You are on page 1of 212

SUPERIOR CORROSION

PROTECTION OF
Plants & Equipments

Presented By

R.K. BHATIA
John Galt Zinga Technologies, Mumbai
A Case

For

Film Galvanization
Technology
ZINGA PRESENTATION
ZINGAMETALL
CORROSION SOLUTIONS

FILM GALVANISING SYSTEM


=
ACTIVE CATHODIC
CORROSION PROTECTION
Mission

ZINGAMETALL provides total corossion


solutions to the industry using the innovative &
unique ZINGA technology in combination with
highly qualified services & coatings, in order to
extend lifetime of investments & assets.
Who is ZINGAMETALL ?
• Private company, located in Belgium
( ISO-9001 certified )

• Formulator, producer & distributor of zinc rich


coating for over 38 years.

• Zingametall : worldwide distribution


( > 45 countries )

• Asia Pacific ( India, China, Singapore, Thailand,


Malaysia, Australia, Indonesia … )
Partners :

• Umicore : supplier of special Zinc powder.


Belgian Company, one of world leaders in production and
distribution of more than 20 non-ferrous metals. (zinc,
copper, cobalt, .. )

• Chemical Industry for binders and thinners

• S.G.S. : third party inspection

• R.U.G. : University of Ghent, lab testing


Certification & warranty ?

• Zinganisation technology certified by


international labs & institutes

• Product warranty ( unlimited )

• Application warranty ( on request )


( via insurance company and independent control
organism = SGS )
History
demand from industry for
re-galvanising capabilities
What is ZINGA and how does it work?
It reacts with the parent metal to form an
electrolytic bond, which results in a
potential of -1114mV between the steel
and the zinc.
Once the steelwork becomes wet, the zinc
ions go into dissolution and the current
begins to flow from the zinc to the steel,
depleting the zinc layer and protecting the
steel beneath.
What is ZINGA and how does it work?
Electrochemical potential

• Hot dip galvanizing - 1.150 mV


• Spray metalization - 1.100 mV
• Zinganisation - 1.114 mV
• IOZ - 1.050 mV
• Epoxy ZR (92%) - 950 mV
• Paint Barrier Coating - 760 mV
• Steel - 650 mV

Zinga has more zinc metal (volume) capacity


than any other coating.
 Europe,

Middle-East,

Asia,

Africa,

Australia,

North-America,

South-America
What is ZINGA and how does it work?

- active cathodic protection

- Zinc = sacrificial anode

- 96% of zinc ( DFT )

- high purity ( 99.995% )

- passive layer = barrier

- protected zinc
What is ZINGA and how does it work?

- one pack

- unlimited shelf life

- unlimited pot life

- easy to apply

- re-loading capacity

- re-coatable

- non-toxic ( BS 6920 )
What is ZINGA and how does it work?

- mechanical flexibility

- not brittle, does not peel off

- relative humidity : 94%

- UV resistant

- matt metallic grey

- surface prep : SA 2.5

- roughness Rz 50-70µm
What is ZINGA and how does it work?

- pH range from 5 -> 12

- t° range : -40°C -> 150°C

- flash point : 47°C

- density : 2.7 kg/dm3

- touch dry : 10’

- 2nd ZINGA coat after 1 hour


WHAT IF ZINGA IS SCRATCHED
THROUGH TO THE BARE METAL?

ZINGA has a 5mm ‘throw’, which means


that scratches up to 5mm wide across
Zinganised surfaces will be protected.
On small areas like scratches and chips,
the surface will often go a light brown-
gray colour.
Advantages of ZINGA

 reliable efficiency
 easy application
 easy maintenance
Reliable efficiency
Hot-dip after 1000 ZINGA after 2000
hours salt spray test hours salt spray test
Easy Application
Easy Maintenance
A new layer of ZINGA re-liquidises the old layer.

Gold film on
first ZINGA layer

Typical zinc rich


paint  no
reliquidisation

After second layer of ZINGA


 gold mixes into old and new
ZINGA layers
 proof of re-liquidisation !
Expected lifetime of zinc coating
What is ZINGA and how does it work?

Field op applications :

- old hot-dipped

- new hot dipped

- existing structures

- workshop
Galvanising with ZINGA
Applications all over the world
OFFICE TOGOLAIS DES PHOSPHATES
PHOSPHATE MINE OFFSHORE CHARGING CRANES - TOGO
The phosphate mine Office Togolais
des Phosphates has placed 2 offshore
charging cranes at 1.6 km in the sea.
These cranes are linked
to the stock department
by means of a conveyor.
These cranes are very mobile
and weigh 325 tonnes each.
The Office Togolais
des Phosphates produces
 2.400.000 tonnes
of phosphates per year.
An average of 5 ships
per month are charged.
In 1994 the cranes were repaired by the French company Africaine de Montage.
A permanent service and maintenance was obligatory during the repair of the cranes.
After grit-blasting, the structures needed to be repaired by welding. These two cranes
and their passing link (the conveyer) were heavily corroded and it was decided that
they had to be protected by an anti-corrosion system providing cathodic protection:

ZINGA WAS CHOSEN !!

The application was done in 1995-96 under the supervision


of the controlling organism Socotec.

System:
ZINGA 2 x 60 µm Surface preparation: GRIT-BLASTING
In 2006 an inspection was done because an overall maintenance program was
planned to extend the lifetime of the structure.

Only some local minor repairs had to be


done to remove blisters
(possibly due to solvent retention)
and rust spots (due to mechanical abrasion
and insufficient local surface preparation).

ZINGA in perfect condition

 structure in an extremely aggressive offshore environment


 easy to evaluate and monitor the condition and
the layer thickness of ZINGA
 re-charging: lifetime can be extended
 ongoing maintenance program in place for these cranes and conveyor
IRELAND: KILLYBEGS FISHING PIER
KILLYBEGS FISHING PIER
IMMERSED PIER LEGS -IRELAND
In July 2006, a second inspection System:
ZINGA 1 x 25 µm + 3 x 40 µm
took place, 6 years after
the application and 3 years after
the first inspection.
The results are again promising.
ZINGA
Technology
ZINGA Data Sheet

• One component organic zinc coating.


• 96% zinc in the dry layer.
• min. 97% metallic zinc.
• Organic thermo-set binder.
• Zinc purity of 99.995%.
• Zinc particle size of 2 – 15 µm.
• Theoretical coverage : 3,6 m² / kg at 60 µm
Zn ≤ 92%
ZINGA Zn ≥
96%

6-8
2 - 3 µm
µm
Distilled zinc Atomised zinc

SMALLER ZINC PARTICLES


WITH
A LAMELLAR STRUCTURE FOR
LARGER CONTACT SURFACE
Unique characteristics and
advantages of ZINGA compared to
other zinc rich paints and hot-dip
• Zinc particles :
- special shape
- small size
- high purity
- higher electro-mechanical pot.
- protected zinc
®
ZINGA VERSUS HOT-DIP
HOT-DIP ZINGA®
YES CATHODIC PROTECTION YES
NO ENVIRONMENT FRIENDLY YES
NO EASY APPLICATION YES
SUITABLE FOR STRUCTURES
NO OF ALL DIMENSIONS YES
APPLICATION IN
NO HIGH HUMIDITY YES
RECOATABLE WITH
NO LITTLE SURFACE PREPARATION YES
RELIQUIDISING OF THE LAYERS
NO RECHARGING YES
NOT ALWAYS RESISTANT TO DAMAGE YES
ZINGA VERSUS ZINC RICH PAINT
®

PAINT ZINGA®
YES* CATHODIC PROTECTION YES
NO LONGTERM RESISTANCE YES
PROTECTION AGAINST CREEP
NO RUST AND BLISTERING YES
APPLICATION AT LOW
NO TEMPERATURES YES

NO APPLICATION IN DAMP CONDITIONS YES


PAINTING OVER WITH LITTLE
NO SURFACE PREPARATION YES
MELTING TOGETHER OF LAYERS
NO RECHARGING YES
NO RESIST TO MECHANICAL DAMAGE YES
Film Galvanizing Coating
• Active Protection
– Through sacrificial cathodic action of zinc in the
film
– Zinc gets consumed in the corrosion process
during life time to protect underlying steel
• Passive Protection
– Creates a barrier by lamellar structure of
atomized zinc
– Oxides upon application and create additional
barrier against environment
Uses of Film Galvanising

Film Jetty & Offshore

Power Stations Galvanising structures (risers &


conductors) in Tidal

Coatings
& splash zones
Testimonials & Reports
2. ZINGA (film galvanisation)
d) Report/certificates
Report and certificates from all over the world.
Some of them are:
 British Board of Agrément
major approval body in the UK
“In the opinion of the British Board of Agrément, Zinga is fit
for its intended use provided it is
installed, used and maintained as set out in this Certificate.”

BBA certificate

 BNF Fulmer Research Institute


same galvanic protection as hot-dip at a depletion
rate of 1/3
(when immersed ~ Pier legs in Killybegs, Ireland)

•“Zinga offers galvanic protection to steel comparable to that offered


by galvanised steel.
•Under the continuous immersion conditions studied, the Zinga coated
mild steel specimens corroded at a lower rate than galvanised zinc coated
specimens.
Graph from BNF Fulmer
•The electrochemical work has confirmed that Zinga is a corrosion resistant
zinc coating which protects mild steel effectively under simulated marine conditions.”
2. ZINGA (film galvanisation)
d) Report/certificates
 Det Norske Veritas
practical ballast tank test
Tests done:
“180 days testing in condensation chamber
180 days testing in wave tank
DNV
Evaluation of results after testing, including blister detection
(when applicable), undercutting from scribe, adhesion and coating flexibility”

Conclusion
“The results from the performed testing show that Zinga coating has a beneficial corrosion
protective performance, probably due to its qualities with regard to cathodic protection
related to the high zinc content.”

 SGS Yarsley Technical Services (BS 476 part 6 and part 7)


no fire propagation
“In accordance with the Flame Spread Classification given in the Standard and reproduced above, the results show
that the material has a Class 1 surface.”

This is the best result possible.

 Jadavpur University and National Metallurgical Laboratory (India)


ZINGA was best in a comparison to other means of corrosion protection of rebars:
Fusion Bonded Epoxy Coating
Hot-dip
Alloys
2. ZINGA (film galvanisation)
d) Report/certificates
Report and certificates from all over the world
Some of them are:
 NORSOK
Tests done:
4200 hours immersion in seawater
4200 hours cyclic test
pull-off (7MPa)
no cathodic disbondment

Conclusion:
“The system Zinga, dry film thickness 60/60 IJm, meets the evaluated
requirements of Norsok M·SOI Rev. 5 system 7”

 Water Regulations Advisory Scheme


+ comparable certificates from
other countries (e.g. Iran)
contact with potable water
Conclusion:
“ZINGA has passed full tests of effect on water quality”
WRAS certificate
NORSOK report
M-501, Rev. 5 for System 7
2. ZINGA (film galvanisation)
d) Report/certificates
Report and certificates from all over the world
Some of them are:

 Amirkabir University (Iran)


tests on Zinganised rebars
“It is observed that the coating of rebars with ZINGA protects the steel core
against corrosion by cathodic protection as sacrificial anode.”

 KTA TATOR (US)


Slip coëfficiënt (0,52) (Hot-dip ±0,19)

Amirkabir University

(most of these reports can be downloaded from our website: www.zinga.eu)


2. ZINGA (film galvanisation)
d) Report/certificates
Report and certificates from all over the world
Some of them are:

 4 year Field test at Kennedy Space Centre (USA):


Pacific Rim Corrosion Research Program (PRCRP) ended in 2005
The picture has been taken after 4 years. You see no red rust, only the
white rust in the scribe where ZINGA has cathodically protected the
bare metal.

 The above report resulted in the approval


by the US Army and US Navy
Zinga conforms to the requirements of CID A-A59745.
Additionally, it has successfully undergone additional testing.

(most of these reports can be downloaded from our website: www.zinga.eu)


2. ZINGA (film galvanisation)
d) Report/certificates
Report and certificates from all over the world
Some of them are:

 NATO Approval
In 1989 Zingametall received a Manufacturer’s card and a NATO Stock Number for ZINGA
A NATO Stock Number is recognised as a stock number of the armies of the member states.
Every product that is accepted by the NATO can be used by all the armies of the
NATO member states without the necessity or obligation to test the product again.

(most of these reports can be downloaded from our website: www.zinga.eu)


2. ZINGA (film galvanisation)
d) Report/certificates
Report and certificates from all over the world
Some of them are:

 APAS Recognition
After a thorough research of test reports, applications in Australia
and a visit to the factory in Belgium, Zingametall BVBA was
acknowledged as a recognized manufacturer by the APAS.

“APAS (Australian Paint Approval Scheme) is the largest


and most widely recognized paint scheme in the world”
(http://www.apas.gov.au/index.asp).

(most of these reports can be downloaded from our website: www.zinga.eu)


KEPCO Transformator applications
South-Korea
Test 11 – 2005
Order 02 - 2009

Inside :
Zingaceram EP 1 x 80 µm
Outside :
Zinga 1 x 60 µm
Zingaceram PU 1 x 80 µm
Transformer - Pakistan

09 -2007
Kiev Energo Power Plant (Ukraine
Offshore Wind Farm Foundations 2003)
(Denmark 2003)

Chernobyl Nuclear
Power Station
(Ukraine 2002) Bridge (Canada)
Offshore Wind Farm
(Denmark 2002)
80 piles, ~35 meters each,
~40,000 liters coating......

Rebars of
the Hangzou Bay Bridge
(China 2005)

140 filter-tanks for Source Water


(Libya 2002-2003)
Taiwan Power 2005
24 Windmill towers
Storage tanks potable water
Tazerbo - Libya
Pump house – power plant
Offshore Wind Farm (Denmark 2002)
80 piles, 35 meters each, 40 000 liters coating
SHELL TANK - MOROCCO
On this picture you see a storage tank for chemical products
belonging to the company SHELL. These tank was treated in August
2006. It was gritblasted to SA 2,5 and then treated with ZINGA and
topcoated with Alufer N and a local polyurethane paint ( Hempel ).

System:
ZINGA 1 x 60 µm
Alufer N 1 x 80 µm
Pu local
TAIWAN POWER COMPANY
ZEPHYROS WIND MILLS - TAIWAN

System:

Inside :
ZINGA 1 x 60 µm
Zingaceram EP 1 x 100 µm
Outside :
ZINGA 1 x 60 µm
Zingaceram EP 2 x 100 µm

06 - 2005
BRAITHWAITE TANK –UNITED KINGDOM

System : Old Tanks


Surface preparation : Sweep-blast
ZINGA 2 x 60 μm

System : New Tanks


Surface preparation :SA 2,5 @ Rz 65µm
ZINGA 2 x 60 μm
BRAITHWAITE TANK –UNITED KINGDOM

System : Old Tanks


Surface preparation : Sweep-blast
ZINGA 2 x 60 μm

System : New Tanks


Surface preparation :SA 2,5 @ Rz 65µm
ZINGA 2 x 60 μm
Alcoa Australia Cooling tower
System:

Blasting Sa 2.5 @ 60µm


ZINGA 2 x 60 μm
Reference information (specifically defence structures)

 Reports and approval letters

• Army trucks (US)


Field test (executed by the US Army Tank Automotive
Command: TACOM) in Hawaï ended in 1997 with a
report saying that ZINGA is approved because is
provides a >30% increase in corrosion protection than
all other anti-corrosion products.
Reference information (specifically defence structures)

 Reports and approval letters

• NATO Approval
In 1989 Zingametall received a Manufacturer’s card and a NATO Stock Number for ZINGA
A NATO Stock Number is recognised as a stock number of the armies of the
member states.
Every product that is accepted by the NATO can be used by all the armies of the
NATO member states without the necessity or obligation to test the product again.
Reference information (specifically defence structures)

 Project reference data

• MDOT Missisipi bridge (US)


Bridges are controlled by their defence system
2500m² Zinganised in 2002
No topcoats were applied
An inspection in 2007 showed no sign of rust.

Press release from 1999 saying ZINGA


will be used for the refurbishment of this bridge.
Reference information (specifically defence structures)

 Project reference data

• Nexrad radar tower (US)


2009
10m high radar tower
2 x 60µm DFT ZINGA to reload the old hot-dip.
Located on the Altus Air Force Base CR EW183 in Frederick, Oklahoma.
Reference information (specifically defence structures)

• Belgian Navy (Belgium)


Since 1990, the Belgian Navy has been using ZINGA
a.o. on an antenna and Navy Ships
Reference information (specifically defence structures)

• NATO Pump Stations (Belgium)


Application in 1986
ZINGA 2 x 60µm DFT
On numerous pump stations all over Belgium
17 years after application an official inspection
showed the pump stations in excellent state
Reference information (specifically defence structures)

• Army tent poles (United Kingdom)


In 2005
8000 tent poles (2,2 m in length each)
ZINGA 1 x 60µm DFT (by dipping)
Reference information (specifically defence structures)

• Zeus Cable Ship (Canada)


Application in 1986
On the ventilation system
4.400m²
ZINGA 1 x 100µm DFT
3. Reference information (specifically Marine
environments)

• Pacific Grain Elevator (Canada)


In 1998
Repair of larger non-mobile old hot-dipped parts
ZINGA 2 x 60µm DFT
3. Reference information (specifically Marine
environments)

• BC Ferry Terminal (Canada)


Between 1988 and 1992
ZINGA 2 x 60µm DFT (by brush)
An independent inspection in 2002 and another in 2005 showed no
need for repair
3. Reference information (specifically Marine
environments)

• Yuehai Train Ferry Pier Terminal (China)


In 2003
Allows 4 trains to be transported by boat
ZINGA 2 x 30µm DFT + Aquazinga 2 x 40µm DFT (extra abrasion resistance)
3. Reference information (specifically Marine
environments)

• El Salaam Bridge (Egypt)


Bridge to carry a gas pipeline (from GASCO)
In 2007
ZINGA 2 x 60µm DFT
3. Reference information (specifically Marine
environments)

• Shell storage tanks (Morocco)


Since 2006
4 huge storage tanks for hydrocarbon products
ZINGA 1 x 60µm DFT + Alufer N 1 x 80µm DFT + topcoat
Very close to the ocean
3. Reference information (specifically Marine
environments)

• Kalvoya Bridge (Norway)


In 1985
ZINGA 2 x 60µm DFT
In 1995 an independent inspection showed no need for repairs.
In 2010 only 30µm ZINGA had sacrificed itself to
protect the metal underneath
DON MUANG TOLL WAY Lamppoles - Thailand

System:
Zinga 1 x 40 µm 9-2008
Harbor Cranes - Iran
Rail Wagon - Senegal

07 - 2006
SCHWENK – CEMENT FACTORY - GERMANY
In 1992 the new plant of the cement factory Schwenk was treated with ZINGA.
Application technique: airless spraying. These pictures were taken during construction.
30 tons of ZINGA were used for this application.
In February 2003, the condition of the ZINGA layer
was inspected. On the pictures you can see that the
ZINGA is still in perfect condition and shows no
trace of rust after more than 10 years.

System:
ZINGA 2 x 60 µm
LAFARGE – SOUTH AFRICA
Pictures of the infrastructure of the company
Lafarge, treated with ZINGA,
dated September 1997.

System:
ZINGA 2 x 60 µm

System:
ZINGA 2 x 60 µm
GREENVIEW CEMENT – GHANA 2004

System: Test application

Blasting Sa 2.5 @ 60µm


ZINGA 2 x 60 µm
Greenview Cement - Ghana 2009

03 - 2009
PAESEN CONCRETE MILL - BELGIUM
These are pictures of a concrete mill of the company Paessen taken
in April 2006. The silos were sandblasted and coated with ZINGA and
topcoated with 2c Pu Primer Finish mist coat and full coat.

System:
ZINGA 2 x 60 µm
2c Pu Primer Finish mist coat
full coat
Zingametall references

Road Bridges
Rail Bridges
CANADA: OVERLANDER BRIDGE

CONFERATION
BRIDGE
CANADA:
QUEENSLAND MAIN ROADS - AUSTRALIA
Customer: Queensland Main Roads, Queensland Rail - Department of Infrastructure, Energy & Resources

Queensland Rail has specified and used ZINGA since 2001.


All Queensland Rail Bridges re-coats since that date have been specified
ZINGA Liquid Galvanising. The bridges were in poor condition.

System:

Blasting SA 2,5@ 60 µm
ZINGA 1 x 60 µm
ALU ZM 1 x 60 µm

The Burdekin River Bridge


Queensland Rail – Australia
Corduroy Bridge
System:
ZINGA 2 x 60 µm

Queensland Railway Corduroy Bridge


Queensland Rail - Australia

System :
Zinga 2 x 60 µm
Watersaturation
Queensland Rail – Australia
Tooley Footbridge

System :
Zinga 2 x 60 µm
Watersaturation
Queensland Rail – Australia
Rathdowney Rail Bridge
System:
Zinga 2 x 60 µm

June 2003
Fly-over Bridge - Taiwan

07 - 2005
Fly-over Bridge Taiwan

06-2005
Biloxy Bascule Bridge - USA

Situation after 5 years 11 - 2007


Sunshine Coast Culvert – Queensland
Australia

08 - 2008
Zingametall references

Stadiums and
Airports
5. Reference information

 Other structures
• Bird’s nest (China)
In 2006
On sensitive parts
ZINGA 2 x 40µm DFT
(+ sealer + topcoat)

• National grand theatre Beijing (China)


In 2005
ZINGA on underwater structures in aquarium
ZINGA 2 x 60µm DFT
5. Reference information

 Other structures
• Mumbai domestic airport (India)
In 2006
On all steel structures in the halls
ZINGA 1 x 60µm DFT + PU topcoat

• Savarnabhumi airport (Thailand)


From 2002 to 2006
On 9200 small steel structures
ZINGA 1 x 50µm DFT
3. Reference information

 Other structures
• Guangzhou New Baiyun Airport (China)
In 2002
Touch up of new hot-dip
ZINGA 1 x 60µm DFT
MUMBAI DOMESTIC AIRPORT - INDIA
The domestic terminals in Mumbai with the same name as its international wing are
located in Santa Cruz, East. There are two domestic terminals - Terminal 1A
(with an area of 28960sqm), and Terminal 1B (with an area of 45000 sqm).
Here, peak traffic occurs during daytime.

All steel structures including the huge curbed spans of the new airport of Mumbai
Domestic Airport are coated with Zinga and finished with a white PU.
System:
ZINGA 2 X 60 µm
Topcoat Pu white
GUANGZHOU NEW BAIYUN AIRPORT - CHINA

Touch up of HDG
Zinga 1 x 40 µm 02-2002
Düsseldorf Airport – Germany
Engine test area

System :
Zinga 2 x 60 µm 1990
BIRD’S NEST – CHINA
Olympic Games 2008

System:
Blasting Sa 3 @ 60µm
Zinga 2 x 40 µm 9-12 2006
ACCRA LIGHT POLES - GHANA
On these pictures you can see light poles of
a sports stadium, the application of ZINGA
started in April 2007 by Zinga Ghana.
System:
ZINGA 1x 65 µm
Alufer WR 1 x 80 µm
Zingametall references

Oil and Gas


SHELL TANK - MOROCCO
On this picture you see a storage tank for chemical products belonging
to the company SHELL. These tank was treated in August 2006.
It was gritblasted to SA 2,5 and then treated with ZINGA and topcoated
with Alufer N and a local polyurethane paint (Hempel ).

System:
ZINGA 1 x 60 µm
Alufer N 1 x 80 µm
Pu local
OIL STORAGE TANK - EXXON MOBILE
UNITED KINGDOM
This oil storage tank is located in an area called Fawley, one of Esso’s biggest
refineries in the United Kingdom, which is actually south of Southampton
on the south coast of England.
The application was done in August of 2007,
the oil storage tank has been blasted
with a profile average of 75 µm.

System:

before application ZINGA 3 x 60 µm

after application
METRONCO - GHANA
On these pictures you see a pipeline (1,5 km long) for
the transport of harsh oil in Tema, Ghana.

System:
ZINGA : 1 x 60 µm
ZingaCeram EP Mio : 1 x 80 µm
ZingaCeram PU : 1 x 60 µm
Zingametall references

Industrial
Steel Structures
Cocoa silo Barry Callebaut - Ghana

System :
Blasting Sa 2.5
Zinga 2 x 60 µm

05-2008
Airconditioning system -Thailand

07-2005

System :
Blasting Sa 2.5
Zinga 2 x 60 µm
Roof coating test Barry Callebaut - Ghana

HP cleaning + Sweeping
EP PA Primer 80 µm
Zingaceram EP Mio 120 µm
Zingaceram PU top 60 µm 08-2008
KUMBA RESOURCES COAL MINES - SOUTH-AFRICA

These collieries belong to Kumba Resources South Africa.


(SA Coal, Iron & Steel Company) System:
ZINGA 2 x 40 µm
The specification used was
2 x 40 microns of ZINGA
as an unique coating system
Coal Reclaim Stacker – South Africa
Exxarro Grootegeluk Mine

08 - 2007
Coating of feet conveyor belts
Sishen Ore Mine – South Africa

08 - 2007
Conveyors Exxarro Grootegeluk
CoalmineSouth Africa

01 - 2008
5. Reference information

We have many interesting reference documents on applications in different


fields.
This is a small selection of them:
(you can find more on our website: www.zinga.eu)

 Bridges
• QR Railways Burdekin river bridge (Australia)
Since 2001
Maintenance program (Queensland Rail)
ZINGA 2 x 60µm DFT

• Kalvoya bridge (Norway)


In 1985
30µm DFT ZINGA depletion after 25 years
Only minor repairs were required
5. Reference information

 Bridges
• MDOT Mississippi bridge (US)
In 2002
2500m²
ZINGA 2 x 75µm DFT
An inspection in 2007 showed no sign of rust.

• Hangzhou Bay Cross-sea Bridge;


37 km (China)
In 2005
On rebars in bridge
ZINGA 1 x 60µm DFT
5. Reference information

 Bridges
• BC Ferry Terminal (Canada)
Between 1988 and 1992
ZINGA 2 x 60µm DFT (by brush)
An independent inspection in 2002 and
another in 2005 showed no need for repair

• IRPC Petrochemical complex


(Thailand)
In 2009
On jetty (gas pipeline and supporting
structure)
Close to sea
On 15.000m² and growing
ZINGA 1 x 40µm DFT +
Alufer N 1 x 80µm DFT
5. Reference information

 Bridges
• El Salaam Bridge (Egypt)
Bridge to carry a gas pipeline (from GASCO)
In 2007
ZINGA 2 x 60µm DFT
5. Reference information

 Storage tanks
• Dangote (Ghana)
In 2009
In repair of a previous system that failed after
only 3 years
On every metal part of the plant
At 100m of the ocean
ZINGA 2 x 60µm DFT

• NATO Pump Stations (Belgium)


Application in 1986
ZINGA 2 x 60µm DFT
On numerous pump stations all over Belgium
17 years after application an official inspection
showed the pump stations in excellent state
5. Reference information

 Storage tanks
• Quartes (Belgium)
In 1980
On previously hot-dipped storage tanks
4 silos, 20 m in height, 4 m in diameter
4000 m²
ZINGA 2 x 60µm DFT
30 years after application only minor repairs
were required

• Braithwaite Potable Water Tanks (UK)


Application in 2007
On the inside of 9 storage tanks for potable water
ZINGA 2 x 60µm DFT
5. Reference information

 Storage tanks
• Pulp and Paper (Canada)
Since 1988
On previously hot-dipped storage tanks
for several pulp factories
ZINGA 2 x 60µm DFT
14 years an independent inspection
showed no need for repair

• Shell storage tanks (Morocco)


Since 2006
4 huge storage tanks for hydrocarbon products
ZINGA 1 x 60µm DFT + Alufer N 1 x 80µm DFT
+ topcoat
Very close to the ocean
5. Reference information

 Storage tanks
• Univar storage tanks (Norway)
In 2008
Outside of 48 storage tanks for chemicals
ZINGA 1 x 60µm DFT + Alufer WR 1 x 60µm DFT
(after CO2 cleaning)

• Red Bull storage tanks (Thailand)


In 2008
Inside of 6 storage tanks (700m² inside alone)
for wheat to produce whisky
ZINGA 1 x 60µm DFT
5. Reference information

 Storage tanks
• Exxon Mobil oil storage tank (UK)
In 2007
Floating roof of a crude oil storage tank
ZINGA 2 x 60µm DFT
5. Reference information

 Electricity, pylons, poles, transformers


• Trash racks (South Korea)
In 2008 & 2010
At the Young Heung Power Plant, to filter big
floating objects out of sea water from getting
into the cooling system.
ZINGA 2 x 40µm DFT + topcoat

• KEPCO Transformers (South Korea)


Since beginning 2009
Thousands of transformers
ZINGA 1 x 60µm DFT + Zingaceram topcoats
5. Reference information

 Electricity, pylons, poles, transformers


• Krasikov (Czech Republic)
In 1994
ZINGA 1 x 50µm DFT + topcoat
An independent inspection in 2003 showed
the system in excellent condition

• Slavetice (Czech Republic)


In 2000
ZINGA 2 x 40µm DFT
To repair an Atmofix anti-corrosion protection
on sensitive points
Artificial weathering tests
• Salt spray tests
Hot-dip after 1000 hours Film Galvanising after 2000 hours
salt spray test
salt spray test

Productivity and Standards Board, Singapore


Salt spray test 2000 hours
Film Galvanising, hot-dip and metallisation

ZINGA metallisation hot-dip


University of Gent, Belgium
Salt spray test 500 hours
Comparison Film Galvanising , organic zinc-rich
paint and inorganic zinc-rich paint

Korea Institute of
Machinery and Materials,
South Korea
Tests on mechanical resistance
• Adhesion tests by cross-cut
Salt spray test
3000 hours
on ZINGA

State University of Gent,


Belgium
Adhesion test
by cross-cut
Gt 0 and Gt 1

State University of Gent, Belgium


Tests on mechanical resistance
• Adhesion tests by cross-cut
• Adhesion tests by pull-off
• Flexibility tests
Bend test

Stangers Consultants, UK
Flexibility tests on nuts and bolts

Avlock International Fastening Systems, South Africa

Hedley Purvis, UK
Tests on mechanical resistance
• Adhesion tests by cross-cut
• Adhesion tests by pull-off
• Flexibility tests
• Tests on resistance to abrasion
Tests on mechanical resistance
• Adhesion tests by cross-cut
• Adhesion tests by pull-off
• Flexibility tests
• Tests on resistance to abrasion
• Tests on resistance to impact
Impact test

Stangers Consultants, UK
Tests on mechanical resistance
• Adhesion tests by cross-cut
• Adhesion tests by pull-off
• Flexibility tests
• Tests on resistance to abrasion
• Tests on resistance to impact
• Tests on weldability
Test on weldability
40 µm ZINGA

Soudometal, Belgium
Tests on resistance to liquids
• Immersion tests
Immersion test on sea buoys

Direction of the French Department


for Equipment, Maritime Services, France
Tests on resistance to liquids
• Immersion tests
• Tests on resistance to aggressive
substances
Test on resistance to
solutions with
pH 3 and pH 12

State University of Gent, Belgium


Tests on toxicity
• Tests on toxicity of the wet product

Product name : ZINGA

We, ZINGAMETALL b.v.b.a., hereby certify that the above


mentioned product contains less than 1 ppm of benzene,
and that based on the European Community (EC) directives
on the classification of dangerous products, the product is
not classified as toxic.

Note P of the EC directives applies :


The EC classification as a carcinogen need not apply if it
can be shown that the substance contains less than
0.1 % w/w benzene (Einecs No 200-753-7).
Tests on toxicity
• Tests on toxicity of the wet product
• Tests on potable water quality
Test on potable water in
contact with ZINGA

Water Quality Centre, UK


Tests on cathodic behaviour
• Tests on electro-galvanic action
Test on electro-galvanic action of
ZINGA in comparison with hot-dip

Forschungs- und Materialprüfungsanstalt


Baden-Württemberg, Germany
Test on electro-galvanic
action of ZINGA in
comparison with hot-dip

BNF Fulmer Metals Technology Centre, UK


Tests on cathodic behaviour
• Tests on electro-galvanic action
• Tests on zinc content in the dry layer
• Tests on blending of successive layers
Test on blending of successive ZINGA layers
Gold film on
first ZINGA layer
Normal zinc rich
paint  no
reliquidisation

After second layer of ZINGA


 gold mixes into old and new
ZINGA layers
 proof of reliquidisation !

State University of Gent, Belgium


Tests on cathodic behaviour
• Tests on electro-galvanic action
• Tests on zinc content in the dry layer
• Tests on blending of successive layers
• Tests on corrosion speed
Corrosion rate of ZINGA =
1/3 of corrosion rate of hot-dip

Bangladesh University of Engineering and


Technology, Bangladesh
Weight loss of ZINGA =
1/10 of weight loss of hot-dip

South African Bureau


of Standards,
South Africa
NATO Certification
• Zinga is certified by NATO
• No prior approval needed for supplies
of defense components coated with
Zinga to NATO countries
Vessel being moved from Slip Way to Dry Docks
Offshore Wind Farm (Denmark 2002)
80 piles, ~35 meters each, ~40,000 liters coating
Zinga Coating on
Immersed Pier Legs at
Port Harbour
Customer
• Office Togolais de Phosphates
– Mines located on Gulf of Guinea
Background
• 2 offshore charging cranes at 1.6 km in
the sea
• Constant exposure to salinity and sea
water
• Mobile
• Weighs 325 tones each
• Mine phosphate production – 240mmt /
year
Decision on Film Galvanising
• In 1994 the 2 cranes and the conveyer were
heavily corroded and it was decided that
they had to be protected by an anti-corrosion
system providing cathodic protection.
• The cranes were repaired and recoated by
the French company Africaine de Montage.
Permanent service was obligatory during the
works. After grit-blasting, the structures
needed to be repaired by welding.
Decision on Film Galvanising
• Zinga was selected primarily due to…
– Only coating providing cathodic protection
– Easy application on site
– Superior weldability
– Easy maintenance
– Only coating providing active and passive
corrosion protection
• The application was done under supervision
of the controlling organism Socotec
Inspection 2006
• Inspection was carried out after 12
years of application
Inspection Testing
• Adhesion: Excellent
• Dry Film Thickness: ±100µ
• Overall appearance: Good
• Contamination: Phosphate Dust
• Corrosion: Localized blister formation
• Advice: Local repairs after water
washing and manual tool cleaning
Synopsis
• 12 years old Zinga unique system
• Still working in the harshest environment
• Factors affecting coating life:
– Salinity
– Sea Water
– Rock Phosphate dust
– Mechanical Damages
• Easy to Inspect & Maintain
• Low cost per sq.m per year & reduced
maintenance cost
• Saved maintenance cost = Net Profit!!!
The Istanbul – Izmir Motorway & The Marmara Bridge Project

System
1 x 60µ Zinga
1 x 80µ Alufer N
1 x 60µ Zingaceram ZM PU
Total = 200 µ
ISO 12944-6 C5M-H
The south viaduc : 160.000 m²
The north viaduc : 100.000 m²
The Bridge : 220.000 m²

Total : 480.000 m²
Zingametall

ISO 12944

www.zinga.eu
2. ISO 12944
a) What is ISO 12944
Before ISO 12944, people responsible for corrosion tenders needed to
specify in high detail:
 What composition of the system (2, 3 or more layer systems)?

 What type of primer, sealer, topcoat?

 What layer thicknesses?

 Specified design life?

 Proof of quality of the system (responsibility issues)?

All this meant little competition was possible and


sub-optimal systems were chosen, which in turn meant that
corrosion costs were higher due to more frequent and more expensive
maintenance schemes than should be necessary.
2. ISO 12944
a) What is ISO 12944
The ISO 12944 standard is intended to
 Assist engineers and corrosion experts in

 Adopting best practice in corrosion protection of structural steel

 At new construction and repairs

ISO 12944 is
 Progressively superseding
regional standards

 To become a truly
global benchmark in
corrosion control
2. ISO 12944
b) Purpose
Selecting specifications that comply with ISO 12944 provides:
 Confidence that the corrosion protection you specify will be fit for purpose

 An objective approach to coating selection

 A simplified matrix of coating systems to


select from

 A meaningful coating design life

 A universally accepted standard


2. ISO 12944
b) Purpose
This standard allow your customer:
 To know that what we present them is really tested and approved

 By an independent test centre according

 To an international and very complete standard


3. Zingametall results
a) ZINGA 2 x 60µm DFT
For this system we fall in the category
 Atmospherically: C5-I-Medium (I: Industry)
or C5-M-Medium (M: Marine)
or C4-High
 Immersion: Im2-Medium
and Im3-Medium
Medium: life expectation between 5 and 15 years
High: life expectation >15 years

Since 1988, several pulp and paper factories in Canada used ZINGA in 2 layers of 60µm DFT to treat their
structures. In 2005 (17 years after application), no touch-ups were necessary.
This agrees with the ISO 12944-6 test results for ZINGA 2 x 60µm DFT predicting a life expectancy of >15
years in an industrial zone.
3. Zingametall results
a) ZINGA 2 x 60µm DFT
Atmospherically:
 C5-I: industrial zones with high humidity and aggressive environment
(continuous condensation and high pollution)

 C5-M: Coastal zones and marine zones with high salinity


(continuous condensation and high pollution)

 Medium: life expectation between 5 and 15 years

 C4: industrial or coastal (with moderate salinity) zones


(chemical factories, swimming pools, shipyards)

 High: life expectation >15 years


3. Zingametall results
a) ZINGA 2 x 60µm DFT → 120µm
Examples of existing systems for atmospheric conditions that fall into
that same category are:
 100µm epoxy combination
+ 3 layers adding up to 300µm DFT epoxy combination
Total thickness: 400µm → 400µm

 80µm hot-dip
+ 1 x 80µm DFT primer (epoxy or polyurethane)
+ 3 layers adding up to 240µm DFT epoxy or polyurethane
Total thickness: 400µm → 400µm

 100µm metallisation
+ 1 sealer coat (epoxy or polyurethane)
+ 3 layers adding up to 320µm DFT epoxy or epoxy combination
Total thickness: 420µm → 420µm
3. Zingametall results
a) ZINGA 2 x 60µm DFT
Immersion:
 Im2: sea or brackish water
(harbors with locks, jetties, offshore structures;
make sure there is no stray current)

 Im3: soil
(underground storage, iron poles)

 Medium: life expectation between 5 and 15 years


3. Zingametall results
a) ZINGA 2 x 60µm DFT → 120µm
Example of existing system for immersion conditions that fall into
that same category are:
 60µm DFT zinc rich primer
+ 3 to 5 layers adding up to 360µm DFT
Total thickness: 420µm DFT → 420µm
3. Zingametall results
b) ZINGA 2 x 90µm DFT
For this system we fall in the category
 Atmospherically: C5-I-High (I: Industry)
or C5-M-High (M: Marine)

 Immersion: Im2-Medium
and Im3-Medium
Medium: life expectation between 5 and 15 years
High: life expectation >15 years

The phosphate Mine in Togo (Office Togolais des Phosphates) was treated in 1994 with 2 layers of ZINGA.
In 2006 (12 years after application), no trace of rust was found.
This agrees with the ISO 12944-6 test results for ZINGA 2 x 90µm DFT predicting a life expectancy of >15
years in an industrial zone with high humidity and aggressive environment.
3. Zingametall results
b) ZINGA 2 x 90µm DFT
Atmospherically:
 C5-I: industrial zones with high humidity and aggressive environment
(continuous condensation and high pollution)

 C5-M: Coastal zones and marine zones with high salinity


(continuous condensation and high pollution)

 High: life expectation >15 years


3. Zingametall results
b) ZINGA 2 x 90µm DFT → 180µm
Examples of existing systems for atmospheric conditions that fall into
that same category are:

 60µm zinc rich primer (epoxy or polyurethane)


+ 3 to 4 layers adding up to 400µm DFT epoxy combination
Total thickness: 460µm → 460µm

 80µm hot-dip
+ 1 x 80µm DFT primer (epoxy or polyurethane)
+ 3 layers adding up to 320µm DFT epoxy or polyurethane
Total thickness: 480µm → 480µm

 100µm metallisation
+ 1 sealer coat (epoxy or polyurethane)
+ 3 layers adding up to 450µm DFT epoxy or epoxy combination
Total thickness: 550µm → 550µm
3. Zingametall results
b) ZINGA 2 x 90µm DFT
Immersion:
 Im2: sea or brackish water
(harbors with locks, jetties, offshore structures;
make sure there is no stray current)

 Im3: soil
(underground storage, iron poles)

 Medium: life expectation between 5 and 15 years


3. Zingametall results
b) ZINGA 2 x 90µm DFT → 120µm
Example of existing system for immersion conditions that fall into
that same category are:
 60µm DFT zinc rich primer
+ 3 to 5 layers adding up to 360µm DFT
Total thickness: 420µm DFT → 420µm
Thank You All !

Now lets Zinganize the world…