Galvanize It!

Seminar
American Galvanizing Association

American Galvanizers Association

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

American Institute of Architects
Learning Units (HSW)

National Council of Examiners for Engineering & Surveying

Professional Development Hours

Continuing Education
AIA/CES Policy on Endorsement: The following program is registered with the AIA/CES and does not include content that may be deemed or construed to be an approval, sponsorship, or endorsement of any material of construction or any method or manner of handling, using, distributing, or dealing in any material or product.
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Continuing Education
The American Galvanizers Association has met the standards and requirements of the Registered Continuing Education Providers Program. Credit earned upon completion of this program will be reported to RCEPP. A certificate of completion will be issued to each participant. As such, it does not include content that may be deemed or construed to be an approval or endorsement by NCEES or RCEPP.
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Purpose of this Seminar

The purpose of this seminar is to inform and educate architects, engineers, and other specifiers about hot-dip galvanized steel and how it can address the growing corrosion problem throughout North America.

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

The Corrosion Problem

The Corrosion Problem

Bridge in Denver, CO Bridge in Denver, CO

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The Corrosion Problem

Corroded Trolley

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The Corrosion Problem

Coors Field Denver, CO

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The Corrosion Problem

Corroded Pier
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The Corrosion Problem

Williamsburg Bridge - New York City, NY

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Corrosion Costs
NACE, CC Technologies, & FHWA jointly produced a report in 2001 detailing the costs of corrosion
$297 billion USD annually 3.1% of US GDP (1998)

Hazardous
Public safety, property damage, environmental contamination

Natural Resources
Waste production, increased energy consumption

Public Outcry
Traffic, inconvenience
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The Solution: Hot-Dip Galvanizing

Barrier Protection

Weathered Guardrail
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Cathodic Protection: Galvanic Series

ZINC - Anode STEEL - Cathode

This arrangement of metals determines what metal will be the anode and cathode when the two are put in a electrolytic cell (arrangement dependent on salt water as electrolyte).
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Cathodic Protection
Exposed Steel is Protected Zinc Coating

Bare Steel

With a cathodically protective coating, such as galvanized steel, damaged areas will be protected by the surrounding zinc
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HDG Process
Steel is dipped in a series of tanks including solutions that remove impurities from the steel surface. The galvanizing reaction only occurs on perfectly clean steel. The steel is inspected after galvanizing to ensure conformance to the appropriate specifications.

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Long-Lasting Zinc Protection

Barrier Cathodic Zinc Patina
Barrier

Long-lasting Protection

Zinc Patina

Cathodic

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HDG Process: Surface Prep

Zinc-iron metallurgical bond only occurs on clean steel Degreasing
Removes dirt, oils, organic residue

Pickling
Removes mill scale and oxides

Fluxing
Mild cleaning, provides protective layer

Caustic cleaning

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HDG Process: Galvanizing

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

Zinc bath removal

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HDG Process: Inspection

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

Metallurgical Bond

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Edge Protection

Same thickness at corner

Micrograph of galvanized edge

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Additional Benefits of HDG

Complete Coverage

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Additional Benefits of HDG

Variety of sizes and shapes

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Additional Benefits of HDG

Availability

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Galvanizing is Green
Zinc is 100% recyclable as is the steel
Properties of zinc do not degrade w/ reprocessing Zinc is a natural element in the Earths crust

The longevity of galvanizing means no additional energy exerted or waste created maintaining galvanized structures
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Estimated Service Life of HDG

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Other Zinc Coatings for Corrosion Protection

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

Metallizing Appliation
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Zinc Rich Paint

Metallic zinc dust
Inorganic Organic

Barrier protection Cathodic protection

Limited Dependent on % Zn
Zinc Rich Paint Application

Use salt spray data to make performance claims

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Sheet Galvanized
Produced by a continuous in-line hot-dip process
Coil-to-coil process
400-500 FPM

Air knives remove excess zinc Pure zinc with little alloy layer
Galvannealed (Zn-Fe) Galvalume (55% Al)
Sheet Steel of Continuous

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Sheet Galvanized
ASTM A653 specify total coating weights, most common G60 and G90
Weights represent total coating weight for both sides of the sheet Coating Weight (ounces/sq. ft.) Coating Thickness per Side (mils)

G60 G90

0.60 0.90

0.54 0.81
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Electroplated
Strip, sheet, or small parts
Smooth finish Slightly more expensive than sheet galvanized

Good formability Paintable

Electroplating Application

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Zinc (Mechanical) Plating

Similar to electroplating
used for fasteners and small parts

Parts are tumbled in drum with zinc powder and glass beads
mechanically bonded zinc

Mechanical Plating Application

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Other Zinc Coatings

Metallizing Hot-Dip Galvanized Sheet Galvanized

Zinc-Rich Paint
Electroplated

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Design & Fabrication

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Materials Suitable for Hot-Dip Galvanizing

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Hot-Dip Galvanized Fasteners

Hot-dip galvanized fasteners are recommended for joining HDG structurals

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Steel Reactivity

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Coating Appearance
Newly Galvanized
No Spangle

Newly Galvanized
Dull Coating

Newly Galvanized
Highly Spangle

Newly Installed
Shiny & Dull Coating

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Combining Different Materials

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Weathering of Galvanized Steel

Photo taken: 12/18/02

Photo taken: 03/28/03

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Dissimilar Thicknesses
Different thickness
Zinc bath temperature at different times

Similar thickness
Maintain original shape

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Galvanizing Oversized Pieces

Progressive Dipping
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Material Handling

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Venting & Drainage

Vent

Drain
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Specifications & Inspection

ASTM Standards for Galvanizing

Galvanized Products
ASTM A 123 general ASTM A 153 small parts ASTM A 767 rebar

Supporting Specifications
ASTM A 143 embrittlement ASTM A 384 distortion ASTM A 385 high-quality coatings ASTM A 780 repair ASTM D 6386 surface prep for painting over
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ASTM A 123
Standard Specification for Zinc (Hot-Dip Galvanized) Coatings on Iron and Steel Products
Coating Thickness material category and steel thickness Finish continuous, smooth, uniform Adherence should be tightly adherent through all expected uses of article
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ASTM A 153
Standard Specification for Zinc Coating (HotDip) on Iron and Steel Hardware
Coating Thickness material category, steel thickness, length Finish continuous, smooth, uniform Adherence should be tightly adherent through all expected uses of article
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ASTM A 767
Standard Specification for Zinc-Coated (Galvanized) Steel Bars for Concrete Reinforcement
Coating Thickness smooth or deformed (no wire), bar size Chromating prevent reaction between fresh cement and recently galvanized material Bend Diameters flaking and cracking due to fabrication are not rejectable.
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ASTM A 780
Standard Practice for Repair of Damaged and Uncoated Areas of Hot-Dip Galvanized Coatings
Zinc-rich paint, zinc-based solder, or metallizing
Zinc-rich paint - most common but must have certain amounts of zinc dust as required by spec Zinc-based solder good for small areas, closely mirrors typical HDG coating appearance Metallizing excellent corrosion protection

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Hot-Dip Galvanizing
Costs Less & Lasts Longer

Quantitative Analysis
Initial cost vs. Lifecycle cost
Based on 2006 galvanizing industry survey nationwide 2006 KTA-Tator paper paint industry survey nationwide Standard mix of steel products (structural, tubing, plate) 10,000 ft2 project

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

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Initial Cost
Material Shop cleaning labor Shop application Field labor

Pneumatic Bulk Trailers

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Initial Cost ($/ft2)

Coating System Inorganic Zinc Inorganic Zinc/Epoxy $/ft2 $1.31 $2.09

Hot-Dip Galvanizing Acrylic WB Primer/Acrylic WB Intermediate/Acrylic WB Topcoat Inorganic Zinc Primer/ H-B Epoxy/Acrylic Urethane

$1.92
$2.51 $3.07

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

Maintenance repaint at 5% rust in a moderately industrial environment 30-Year Project Performance

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Life-Cycle Cost ($/ft2) 50-Year Project Performance

Coating System Hot-Dip Galvanizing Inorganic Zinc $/ft2 $1.92 $3.21

Inorganic Zinc/Epoxy
Inorganic Zinc Primer/ H-B Epoxy/Acrylic Urethane Acrylic WB Primer/Acrylic WB Intermediate/Acrylic WB Topcoat

$4.83
$6.43 $7.98
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What Does All of This Mean?

Coating System Hot-Dip Galvanizing Inorganic Zinc Inorganic Zinc/Epoxy Inorganic Zinc Primer/ H-B Epoxy/Acrylic Urethane Acrylic WB Primer/Acrylic WB Intermediate/Acrylic WB Topcoat Cost $19,200 $32,099 $48,261 $64,302 $79,802
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Duplex Systems: Painting & Powder Coating Hot-Dip Galvanized Steel

Why Paint a Perfectly Good Galvanized Part?

Aesthetics
Architects decision

Identification Hostile Environment to Zinc Repair of Existing Galvanized Articles

Extended Life of the Product
Light Rail Station

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Galvanized Surface Coating Condition

Newly Galvanized Steel Partially Weathered Galvanized Steel Fully Weathered Galvanized Steel
Painted Bridge Rail
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Passivation Cycle
Time
0 48 hrs.

48 hrs. 6 mo.

6 mo. 2 yrs.

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Sweep Blasting

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Duplex System Layers

Fence Pole
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Duplex System Synergistic Effect

Paint Provides Barrier for Galvanized Surface Galvanized Coating Provides Slow Corrosion Under Paint Paint Peeling due to Corrosion is Minimized Paint & Galvanizing together have 1.5x to 2.5x Life of Individual Lifetimes

Skaneateles Community Center

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Galvanized Steel Project Applications

Brooklyn Bridge
Date Galvanized 1999
Sector Bridge & Highway Environment Industrial

Location New York, NY

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CALTRANS District 7 HQ
Date Galvanized 2004 Sector Building & Architecture Environment Urban Location Los Angeles, CA

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The Cloud at Fashion Show Mall

Date Galvanized 2003
Sector Building & Architecture Environment Urban

Location Las Vegas, NV

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Harrisburg Airport Transportation Facility

Date Galvanized 2004
Sector Building & Architecture Environment Urban

Location Harrisburg, PA

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Cell Towers Tree Application

Date Galvanized 2004
Sector Electrical, Utility & Communication Environment Rural

Location California

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Leprino Foods
Date Galvanized Unknown Sector Food & Agriculture

Environment Rural Location Waverly, NY

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Piers 1 & 21 Replacement

Date Galvanized 2002 Sector Water & Marine

Environment Marine Location Norfolk, VA

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AGA Resources
1-800-HOT-SPEC (800.468.7732)
aga@galvanizeit.org www.galvanizeit.org

Technical Library
Galvanizing Insights e-Newsletter
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