Galvanization Tour 2012
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Transcript of Galvanization Tour 2012
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Big R Bridge
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AZZ Galvanizing Services
Kevin Irving
Marketing Manager Northern Ops
815-693-4242
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Tour of the City
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Weathering Steel
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I-69 Bridge
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Ford County – 00N, 2350E
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New Galvanized Bridges in
Chicago
35th Street & Dan Ryan 362 Tons
51 Street & Dan Ryan 349 Tons
Douglas Lake Connection 1444 Tons
57th Street & Dan Ryan 346 Tons
67th Street & Dan Ryan 403 Tons
Michigan Ave over I-94 234 Tons
91st Street & Dan Ryan 234 Tons
26th Street & Dan Ryan 194 Tons
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CTA , IL Toll Road, IDOT &
Counties
Over 50 Million Pounds of
Bridges were Galvanized
in Illinois in last 5 years.
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26th Street & the Dan Ryan
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Tappenzee Bridge
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Tappenzee Bridge
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Michigan/MI-102 Bridge Rail
Date Galvanized 2007
Components Galvanized Guide rails
Environment Urban
Location Detroit, MI
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Michigan / MI-102 Bridge Rail
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Richland County Bridge
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Knox County, OH - Before
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Knox County, OH - After
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Seneca County, OH - Before
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Seneca County, OH - After
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Village of Glouster County, OH - Before
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Village of Glouster, OH - After
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Village of Minerva, OH - Before
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Village of Minerva, OH - After
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Corrosion Problem – Case
Study The Williamsburg Bridge
built in 1903 in New York City
1991 inspection revealed severe corrosion direct cost of repairs was $750 million
indirect cost approximately $8.2 billion
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40% of Carbon Steel Goes
to Replace Corroded Steel
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At a Cost of
$350 Billion per Year
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Equivalent of Building
562 Willis Towers (Sears)
Every Year
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Corrosion Process
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Law of Entropy
Tendency for metal, after production and shaping,
to revert back to its lower, more natural energy
state or ore
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Definition of Corrosion
Corrosion (n): the chemical or
electrochemical reaction between a material
and its environment that produces a
deterioration of the material and its
properties
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Return Current
Path
Electrolyte
+ Anode Cathode
Bimetallic Couple
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Long-Lasting Zinc Protection
• Barrier • Cathodic • Zinc Patina • Metallurgical Bond
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Barrier Protection
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Cathodic Protection
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Galvanic Series of Metals
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).
ZINC = ANODE
STEEL = CATHODE
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Sacrificial Zinc Anodes
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Zinc
Zinc Oxide
Zinc Hydroxide
Zinc Carbonate
Zinc Patina
Air Moisture
Carbon Dioxide
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The History of Galvanizing
79 AD 1772 1829 1870 Today
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Galvanizing Process
Pre-Inspection
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We Protect More Than Steel
HDG Process: Surface
Preparation
Thorough cleaning is
necessary as zinc will
only adhere to clean steel
Degreasing –
removes dirt, oils,
organic residue
Degreasing Tank
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We Protect More Than Steel
HDG Process: Surface
Preparation
Thorough cleaning is
necessary as zinc will
only adhere to clean steel
Degreasing –
removes dirt, oils,
organic residue
Pickling – Removes
mill scale and oxides
Pickling Tank
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We Protect More Than Steel
HDG Process: Surface
Preparation Thorough cleaning is
necessary as zinc will
only adhere to clean steel
Degreasing –
removes dirt, oils,
organic residue
Pickling – Removes
mill scale and oxides
Fluxing – Mild
cleaning, provides
protective layer Flux Tank
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We Protect More Than Steel
HDG Process: Galvanizing
Steel immersed in bath
of molten zinc (~830 F)
> 98% pure zinc, up to
2% additives (Al, Bi, Ni)
Zinc reacts with iron in
steel to form coating
Reaction is complete
when steel reaches
bath temperature
Galvanizing Bath
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Hot-Dip Galvanizing
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FHWA Rebar Seminar –
Providence, RI, 27 March 2008
71
Hot Dip (Dry) Galvanizing
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HDG Process: Inspection
Steel is inspected
after galvanizing to
verify conformance to
specs
Visual inspection to
identify any surface
defects
Magnetic thickness
gauge to check
coating thickness
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Metallurgical Bond
steel
Gamma
Delta
Zeta
75% Zinc 25% Iron
90% Zinc 10% Iron
100% Zinc
94% Zinc 6% Iron
Eta
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Abrasion Resistance
DPN = 159
DPN = 245
DPN = 180
DPN =70
DPN = 250
Eta Zeta Delta Gamma Steel
DPN: Diamond Pyramid Number
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Edge Protection
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Complete Protection
Edges
Welds & Seams
Hard to Reach Spots
Typical Spray Application Hot-Dip Galvanizing
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Variety of Sizes & Shapes
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Availability
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It’s a Natural Element
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It’s Essential
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SAFE
GREEN
ESSENTIAL
FOR LIFE
HOT DIP GALVANIZING
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It’s Recyclable
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Sustainability: Galvanizing is
Green Zinc and steel are 100% recyclable
Properties of zinc (and steel) do not degrade with reprocessing
Zinc is a natural element in the Earth’s crust
Recycled content contributes to LEED
Galvanizing’s maintenance-free durability ensures no additional energy, materials, or emissions during use
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Hot-Dip Galvanizing & LEED®
HDG contributes points under Materials &
Resources Credit 4: Recycled Content Credit 4.1: Use materials with recycled content
(10%)
sum of post consumer recycled content plus one-half of
the pre-consumer content equals 10% of the total value
of the materials in the project
Credit 4.2: Use materials with recycled content
(20%)
sum of the post consumer recycled content plus one-half
of the pre-consumer content constitutes at least an
additional 10% beyond Credit 4.1 (total of at least 20%)
of the total value of the materials in the project
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Other Zinc Coatings
Metallized Hot-Dip Galvanized
Zinc-Rich Paint Galvanized
Sheet Electroplated
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Zinc Coating Life Predictor
Anticipates service life
Program performs
calculations
Statistical methods
Neural network
technology
Worldwide corrosion
database
Atmospheric
categories
Rural
Suburban
Temperate marine
Tropical marine
Industrial
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Estimated Service Life of
HDG
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Metallurgical Bond
steel
Gamma
Delta
Zeta
75% Zinc 25% Iron
90% Zinc 10% Iron
100% Zinc
94% Zinc 6% Iron
Eta
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Design & Fabrication
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Liaison Between...
Design Engineer
Fabricator
Galvanizer
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Avoid Combining Different Materials
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Welding Procedures
and Flux Removal
Remove prior to galvanizing
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Seal Welding
Viscosity of zinc
prevents it from
entering gaps less
than 3/32”
Complete seal-welding
or stitch-welding with
at least 3/32” gap
between surfaces
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Galvanizing Oversized Pieces
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26th Street & the Dan Ryan
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Material Handling
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Allowing for Proper Venting & Drainage
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Improper Venting
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Marking
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ASTM A 123
Coatings on Iron & Steel Products
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ASTM A 153
Coatings on Iron & Steel Hardware
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ASTM A 385
Providing High-Quality Zinc Coatings
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ASTM A 767
Zinc-coated Steel Bars for Concrete Reinforcement
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132
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133
www.galvanizedrebar.com
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134
Advantages of Hot Dip
Galvanized Rebar
Corrosion resistant
Low cost
Tough
Long history of performance 1948 Royal Navy Dockyards, Bermuda
Higher bond strength
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Stearns Bayou Bridge
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ASTM A 780
Repair of Damaged & Uncoated Areas of Hot-Dip
Galvanized Coatings
Zinc-Based Alloys Zinc Dust Paint
Metallizing
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ASTM D 6386
Standard Practice for Preparation of Zinc (Hot-Dip) Galvanized Coated Iron & Steel Product & Hardware Surfaces
for Painting
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“All commonly practiced
welding and cutting
techniques can be used on
Galvanized Alloyed steel”
American Welding Society
D – 19.0
Welding Zinc Coated Steel
AZZinc Protects
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Preparation of Weld Area
“weld area should be free of
Galvanizing, 1 to 4 inches
back, both sides, top and
bottom”
AZZinc Protects
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Removing the Galvanizing
1) Grind it off
2) Burn it off
3) Apply Galva Stop before Galvanizing
AZZinc Protects
Preparation of Weld Area
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Weathering of Galvanized Steel
Photo taken 12/18/02
Photo taken 03/28/03
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Steel Chemistry Sandelin Curve
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Irregular Zinc-Iron
Alloy Layers
Typical Zinc-Iron Alloy Layers
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Electrochemical Corrosion Zone
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Painting Over Galvanized Steel
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Painting Galvanized Steel
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Painting Ungalvanized Steel
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Synergistic Effect
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Safety Marking
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Color
Coding
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Stark County – Pro Football Hall of Fame Bridge
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Stark County – Pro Football Hall of Fame Bridge
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Real-world
Applications
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Stears Bayou Bridge
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Stearns Bayou Bridge
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Cost Analysis of
The Stearns Bayou Bridge
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Stearns Bayou Bridge
First fully galvanized bridge in the US
Built in Michigan 1966
All steel components were galvanized handrail
diaphragms
fasteners
shear connectors
beams
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Stearns Bayou Bridge Options
Option 1:
Paint the steel structure
Preparation costs
were not included
Option 2:
Galvanize the structure
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Cost Comparison
Initial cost
Maintenance
Maintenance
Maintenance
Maintenance
Initial cost
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What $8,700.00 Bought the Specifier
46 years of:
A rust-free surface
A spangled appearance
A coating thickness of an average of
4.4 mils today
48 more years maintenance free
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Spring Lake Bridge MI
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Dick Vale Bridge Peru, ME
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Montgomery County -Maryland
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We Protect More Than Steel
7th Avenue Light Rail Transit
Date Galvanized 2005
Components Galvanized Columns, arms, light posts,
handrails, benches, hardware
Environment Urban
Location Calgary, AB
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Fallowfield Township – Washington County PA
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Bryants Bridge – Saratoga County N. Y.
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Hot-Dip Galvanizing
Costs Less Lasts Longer
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The Cost of Corrosion
Protection Initial cost will always factor into decision
Life-cycle cost analysis is more complete
Includes all future maintenance costs
Provides total cost of the project over its life
Life-cycle cost calculation automated
online at
www.galvanizeit.org/galvanizingcost/
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Quantitative Analysis
Data Sources:
Paint – 2008 KTA Tator paper Nationwide survey of the paint industry
Presented at NACE 2009
Galvanizing – 2008 AGA Industry Survey
Project Parameters Standard mix of steel (structural, tubing, plate)
30,000 ft2 project
Moderately industrial environment
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Initial Cost Parameters
Paint
Material (one- or two-
pack product, number
of coats, etc)
Shop cleaning labor
Shop/field application
Field labor
Galvanizing
Process is inclusive
of all cleaning,
material, and labor
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Initial Cost
Coating System $/ft2 Total
Inorganic Zinc $1.35 $40,410
Hot-Dip Galvanizing $1.60 $48,000
Inorganic Zinc/Epoxy $2.16 $64,800
Acrylic WB Primer/ Acrylic WB
Intermediate/ Acrylic WB Topcoat $2.55 $76,620
Inorganic Zinc Primer/ Epoxy/
Polyurethane Topcoat $3.17 $94,950
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Life-Cycle Cost
Maintenance costs calculated on a
practical maintenance cycle (vs. ideal)
Unique to each paint system
Manufacturer recommended cycles provided
in the KTA Tator paper
NACE model for NFV and NPV
calculations
2% inflation; 4% interest
50-year life
Maintenance repaint at 5% rust
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Life-Cycle Cost ($/ft2) 60-Year
Life Coating System $/ft2
Hot-Dip Galvanizing $1.60
Inorganic Zinc $5.16
Inorganic Zinc/Epoxy $8.07
Inorganic Zinc Primer/Epoxy Intermediate/
Polyurethane Topcoat $10.04
Acrylic WB Primer/ Acrylic WB
Intermediate/ Acrylic WB Topcoat $14.82
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Total Cost of 60-Year Project
Coating System Total
Hot-Dip Galvanizing $48,000
Inorganic Zinc $154,800
Inorganic Zinc/Epoxy $242,100
Inorganic Zinc Primer/ Epoxy/
Polyurethane $301,200
Acrylic WB Primer/ Acrylic WB
Intermediate/ Acrylic WB Topcoat $444,600
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Kevin Irving
Marketing Manager Northern Ops
815-693-4242
Thank You!
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Knox County, OH - Before
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Knox County, OH - After
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Seneca County, OH - Before
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Seneca County, OH - After
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Village of Glouster County, OH - Before
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Village of Glouster, OH - After
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Village of Minerva, OH - Before
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Village of Minerva, OH - After
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202
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203
www.galvanizedrebar.com
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204
Advantages of Hot Dip
Galvanized Rebar
• Corrosion resistant
• Low cost
• Tough
• Long history of performance – 1948 Royal Navy Dockyards, Bermuda
• Higher bond strength
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Stearns Bayou Bridge
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Stearns Bayou Bridge
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Electrical Utilities
Cellular Clock Tower
Raleigh
North Carolina
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Piers 1 & 21 Replacement
Date Galvanized 2002
Components Galvanized Fenders and corner bolsters
Environment Temperate marine
Location Norfolk, WA
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Texas Motor Speedway
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Galvanized
Painted
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Corrosion Problem – Case
Study The Williamsburg Bridge
built in 1903 in New York City
1991 inspection revealed severe corrosion direct cost of repairs was $750 million
indirect cost approximately $8.2 billion
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Law of Entropy
Tendency for metal, after production and shaping,
to revert back to its lower, more natural energy
state or ore
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Galvanic Series of Metals
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).
ZINC = ANODE
STEEL = CATHODE
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Zinc is Natural
Air
Water
Soil
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Sacrificial Zinc Anode
In an “Electrochemical” Corrosion Cell, Zinc
will sacrifice itself consistently and rapidly
as long as all of the Corrosion Elements
are present (i.e. Anode, Cathode,
Electrolyte & Return Current Path)
(Accelerated Corrosion Testing)
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Sacrificial Zinc Anodes
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Corrosion of Bare Steel
Microscopic anodic and cathodic areas exist on a
single piece of steel
As anodic areas corrode, new material of different
composition is exposed with different electrical
potential
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Seal Welding
Viscosity of zinc
prevents it from
entering gaps less
than 3/32”
Complete seal-welding
or stitch-welding with
at least 3/32” gap
between surfaces
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Electrochemical Corrosion Zone
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Chemical Corrosion Zones
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AZZinc Touch-up
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