Publication - Painting, Coating & Corrosion Protection - Perry Metal Protection - Specifying Hot Dip Galvanizing
Publication - Painting, Coating & Corrosion Protection - Perry Metal Protection - Specifying Hot Dip Galvanizing
Publication - Painting, Coating & Corrosion Protection - Perry Metal Protection - Specifying Hot Dip Galvanizing
The following steps should be followed to select the most appropriate corrosion protection coating:
The NZ Building Code requires the detailing and specifying for durability of steel structures and members with a
specified intended life of not less than 50 years for building structures. A shorter life to first maintenance may be
selected in conjunction with a maintenance programme which together will meet the durability provisions of NZBC
Clause B2. Where components of the structure are not accessible for maintenance after assembly the coating must
achieve the specified intended life.
General atmospheric environments (macroclimate) are classified into six atmospheric corrosivity categories (C1 to C5
and CX) based on the corrosion rates of mild steel given in ISO 9223. In addition to climatic effects, the site specific
environmental effects (microclimate) need to be considered. Factors requiring consideration include whether the steel
surface is shaded, in a wet location, and whether the steel is in contact with timber or concrete. The most significant
microclimate effect is if the steel surface is sheltered from rain washing but exposed to the windblown marine salts as
this greatly influences the corrosion rate.
The life to first maintenance available options takes into account the asset owners expectations, and the general
principles of design to avoid corrosion. The ease of maintenance of the coated article if the life to first maintenance of
the coated article is less than the required durability also requires consideration.
SPECIFYING HOT DIP GALVANIZING
DESIGN AND DURABILITY OF HOT DIP GALVANIZING
Hot dip galvanizing has proven to be more serviceable and predictable than all other steel protective coatings in the
New Zealand atmosphere. Its excellent performance is due to its inherent corrosion resistance, high
tolerance to mechanical damage and inertness to the high UV levels prevailing over all of New Zealand.
A detailed section on the design of duplex coatings (paint over HDG) is included, with two performance options for
durability (aesthetic and corrosion).
For engineers and fabricators the design details are extensive and pictorial advice on good design practice provides
clear instruction. Appendices to the Standard also cover corrosion in different environments, including bimetallic
corrosion and the interaction of HDG steel with soil, concrete, water, chemicals, and wood.
A single table is provided in AS/NZS 2312.2 for designers to compare the expected durability of different galvanized
products, allowing for a faster product selection process. The durability of a HDG coating is calculated from the
minimum average coating thickness in AS/NZS 4680, which also means non-standard HDG thicknesses can be
easily assessed for estimated life to first maintenance.
The corrosion rate of a zinc coating is affected by the time for which it is exposed to wetness, air pollution and
contamination of the surface. To a first approximation, the corrosion of all zinc surfaces is at the same rate in a
particular environment. A brief description of macro environment corrosivity categories are detailed below.
Category C2 - External environments in this category are mostly areas beyond at least 50 km from the sea.
Category C3 - This category mainly covers coastal areas with low salinity. Along ocean front areas with breaking surf
and significant salt spray, it extends from about 1 km inland to between 10 to 50 km inland, depending
on the strength of prevailing winds and topography. This category also includes urban and industrial
areas with low pollution levels.
Category C4 - This category occurs mainly on the coast and can extends from about several hundred metres inland to
about one kilometre inland. Industrial regions may also be in this category.
Category C5 - This category is common offshore and on the beachfront in regions of rough seas and surf beaches and
can extend inland for several hundred metres. This category may also include aggressive industrial
areas, where the environment may be acidic with a pH of less than 5.5.
Category CX - These regions are found at some surf beach shoreline regions with very high salt deposition and are
also be found in severe acidic industrial environments.
MANUFACTURING PROCESSES
AND TOLERANCES Table 1 – Requirements for coating thickness and
mass for articles that are not centrifuged
AS/NZS 4680:2006 is the manufacturing
standard for the hot dip galvanizing coatings
on fabricated ferrous articles. The Standard Article Minimum Minimum Minimum
Thickness Local Coating Average Average
includes requirements for coating mass and mm Thickness Coating Coating Mass
thickness, appearance, defect µm Thickness g/m²
identification, and suitable repair methods. µm
Less than 1.5 35 45 320
Table 1 and Table 2 of AS/NZS4680 state the
1.5 to 3.0 45 55 390
requirements for coating thickness and
3.0 to 6.0 55 70 500
mass, which are based on the steel article
thickness. Over 6.0 70 85 600
Over 6.0+ 85 125 900
A duplex system will increase the service life of the In preparing hot dip galvanized coatings for painting,
HDG article beyond that of the unpainted article. the basic requirements are largely the same as for
Further, the total life of a properly specified, applied other surfaces. Namely, anything that prevents the
and maintained duplex coating system is paint wetting out or adhering to the surface needs to
significantly greater than the sum of the lives of the be removed. Therefore, oils, dirt, dust, salts,
HDG coating and the paint coating alone (by 1.5 – 2.3 corrosion products and other friable material and
times, depending on the environment). soluble salts have to be removed prior to painting.
AS/NZS 2312.2 includes seven decorative and Abrasive sweep (brush) blast cleaning is a common
industrial paint systems suitable for most corrosivity method used for the preparation of a galvanized
environments. coating prior to the application of a paint coating.
The purpose of this procedure is to remove the oxide
film from the zinc surface. Paint coatings should
Painting for decorative, identifying colour be applied as soon as possible after galvanizing or
or enhanced service life abrasive blasting.
While the majority of a hot dip galvanized structure might be exposed to the
atmosphere, it may also be partially embedded in the soil or exposed to
prolonged dampness, such as from the ponding of rainwater. In such
situations, localized painting of the coating with a high build epoxy primer or
the use of a tape or wrap may be needed to avoid premature corrosion in the
exposed areas.
Hot dip galvanized coatings are recommended to be used within the pH range
of 6 to 12. Outside this range, the service life is likely to be unacceptable.
This includes exposure to strong acids and alkalis as well as salts of strong
acids and weak bases and vice versa. Expert advice should always be sort for
these applications.
The total life of a properly specified, applied and maintained duplex coating
system is usually significantly greater than the sum of the lives of the hot dip
galvanized coating and protective organic coating alone. There is a
synergistic effect, that is, the presence of the hot dip galvanized coating
reduces under-rusting of the paint film; the paint preserves the hot dip
galvanized coating from early corrosion. Where it is desired to retain a
reasonably intact layer of paint as a basis for maintenance, the initially
applied paint system should have extra thickness.
Maintenance usually takes place when the duplex coating loses its
appearance or becomes degraded. Hot dip galvanized coatings usually take
longer to degrade than paint. Hence, a hot dip galvanized coating may be
recommended for 20 years or more up to first maintenance, whereas the
same coating when covered by paint is, for reasons of appearance of the paint,
recommended for only 10 years up to first maintenance.
Throughout New Zealand
TALKING TECHNICAL
Perry Metal Protection has four sites conveniently
located throughout New Zealand.
Design, specification and inspection of
galvanized products All four plants have the capacity to galvanize a wide
range of steel structures including mild and low alloy
To ensure consistently good galvanized steel steels, and iron and steel castings.
products, it is essential that the basic
requirements outlined in these guides are We are the only galvanizer in New Zealand with the
incorporated at the design and fabrication capacity to hot dip galvanize lengths up to 18m in length,
stages of production. giving you the flexibility to tackle any kind of job.
CHRISTCHURCH
www.perrymetalprotection.co.nz