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 afterfabrication galvanizers, fabricators,
architects, specifiers, and engineers
The AGA provides technical support on
today's innovative applications and stateof-the-art technological developments in
hot-dip galvanizing for corrosion control
2

Continuing Education Credit

American Institute of
Architects
Learning Units (HSW)

National Council of Examiners

for Engineering & Surveying
Professional Development Hours
3

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.
4

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.
5

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
7

Tour of the City

The Corrosion Problem

The Corrosion Problem

Bridge in Denver, CO
Bridge in Denver, CO
10

The Corrosion Problem

Corroded Trolley

11

The Corrosion Problem

Coors Field Denver, CO

12

The Corrosion Problem

Corroded Pier
13

The Corrosion Problem

Williamsburg Bridge - New York City, NY

14

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
15

The Solution: Hot-Dip

Galvanizing

Barrier Protection

Weathered Guardrail
17

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).
18

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
19

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.

20

Long-Lasting Zinc Protection

Barrier
Cathodic
Zinc Patina

Barrier

Long-lasting
Protection

Zinc Patina

Cathodic

21

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

22

HDG Process: Galvanizing

Zinc bath removal

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.

23

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

26

Edge Protection

Same thickness at corner

Micrograph of galvanized edge

27

Additional Benefits of HDG

Complete Coverage

28

Additional Benefits of HDG

Variety of
sizes and
shapes

29

Additional Benefits of HDG

Availability

30

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
31

Estimated Service Life of

HDG

32

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
34

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
35

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

36

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

0.60

0.54

G90

0.90

0.81
37

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

Good formability
Paintable

Electroplating Application

38

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

39

Other Zinc Coatings

Metallizing

Sheet Galvanized

Hot-Dip Galvanized
Zinc-Rich Paint
Electroplated

40

Design & Fabrication

42

Materials Suitable for

Hot-Dip Galvanizing

43

Hot-Dip Galvanized Fasteners

Hot-dip galvanized
fasteners are
recommended for
joining HDG structurals

44

Steel Reactivity

45

Coating Appearance
Newly
Galvanized

Newly
Galvanized
Dull Coating

No Spangle

Newly
Galvanized

Newly
Installed

Highly Spangle

Shiny & Dull

Coating

46

Combining Different
Materials

47

Weathering of Galvanized Steel

Photo taken: 12/18/02

Photo taken: 03/28/03

48

Dissimilar Thicknesses
Different
thickness
Zinc bath
temperature at
different times

Similar thickness
Maintain original
shape

49

Galvanizing Oversized Pieces

Progressive Dipping
50

Material Handling

51

Venting & Drainage

Vent

Drain
52

Specifications &
Inspection

ASTM Standards for Galvanizing

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

Supporting Specifications
ASTM
ASTM
ASTM
ASTM
ASTM

A 143 embrittlement
A 384 distortion
A 385 high-quality coatings
A 780 repair
D 6386 surface prep for painting over
54

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
55

ASTM A 153
Standard
Specification for Zinc
Coating (Hot-Dip) on
Iron and Steel
Hardware
Coating Thickness material category, steel
thickness, length
Finish continuous, smooth, uniform
Adherence should be tightly adherent through
all expected uses of article
56

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.
57

ASTM A 780
Standard Practice for Repair of
Damaged and Uncoated Areas of HotDip 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

58

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
60

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
61

Initial Cost
Material
Shop cleaning
labor
Shop application
Field labor
Pneumatic Bulk Trailers

62

Initial Cost ($/ft2)

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

$/ft2
$1.31
$2.09
$1.92
$2.51
$3.07
63

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

Maintenance repaint at 5% rust in a

moderately industrial environment
30-Year Project Performance
64

Life-Cycle Cost ($/ft2)

50-Year Project Performance
Coating System
Hot-Dip Galvanizing
Inorganic Zinc
Inorganic Zinc/Epoxy

$/ft2
$1.92
$3.21
$4.83

Inorganic Zinc Primer/

H-B Epoxy/Acrylic Urethane

$6.43

Acrylic WB Primer/Acrylic WB
Intermediate/Acrylic WB Topcoat

$7.98
65

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
66

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

68

Galvanized Surface
Coating Condition
Newly Galvanized
Steel
Partially
Weathered
Galvanized Steel
Fully Weathered
Galvanized Steel
Painted Bridge Rail
69

Passivation Cycle
Time
0 48 hrs.

48 hrs. 6 mo.

6 mo. 2 yrs.

3
70

Sweep Blasting

71

Duplex System Layers

Fence Pole
72

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

73

Galvanized Steel
Project Applications

Brooklyn Bridge
Date Galvanized
1999
Sector
Bridge &
Highway
Environment
Industrial
Location
New York, NY

75

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

76

The Cloud at Fashion Show Mall

Date Galvanized
2003
Sector
Building &
Architecture
Environment
Urban
Location
Las Vegas, NV

77

Harrisburg Airport
Transportation Facility
Date Galvanized
2004
Sector
Building &
Architecture
Environment
Urban
Location
Harrisburg, PA

78

Cell Towers Tree Application

Date Galvanized
2004
Sector
Electrical, Utility &
Communication
Environment
Rural
Location
California

79

Leprino Foods
Date Galvanized
Unknown
Sector
Food & Agriculture

Environment
Rural
Location
Waverly, NY

80

Piers 1 & 21 Replacement

Date Galvanized
2002
Sector
Water & Marine

Environment
Marine
Location
Norfolk, VA

81

AGA Resources
1-800-HOT-SPEC (800.468.7732)
aga@galvanizeit.org
www.galvanizeit.org
Technical Library
Galvanizing Insights e-Newsletter
82