrosion protection for steel structures. It has been
to this blog and
used extensively because of its dynamic protective
receive noti cations of
nature consisting of a barrier coating and zinc’s
new posts by email.
sacri cial action.

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Double-dipping is not recommended for tubular
structures because corrosion can occur in the overlap
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portion.

3. Weathering Steel
Weathering steel develops a tight oxide coating that
protects against continuing corrosion of the substrate.
This type of steel develops a nish that is relatively
maintenance-free.

Weathering steels should not be used in bare conditions

in atmospheres with high concentration of corrosive
chemicals, industrial fumes or severe continuous salt fog
or spray environments. It should not be buried without
a method of protection against corrosion.

4. Metalizing
The structure may be protected against corrosion by
thermal spraying a coating over the base metal.
Thermal spraying includes ame spraying, electric arc
spraying, and plasma spraying.

Hot-Dip Galvanizing Process

The typical step-by-step process of hot-dip galvanizing is
shown below. Images are courtesy of PHILGALV
INDUSTRIAL COATING INC during our visit last October
2019.

1. LOADING AND
JIGGING
Loading and Jigging

Proper loading of steel

items for galvanizing to
ensure proper venting
and draining.

2. DEGREASING

Degreasing
Use a hot alkali solution
to remove organic
contaminants such as dirt,
paint markings, grease,
and oil from the steel
surface.

3. HYDROCHLORIC
ACID-PICKLING
Hydrochloric-Acid-Pickling

Uses a diluted solution of

hot sulfuric acid or
ambient temperature
hydrochloric acid to
remove scale and rust
from the steel surface.
4. WATER RINSE

Water Rinse
Removal of acid residues.

5. PRE-FLUXING

Pre-Fluxing
Pre- uxing in zinc
ammonium chloride
solution for surface
conditioning.

6. PRE-HEATING

Pre-Heating
Pre-heating accelerates
the whole HDG process
by 20% compared to the
conventional type. It also
reduces the violent
reaction during the
immersion process.

7. ZINC BATH

Zinc Bath
Immersion of steel to
molten zinc at 450-455
degrees centigrade. The Kettle

product is immersed until

it reaches the
temperature of the kettle.
The zinc then reacts with
the steel to form a zinc-
iron intermediate alloy at
the steel surface.

8. QUENCHING

Quenching
Passivation of the zinc
surface to prevent early
oxidation.

9. DRESSING AND
QUALITY CONTROL
Dressing and QC

Removal of excess zinc,

sharp ends, and
drippings.

10 Major Measurable Benefits of

Hot-Dip Galvanizing
1. Lowest First Cost.
In countries where HDG is widely used, galvanizing
is lower in first cost than other commonly specified
protective coatings for steel due to increasing
labor and material cost.
2. Less Maintenance / Lowest Long Term Cost.
It is cheapest in the long term.
3. Long Life
 The life expectancy of galvanized coating on typical
structural members is far in excess of 50 years in
most rural environments, 20-25 years in severe
urban and coastal exposure.
4. Reliability
Galvanizing is carried out to internationally
accepted standards. Coating life and performance
are reliable and predictable.
5. Toughest Coating
A galvanized coating has a unique metallurgical
structure which gives outstanding resistance to
mechanical damages in transport, erection and
service.
6. Automatic Protection for Damaged Areas
Galvanized coatings corrode preferentially to steel,
providing cathodic or sacrificial protection to small
areas of steel exposed to damaged.
7. Complete Protection
Every part of the item is protected even in
recesses, sharp corners, and inaccessible areas.
8. Ease of Inspection
Galvanized Coatings are assessed readily by eyes
and simple non-destructive thickness testing
methods.
9. Faster Erection Time
As galvanized steel members are delivered, they
are ready for use. No time is lost on-site in surface
preparation, painting, and inspection.
10. A Full Protective Coating can be Applied in Minutes.
A 4-coat paint system requires a week. The
galvanizing process is not dependent on weather
conditions.

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