Internal Workshop – Galvanising /

Chinese Galvanising

Australia | China | Hong Kong | United Arab Emirates | Europe www.inhabitgroup.com

Why Galvanize Steel

Exposed steel surfaces

corrode creating rust.

Rust (iron oxide) is

permeable.

Fun Fact: Rust costs the USA

$400 billion a year (No
Source)

Galvanising creates a zinc

alloy surface which prevents
rust. Yuanda Yard
Galvanising Process:

1. Blasting / Degreasing

2. Acid Pickling

3. Rinsing

4. Fluxing

5. Galvanising

6. Quenching
Standard design items to
consider:

1. Thickness of galvanising

2. Drainage (internal)

3. Air pockets

Drainage / Air Pockets

Case Studies:
Barangaroo T3

- 12 Tonne Steel Members

- 15 meters long

- Galvanising + three coat

paint system

- Issues…
Case Studies:
Barangaroo T3

- Orange Peel

Factors:

- Paint System, application

techniques

- Underlying steel condition…

Case Studies:
Barangaroo T3

- Underlying steel condition

- Flaking and peeling of gal

- Galvanising up to 1200um

- Little adhesion
Case Studies:
Comparison

Comparison of Galvanised Surfaces

Case Studies:
Barangaroo T3 - Causes

- Plate thickness
(inconsistent, heavy)

- Time in the bath (~460oC)

- Payment Strategy ($$$)

- Chinese steel (Si, P)

- Drainage holes
Case Studies:
Barangaroo T3 –
Drainage Holes

- Requirement for internal

galvanising

- Speed of drainage
Case Studies:
Barangaroo T3
– Si / P Content

- China Q235 Grade Steel

- Increased Si / P content
(Delta / Gamma layers)

- Decreased adhesion

- Peeling vs Flaking
Case Studies:
Barangaroo T3 - Solution

- Complete blast back of

galvanising

- Thermal Zinc Spray

- Similar performance to
galvanising
Application of Thermal Spray
- Used on oil rigs
Painting Process:

1. Blast to bare steel

2. Thermal zinc spray

3. Primer – interzinc 251

4. Patch / Interfill / Sand

5. High Build – Interpon 475HS Finished Product

6. Interfine 878
Painting Process:

1. Blast to bare steel

- Class 3 Blast

- Requires painting within 4

hours

Finished Product
Painting Process:

2. Thermal Zinc Spray

- 100um

3. Interzinc 251

- Paint Primer

- WFT vs DFT

Primed Product
Painting Process:

4. Patch and Interfill

- two part

- smooth hammer marks and

welds

- adhesion issues / thermal

expansion

Post Interfill
Painting Process:

5. High Build Epoxy Coat

- two part

- high volume of solids /

corrosions resistance

- Curing rates / cold climates

Post Interfill
Painting Process:

6. Top Coat

- Polyurethane

- Enhances blemishes

Post Interfill
Galvanising:
5. Maximum thickness of Gal
Trouble Shooting – QC
Issues 6. Testing the thickness and
flaking
1. Steel Properties (Si / P)
7. Uneven plate thickness
2. Surfaces including welds
blasted to SA2.5 8. Hollow section drainage

3. Ensure no delay resulting in Mill 9. Handling freshly galvanised

Scale components

4. Minimum thickness of Gal 10. Other…

Thank-you
Bruce Wymond
Matthew Davidson

Australia | China | Hong Kong | United Arab Emirates | Europe www.inhabitgroup.com