SNZ TS 3404 (2018) Durability Requirements For Steel Structures and Components

SNZ TS 3404:2018
Standards New Zealand Technical Specification
Durability requirements for

steel structures and components
Superseding in part NZS 3404.1:2009
SNZ TS 3404:2018
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SNZ TS 3404:2018
COMMITTEE REPRESENTATION
This technical specification was prepared by the P3404 Committee. The membership of the committee was approved and
appointed by the New Zealand Standards Executive.
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The committee consisted of representatives of the following nominating organisations:
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Australasian Corrosion Association
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Building Research Association New Zealand
Galvanizing Association of New Zealand
New Zealand Heavy Engineering Research Association
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Steel Construction New Zealand
University of Auckland
ACKNOWLEDGEMENT
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Standards New Zealand gratefully acknowledges the contribution of time and expertise from all those involved in developing
this technical specification. We wish to thank committee members Dr Charles Clifton, Raed El Sarraf, Dr Zhengwei Li,
Ash Arya, Dr Jing Cao, Zahid Hamid, and observers Ross MacKenzie and Kevin Cowie. We wish to particularly thank the
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New Zealand Heavy Engineering Research Association and National Institute of Water and Atmospheric Research for the
use of Figures 1 to 7.
The P3404 Committee and Standards New Zealand also wish to thank Willie Mandeno and Hanieh Ghominejad of
WSP Opus for their assistance in drafting this document.
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The P3404 Committee and Standards New Zealand would like to acknowledge Steel Construction New Zealand for
commissioning the development of this document.
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Standards New Zealand would also like to thank Standards Australia for allowing the use of modified tables from
AS 2159:2009 Piling – Design and installation: Tables 6.5.2(A), 6.5.2(B), 6.5.2(C) and notes, and Table 6.5.3 and notes,
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reproduced in this technical specification as Tables 10, 11, 12, and 13.
Cover photograph of Haast Bridge courtesy of Raed El Sarraf, WSP Opus.

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COPYRIGHT
This document is Crown copyright administered by the New Zealand Standards Executive. You may not reproduce any part
of it without prior written permission of the New Zealand Standards Executive, unless your actions are permitted by the
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Copyright Act 1994.
Tables 10, 11, 12, and 13 have been reproduced with modifications from AS 2159:2009. Copyright in AS 2159:2009 and its
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content remains with Standards Australia Limited.
We will vigorously defend the copyright in this technical specification. Your unauthorised use may result in a fine of up to
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$10,000 for every infringing copy (up to a maximum of $150,000 for the same transaction and for other specified offences)
or imprisonment of up to 5 years. If the breach is serious, we may also seek additional damages from you as well as
injunctive relief and/or an account of profits.
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Published by Standards New Zealand, PO Box 1473, Wellington 6140.

Telephone: (03) 943 4259, Website: www.standards.govt.nz.
AMENDMENTS
No. Date of issue Description Entered by, and date
SNZ TS 3404:2018
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Standards New Zealand
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TechnicalSpecification
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Durability requirements
for steel structures
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and components
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ISBN (Print) 978-1-77673-253-1

ISBN (PDF) 978-1-77673-254-8
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SNZ TS 3404:2018
CONTENTS
IFC
Committee representation �� ii

IFC
Acknowledgement �� ii
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IFC
Copyright �� ii
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Referenced documents �� v

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Latest revisions �� vii

Review of standards �� vii

Foreword��viii
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Section
1 GENERAL ��1

11 Scope 1
ew
.
............................................................................................................
12 Interpretation 1
.
.................................................................................................
.3 1 DeWnitions 1
.....................................................................................................
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14 Abbreviations 3
.
................................................................................................
15 Notation 3
.
.........................................................................................................
6. 1 SpeciWed intended
life
andthe
New Zealand
Building
Code 3
.......................
7. 1 Time toWrst
major
maintenance
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4
...................................................................
18 Warranty considerations 5
.
...............................................................................
19 Health, safety, and environment protection
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6
.
.................................................
1 10 Inaccessible surfaces 6
.
...................................................................................
1 11 Surface preparation and application of corrosion protection systems 6
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.
.......
1 12 Galvanic corrosion 7
.
........................................................................................
1 13 Detailing for durability 7
.
...................................................................................
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2 CORROSION PROTECTION OF STEEL IN ATMOSPHERIC ENVIRONMENTS ��8

21 Corrosion protection systems 8
.
......................................................................
22 Determining the atmospheric corrosivity category 8
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.
......................................
23 Selecting a complying corrosion protection system 20
.
..................................
24 Average steel loss over the design life of the structure 25
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.............................
25 Assessing the remaining steel loss at the end of the design life 25
.
...............
3 CORROSION OF STEEL IN NON-ATMOSPHERIC ENVIRONMENTS ��27

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1 3. Exposure classiWcation 27
...............................................................................
32 Corrosion rate of steel in non-atmospheric environments 28
.
.........................
33 Selecting a complying corrosion protection system 30
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.
..................................
4 MISCELLANEOUS ��33

41 Inspection of coatings 33
.
................................................................................
42 Inaccessible surfaces 33
.
.................................................................................
43 Protection during transport and handling after corrosion protection 33
.
........
44 Repairs to corrosion protection 34
.
..................................................................
45 Coatings reference areas and test coupons 34
.
..............................................
COPYRIGHT © Standards New Zealand iii
SNZ TS 3404:2018
Table
1 First-year corrosion rates of steel in different atmospheric corrosivity
environments 8
............................................................................................................
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2 Surface-speciWc atmospheric
corrosivity
categories 18
.............................................
3 Other atmospheric corrosivity environments 20
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.........................................................
4 Internal steelwork – Coating required
onlyforappearance, surface-speciWc
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corrosivity category C1 and temporary protection during construction 23
................
5 Coatingsforsurface-speciWc
corrosivity
category
C2 23
...........................................
corrosivity
category
C3 24
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corrosivity
category
C4 24
...........................................
corrosivity
category
C5-M 25
......................................
9 Average corrosion rate (µm/annum) of carbon steel in different environments 26
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.....
10 Exposure classiWcation
forsteel
inwater 27
...............................................................
forsteel
inrefuse
Wll 27
.........................................................
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forsteel
insoil 28
..................................................................
13 Corrosion allowance for steel in non-atmospheric environments 29
..........................
14 Suggested protective coating systems for steel piles in non-atmospheric
environments 31
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..........................................................................................................
15 Average zinc corrosion rate (per side in contact) versus soil water,
pH, or resistivity 32
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.....................................................................................................
Figure
1 North Island corrosivity zone map 10
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.........................................................................
2 South Island corrosivity zone map 11
.........................................................................
3 Auckland corrosivity zone map 12
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4 Wellington corrosivity zone map 13

............................................................................
5 Tauranga corrosivity zone map 14
..............................................................................
6 Christchurch corrosivity zone map 15
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........................................................................
7 Dunedin corrosivity zone map 16
...............................................................................
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iv COPYRIGHT © Standards New Zealand

SNZ TS 3404:2018
REFERENCED DOCUMENTS
Reference is made in this document to the following:
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Joint Australian/New Zealand standards
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AS/NZS - : 1 024 Buried corrugated
metal
structures
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Part 1:2011 Design methods
AS/NZS 02: 1 3 Glossary of paint

andpainting
terms
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AS/NZS 02: 1 32 Guide tothe protectionof structuralsteel against
atmospheric corrosion by the use of protective coatings
AS/NZS -:2 1 3 Guide tothe protectionof structuralsteel against
ew
atmospheric corrosion by the use of protective coatings
Part 1:2014 Paint coatings
Part 2:2014 Hot dip galvanizing
AS/NZS
Part 9:2009
- 5: 0 7 3 Paints
sN
forsteel
structures
Organic zinc-rich primer
Part 15:1998 Inorganic zinc silicate paint
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AS/NZS 0 42 : 5 3 6 Zinc andzinc/aluminium-alloy
coatings
onsteel
wire
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AS/NZS 4 6 80 2 : Hot-dip galvanized

zinc)
( coatings
onfabricated
ferrous
articles
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AS/NZS 02: 9 7 6 4 Hot-dip galvanized zinc)

( coatings onferrous hollow
sections, applied by a continuous or a specialised process
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AS/NZS -0 : 1 5 Bridge design

Part 6:2017 Steel and composite construction
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AS/NZS 6 1 02: 3 1 5 Structural

steelwork
– Fabrication
anderection
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International standards
ISO 8501:---- Preparation of steel substrates before application of paints
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and related products – Visual assessment of surface

cleanliness
Part 1:2007 Rust grades and preparation grades of uncoated steel
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substrates and of steel substrates after overall removal of

previous coatings
ISO 9223:2012 Corrosion of metals and alloys – Corrosivity of

atmospheres – ClassiWcation, determination andestimation
ISO 9224: 2012 Corrosion of metals and alloys – Corrosivity of

atmospheres – Guiding values for the corrosivity categories
COPYRIGHT © Standards New Zealand v

SNZ TS 3404:2018
Australian standards
AS 1 02: 739 1 Continuous hot-dip metallic coated steel sheetandstrip –
Coatings on zinc and zinc alloyed with aluminium and
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magnesium
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AS -: 762 1 Metal
Wnishing
– Preparation
andpretreatment
of surfaces
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Part 4:2005 Abrasive blast cleaning of steel
AS 2159:2009 Piling – Design and installation
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AS 2832:---- Cathodic protection of metals
Part 4:2006 Internal surfaces
AS 3894:---- Site testing of protective coatings
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Part
02: 3 Determination of dryWlm thickness
American standards
ASTM D2244-16
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Standard practice for calculation of color tolerances and
color differences from instrumentally measured color
coordinates
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ASTM D4214-07(2015) Standard test methods for evaluating the degree of
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chalkingof exterior
paint Wlms
Other publications
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American Architectural Manufacturers Association AAMA 2604-05 – Voluntary

.
specication,performancerequirementsandtestproceduresofhighperforman
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organiccoatingsonaluminiumextensionand panels Illinois, USA:

Schaumburg,
.
American Architectural Manufacturers Association, 2005
.
ht
Edmeades, D C andWheeler,D M. ‘Measurement of pH inNew Zealand Soils,an

examination of the effect of electrolyte, electrolyte strength and soil; solution ratio ’
.
New ZealandJournalofAgricultural, Research 33 1, (1990): 106 – 109
rig
.
.
El Sarraf, R, and Clifton, G C New Zealandsteelworkcorrosionandcoatingsguide
.
.
HERA Report R43, 1 - nd
2 ed. Auckland,
New Zealand:
HERA, . 1 02
py
Penhale,
H R. ‘Corrosion
of mildsteelplatesinsome New Zealand
soils.
New ZealandJournalofScience
, no 14 (1971): 336 – 353
Co
.
.
Penhale,H R. ‘Corrosion
of mildsteel
platesinsome New Zealand soils
after
02 years.’ New ZealandJournalofScience
, no 27 (1984): 57 – 68
.
.
New Zealand
Transport
Agency Bridge manual
(SP/M/022)
New Zealand
Transport
Agency Protectivecoatingsforsteelbridges
vi COPYRIGHT © Standards New Zealand

SNZ TS 3404:2018
New Zealand legislation

Chartered
Professional
Engineers
of New Zealand
Act02
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New Zealand
Building
CodeClause
B1 (Structure)
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Building
New Zealand CodeClause
B2 (Durability)
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Registered Architects Act 2005
Websites
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www legislation govt nz
.
.
.
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LATEST REVISIONS
The users of this technical specification should ensure that their copies of the
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above- mentioned New Zealand standards arethe latest
revisions. Amendments to
referencedNew Zealand andjoint Australian/New Zealandstandards canbe foundon
www standards govt nz
.
.
.
.
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REVIEW OF STANDARDS
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Suggestions for improvement of this standard will be welcomed They should be sent
.
totheManager,Standards New Zealand, PO Box 3,7 4 1 Wellington
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COPYRIGHT © Standards New Zealand vii

SNZ TS 3404:2018
FOREWORD
NZS 340 Parts
1 and79 1 :2 Steelstructuresstandardsets out minimum requirements
forthe design,fabrication, erection,
andmodiWcation of steelwork instructuresin
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accordance with the limit state design method or in accordance with the alternative
design method.Itiscurrently referenced
inNew Zealand Building CodeCompliance
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DocumentB1. NZS 340 Parts
1 and2 wasamendedin012 and027.
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In 02 9 a decisionwasmade tosplit NZS 340 Parts 1 and2 into sevenpartsandthat
these parts would be developed and published in a phased manner When all seven
.
parts hadbeenpublished, they would together supersede NZS 340 Parts1 and79 1 :2
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Steelstructuresstandard. NZS
90 2 : 1 . 4043 Steelstructuresstandard–PartMateria :1
fabrication,andconstruction was published setting out minimum requirements for the
selection of materials, corrosion protection systems, and the fabrication, erection, and
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construction of steel structures
.
Mostof the material from NZS :20 3149 . hasnow beenincludedina new joint
Australian/New Zealand standard, AS/NZS 6 102: 1 3 5 Structuralsteelwork–Fabricatio
anderection
the
. The major
scopeof AS/NZS . 1 3 5
SNZ TS 340
exception
Durabilityrequirementsforsteelstructures
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issection 5 corrosion
(
updates
protection)
andcomponents
the
which
, falls
outside
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informationcontained
insection5 of NZS 02: 9 1 340. andisrepublished
asa stand-
alonetechnicalspeciWcation.
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This technical specification provides an advanced framework for specifying the

durabilityrequirements forsteel structuresandcomponents. Itisa simpliWcation
of the
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design procedure for durability determination given in Heavy Engineering and Research
Association Report R4-133:2011 New ZealandSteelworkCorrosionandCoatingsGuid
.
Itwillenable durability requirements tobe metwithout over-speciWcation orunder-
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speciWcation of coatingsystems.
Thistechnical speciWcation hasbeenprepared foruseby asset owners,designers

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engineers
( andarchitects) contractors,
, speciWers of corrosionprotection systems,and
the surface coating industry It covers the corrosion protection of structural steelwork
.
exposedtothe New Zealand atmospheric andnon-atmospheric environments.
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This technical specification has been written to satisfy the requirements of the
New Zealand Building CodeClause B2, the New Zealand Transport Agency (NZTA)
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Bridge manual , andthe NZTA Protective coatings for steel ; as bridges

well as remain
compatible with NZS 340 Parts 1 and7. 9 1 :2 Itshould be usedinconjunction with
AS/NZS 4 1 0 2 : 1 . 2 1 3 2 andAS/NZS . 4 1 0 2 : 2 . 2 1 3 2 As the fabrication anderection provisions
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of NZS 4 0 4 3 areinthe processof beingsuperseded by AS/NZS 1 3 1 5 andAS/NZS, 6 . 0 1 5

SNZ TS 340 isalso written tobe compatible with those documents.
SNZ TS 340 supersedes

inpart
NZS 02:,9 1 340. speciWcally section
5 oncorrosion
protection.Referto
this
technical
speciWcation instead
of clause
6.4 3 inNZS 7. 9 1 : .1 403
viii COPYRIGHT © Standards New Zealand

SNZ TS 3404:2018
Standards
NewZealandTechnical
Specification
Durability requirements for
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steel structures and components
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1 GENERAL
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1.1 Scope
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Thistechnical speciWcation setsout the technical requirements thatarenecessary to
provide the required level of durability to steel structures and their component parts, in
theNew Zealand environment.
1.2 Interpretation
Forthe purposes of thistechnicalspeciWcation,
the
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word‘shall’
refersto
the
requirements
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that are essentialforcompliance withthe technical
speciWcation,
whilethe
word‘should’
refers to practices that are advised or recommended .
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Clauses preWxedby ‘C’andprinted initalictypeareincluded ascommentson the

corresponding clauses They are not to be taken as the only and complete interpretation
.
.
Thetechnical speciWcationcanbe complied with ifthe commentisignored.
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1.3 Definitions
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For the purposes of this

technical
speciWcation
the deWnitions
below,andthose
given
inAS/NZS ,0 1 32 apply:
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Asset owner The owner of the structure being constructed or maintained,

or their nominated representative
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Contractor A person orWrm that undertakes a contracttoperformthe

physical work in relation to the construction or maintenance
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of a steel structure or component
Corrosivity A measure of the ability of an environment to cause

corrosion
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Damp Internal environment where condensation may occur, such

as a non-air conditioned or poorly insulated car parks and
warehouses; or in a high-humidity environment with some
pollution, such as in some food processing plants, sewage
treatment buildings, and animal shelters
COPYRIGHT © Standards New Zealand 1

SNZ TS 3404:2018
Designer An engineer or architect with relevant experience and

skills in the design of structures, who is responsible
for interpretation of the requirements of this technical
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speciWcation whenusedforstructures design.A structural
or materials engineer who is chartered under the Chartered
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Professional Engineers of New Zealand orRegistered
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Architect Act would satisfy this requirement
Design life Period over which a structure or structural element is

required to perform its function
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Dry Internal environment, such as within a fully air-conditioned
ofWce orapartment building
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Durability Thetime elapsed before
theWrstmajor maintenance of a
coating system becomes necessary, to arrest corrosion
Environment Surrounding region which contains one or more corrosive
Exposed
agents
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Opened to airborne salts, is washed by the rain, and can
dry quickly after wetting
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External Exposed to the weather
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Inspector A person who, onthe basis

of experience
orqualiWcations,
iscompetent tocarryoutspeciWcinspection
duties
stipulatedby theassetowner,designer,
orspeciWer,
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the requirementsof this

technical
speciWcation
ora
referenced standard
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Internal Protected from the weather by being located inside the

structure
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Nominaldrylm Thickness speciWed foreachcoat orforthe whole

paint
thickness system to achieve the required durability
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Protective coatings The organisation that manufactured and supplied protective

manufacturer coatings
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Sheltered Open to airborne salts but unwashed by the rain, such as

under an awning or the deck of a steel bridge
Specier A person,who onthe basis of experience andqualiWcations,

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is competent to specify a corrosion protection system for

the given environment and durability requirements
Wet Often wet for extended periods of time, such as crevices,

or inlowpoints andpockets that arenot drained
2 COPYRIGHT © Standards New Zealand

SNZ TS 3404:2018
1.4 Abbreviations
Thefollowing
abbreviations
areusedinthis
technical
speciWcation.
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ACA Australasian Corrosion Association
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APAS Australian Paint Approval Scheme
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FBE Fusion bonded epoxy
NACE NACE International
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NEPCOAT North East Protective Coating Committee
NORSOK NorskSokkels
Konkurranseposisjon
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NZBC New Zealand
Building
Code
NZTA New Zealand

Transport
Agency
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MIC Microbial
inXuenced
corrosion
1.5 Notation
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Thistechnical
speciWcation
usesthe
following
notations:
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Average corrosion rate for up to 10 years that correspond to

the initial period of exposure
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Steel corrosion rate, in µm/annum
Average corrosion rate during the Wrst 30 yearsthat

istaken
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as being the steady-state corrosion rate
Steelwork design life in years

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Total
timetoWrst major maintenance of initial
and
subsequent coating systems applications
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Steel thickness loss in µm/steel surface

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1.6 Specified intended life and the New Zealand Building Code
The provisionsof thistechnical speciWcation shall applytosteel structures with a
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speciWed
intended life
of notless than 50 yearsfora building structure ornot less than
01 yearsfora highway, road,orrailway bridge.Compliance with thisspeciWcation is
intended
toensure that thestructural steelwork issufWciently durable tosatisfy the
requirements
of the New Zealand Building Code(NZBC) Clause B2 orthe New Zealand
Transport
Agency (NZTA) Bridge manual throughout the life of the structure, with only
normal maintenance, including the refurbishment of the protective coating system without
requiringreconstruction ormajor renovation.

SNZ TS 3404:2018
C1.6
The‘speciedintendedlifeofthebuilding’fromClauseB2oftheNew Zealand
BuildingCodedoesnotneedtobethetimetorstmajormaintenanceconside
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when selecting an appropriate method of corrosion protection. A shorter t
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to rst major maintenance could be selected in conjunction with an inspe
andmaintenanceprogramme,whichtogetherwillmeetthedurabilityprovis
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ofNZBCClauseB2.
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1.7 Time to first major maintenance
Thetime toWrst major maintenance isthe expected time fromapplication
of a corrosion
protection system (such as protective coatings) up to when patch repair, patch and
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overcoat, or full refurbishment is required as part of normal maintenance Minor repairs to
.
these protection systems within the construction maintenance period are not considered
whendetermining the time
toWrst majormaintenance. In addition,
priorto
the time of Wrst
sN
major maintenance, minorrepairs toprotective coating may be required
foraesthetic
purposes torejuvenate the
Wnishandrestore loss of gloss andcolour.
Thecriteria
fordetermining
whenthe
time
toWrst
major
maintenance
isreached
are:
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(a) For scattered general breakdown of protective coatings: when a specified
percentage of rust is visible This varies from under 0 5% of the total area for barrier
.
.
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coat systems, which exclude air and water from the steel surface, to up to 2% of
thetotal areaforsacriWcial zinc-based systems whichprotect by galvanic action;
(b) For more severe localised breakdown of the corrosion protection system, for
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examplemissed orundercoated areas: whena speciWed

percentage from%2 to
20% of the total area has occurred; and
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(c) Where widespread blistering,

Xakingorrusting
under
the
corrosion
protection
system surface is evident
.
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The expected time toWrst major maintenance of properly applied protective

coating
systems can be estimated from the atmospheric corrosion category given in Table 2,
with examples of suggested protective coatings given in Table 4 to Table 8 A more
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.
comprehensive listing
isgiveninthe differentparts of AS/NZS .4 102: 1 32
NOTE –
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(1) These times assume planar surfaces on new steel which have been coated under optimum
conditions and as recommended by the manufacturer
.
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(2) Atthe
expected
time
toWrst
major
maintenance,
the selection
of the
mostcost-effective
whole-of-life refurbishment option should be determined, based on the cause of corrosion
breakdown and its extent This should include considering both access and containment
.
(when required) costs, as well as the asset owner’s expectations and requirements
.
Refurbishment options may include patch repair, patch repair and full overcoat, or the full
removal and reapplication of the corrosion protection system
.
SNZ TS 3404:2018
C1.7
The criteria for determining when the time to rst major maintenance
coating system has been reached are based on AS/NZS 231.:04 and
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AS/NZS 231.:04,whichincludepictorialexamples.
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Allcorrosionprotectionsystemscouldrequireminorrepairspriortothet
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rstmajormaintenance,forexamplecausedbymechanicalorweldingdamage,
or areas welded after the coatings have been applied and at corners wher
the coating thickness is difcult to verify. Coating systems also change th
appearanceovertime,suchaspaint,duetoexposuretothesun’sultravioletr
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(UV)This
. couldrequirerefurbishingthecoatingforaestheticreasonspriorto
lossofeffectiveprotectiontotheunderlyingsteelsurface,implicitinthe
rstmajormaintenanceprovisions.
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All the above constitute part of the normal maintenance specied in NZBC
Clause B2.
Forstructureswithaspeciedintendedlifegreaterthanamultipleoftheexpe
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timetorstmajormaintenanceofthecorrosionprotectionsystem,oneormor
refurbishmentsareexpectedtoberequired.
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1.8 Warranty considerations
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The durability range is not a ‘warranty time’ Durability is a technical consideration that
.
can help the asset owner or the designer set up a maintenance programme A warranty
.
time isa consideration that isthe subject of a clauseinthe contract. Althoughthere are
an
no deWnite rules thatlink the twoperiods of time,a warranty of about one-quarter to

one-third of estimated durability should be the maximum expected
.
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A warranty may be provided to protect against a fault in the coating product, or the
workmanship of application, rather than the durability of the coating system Some
.
issues with long warranties are:
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(a) They are oftentoo simple

orconversely
too complex, andthere
may bedifWculties
in enforcing them;
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(b) They may be used as a commercial tool so written to prevent any liability;
(c) After
a longer
time
period,
it may be difWcult
todetermine
who isat
fault;
py
(d) It may require a lengthy and costly court case to recover costs;
(e) Long warranties are likely to attract a price premium;

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(f) Warranties are usually provided on a diminishing scale with only small percentage
of the value at the end of the warranty term;
(g) For coatings (other than galvanizing) the protective coatings manufacturer typically
warrants its product only and the applicator separately warrants they have correctly
applied the coating manufacturer’s product
.
SNZ TS 3404:2018
When preparing
warranties,
thedesign
engineer
orspeciWer
should
take
note
of the
following:
(h) Thereshouldbe aclauseregarding

ordinary
wearandtear.
Thisneedstobe clariWed
d
asthe deWnition
of wearandtearcandependonthe party;
n
(i) It needs to be clear what will be supplied in the event of a failure A warranty may
.
simply cover the cost of paint, but the cost of reapplication may be many times
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this Wgure;
( j) Reference areas or test coupons (see 4 5) will assist in determining whether
.
the failurewas caused by inappropriate speciWcation,defectiveworkmanship,
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or coating material For warranty claims, such areas should be mandatory and
.
coordinated by the owner or owner’s representative;
(k) To overcome possible disagreements about coating failures, allow for the
ew
appointmentof a suitably
qualiWedindependentreferee;
(l) A warranty is intended to protect against a fault in coating product or its application,
which would be expected to manifest itself early in the life of the coating system
sN
.
It is therefore not realistic to expect a commercial warranty to cover the entire
durability expectations noted inthis
technical speciWcation;
(m) An owner concerned about long term durability of a coating system should consider
rd
taking out a maintenance contract and employing an independent coating inspector
during preparation for, and application of, the coating(s)
.
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For additional guidance on warranties refer to HERA Report R4-133
.
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1.9 Health, safety, and environment protection

Itisa dutyof the asset owner,designer, speciWers, contractors,paint manufacturers,
St
inspectors, andall other personnelinvolved ina project tocarry

out theworkforwhich
they are responsible in such a manner that they do not endanger the health and safety
of themselves or others
.
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They shall comply with all the statutory requirements that relate to the region in which
the work, or any part of the work, is to be carried out
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.
1.10 Inaccessible surfaces
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Members with surfaces that cannot be accessed for normal maintenance shall be
assessed forstructural adequacyforthe speciWed design lifeafter allowing
fortheeffects
of corrosion after loss of the protection from the initial coating, in accordance with 2 5
Co
.
.
1.11 Surface preparation and application of corrosion protection systems
Surface preparation, application, or installation of corrosion protection systems, including
qualitycontrol
inspections, shall be undertaken inaccordance withthe relevant speciWed
standards andrecommendations such
( asAS/NZS 4 1 0 2 : .1 2 1 3 2 andAS/NZS ) 4 1 0 2 : 2 . 2 1 3 2
orother speciWedindustry guidance ormanufacturer’s requirements forthe system
selected
.
SNZ TS 3404:2018
1.12 Galvanic corrosion

Galvanic corrosion and its mitigation by protective coatings shall comply with
AS/NZS 4 102: .2 1 3 andAS/NZS .4 102: 32
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1.13 Detailing for durability
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Guidanceondetailing
fordurability
isgiveninAS/NZS , 4 1 0 2 : 1 . 2 1 3 2 AS/NZS , 4 1 0 2 : 2 . 2 1 3 2
andHERA Report R43. 1 -
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SNZ TS 3404:2018
2 CORROSION PROTECTION OF STEEL IN ATMOSPHERIC ENVIRONMENTS
2.1 Corrosion protection systems
d
For the purpose
of this
technical
speciWcation
corrosion
protection
systems
aretaken
n
to include:
ala
(a) Paint
coatings:
suchassacriWcial,
barrier
andwet
( applied)
inhibitive
coatings;
(b) Galvanized coatings: such as hot dip, or continuous;
(c) Thermal sprayed metal coatings: such as arc sprayed zinc, aluminium and their
Ze
alloys;
(d) Thermoplastic powder coatings: such as ethylene copolymers;
(e) Barrier
tape
systems:suchasviscoelastic
for
( examplepetrolatum)
orpolyethylene
ew
tapes
.
NOTE – Thermoset
powdercoatings
suchasfusion
bondedepoxy (FBE) arenot
included.
C2.1
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Forgalvanizedprotectivecoatings,theseincludehotdipgalvanizingsuchast
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typicallyappliedtosteelfabrications(forexample,AS/NZS and 4680) continuous
galvanizingsuchasthoseappliedtosheet,purlins,andcontinuouslygalvan
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tubeandwire(forexample,AS/NZS 453,AS/NZS 4792,andAS 1397).

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2.2 Determining the atmospheric corrosivity category
2.2.1 First-year corrosion rates of steel

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Therangeof Wrst-year corrosion rates ( ) of carbon-manganese steel (the usual type

of steel used in structures) for the different atmospheric corrosivity categories, based
on ISO 9223, is given in Table 1
ht
.
rig
Table 1 – First-year corrosion rates of steel in different atmospheric corrosivity environments
Corrosion Atmospheric corrosivity category

rates C1 C2 C3 C4 C5-Ma or C5-Ia CX (M or I)b
py
(µm/annum) Very low Low Medium High Very high Extreme

Steel p 1.3 13< p 25 25 < p 50 50 < p 80 80 < p 20 200 < p 70
.
NOTE – Based
onTable 1, indicative
Wrst-year
steel
macroclimate
corrosion
rates
forNew Zealand
aregiveninFigure 1
Co
and Figure 2, or the relevant city maps given in Figure 3 to Figure 7

.
a Category
C5 issubdivided
into
Marine
(M) orIndustrial
(I). Marine
isforimmediately
adjacent
toseashore
except

opensurf.Industrial
isforwithin
industrial
facilities
with
corrosive
processes
andtypically
requires
site-speciWc
determination It also applies to geothermal areas in accordance with note of3 both Table 2 and Table 3
.
.
b Category CX is subdivided into marine or industrial Marine is for the most exposed open surf beaches; industrial

.
forthe
is typically mostsevere
geothermal
exposure

SNZ TS 3404:2018
C2.2
Theregionalcorrosivityzonemapsshowthedirectionandintensityoftwosort
wind;prevailingwindandcommonwind.Thedifferencemeteorologicallyisthat
d
thecommonwindisalocaleffectwindgeneratedbythelocalpressurecondition
n
whereastheprevailingwindisgeneratedbytheregionalweatherpatterns
localeffectoncorrosivityisthesame;however,thedifferenceisinthewayth
ala
wind is generated. It is most marked in Christchurch and Dunedin where the
prevailingwindisfromthewesterlyquarter,thatis,the‘roaring40s’westerlyw
belt, but the effects of the Alps and the cold sea off the east coast means the
north-easterlyandthesoutherlywindsarethemostfrequentlyobservedwi
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SNZ TS 3404:2018
n d
ala
Corrosivity (µm/annum)
C2 1.3 < ≤25
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C3 25 < ≤50
C4 50 < ≤80
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NOTE – Zone C4 is not shown where

it is less than 1 km from the coast.
Zone C5 is also not shown as it usually
extends between 50 and 500 m
inland from breaking waves.
Figure 1 – North Island corrosivity zone map

SNZ TS 3404:2018
n d
ala
C1 ≤1.3
Ze
C2 1.3 < ≤25
C3 25 < ≤50
ew
C4 50 < ≤80
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Figure 2 – South Island corrosivity zone map

SNZ TS 3404:2018
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C2 1.3 < ≤25 Climate data used is based on the 30-year
period 1971 – 2000. Valid for distances
C3 25 < ≤50 further than 500 m from the sea.
Figure 3 – Auckland corrosivity zone map

SNZ TS 3404:2018
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Figure 4 – Wellington corrosivity zone map

SNZ TS 3404:2018
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n
ala
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Figure 5 – Tauranga corrosivity zone map

SNZ TS 3404:2018
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n
ala
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Figure 6 – Christchurch corrosivity zone map

SNZ TS 3404:2018
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Figure 7 – Dunedin corrosivity zone map

SNZ TS 3404:2018
2.2.2 New Zealand surface-specific corrosivity categories

Table 2 outlines the surface-speciWc atmospheric corrosivitycategories fordifferent
locations, taking into account both the macroclimate and microclimate effects
.
d
For cases not covered in Table 2, use the guidance given in Table 3
n
.
ala
C2.2.2
HERAReportR4-13providesamoredetailedcalculateddeterminationofthe
atmosphericcorrosivitycategoryandextentofexposureconditions.Weather
Ze
ofthecoatingsystemduringconstructioncouldbemoreseverethaninitsna
state. This is often the case with single paint systems applied to wire-brus
steelwork.Toensuretheintendedin-serviceperformanceofthecoatingsystem
achieved,theallowableperiodofconstructionexposureissetathalftheexpe
ew
timetorstmajormaintenance.
Areas shown as C2 north of Auckland to south of Dargaville, and Wellington to
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southofPoriruaEast,shouldbetakenasbeingborderlineC2/C3.
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Table2–Surface-specicatmosphericcorrosivitycategories
18
Macroclimate Typically Location Characterised by Surface-specic
corrosion category atmospheric corrosivity
(from External Internal
AS/NZS) 4 1 0 2 : 1 . 2 1 3 2 Exposed Sheltered Wet Dry Damp
Co
SNZ TS 3404:2018
Within 200 metres of breaking

surf on the west and south
py
coasts of the South Island
Within 100 metres of breaking
rig
surf on west and south coasts Heavy salt deposits
C5-M of the North Island All coasts Almost constant smell of C5-M C4
ht
Within 50 metres of breaking salt
seasprayinthe air
surf on all other coasts
St
This environment may be
extended inland by prevailing
an
winds and local conditions
Within 500 metres inland of
da
C1
breaking surf
rd
Within 50 metres of
Medium salt deposits
calm salt water such as
C4 All coasts Frequent smell of salt C4 C5-M
sN
harbour foreshores
sea spray in the air
This environment may be
ew C3
extended inland by prevailing
winds and local conditions
West and south coasts of
Within 20 km of breaking surf C5-M
Ze
South Island Minor salt deposits
C3 East coast of both islands, Occasional smell of salt C3
ala
Within 5 km of salt water west and south coasts of in the air C4 C5-M
North Island, and all harbours
n d
COPYRIGHT © Standards New Zealand
Table2–Surface-specicatmosphericcorrosivitycategories
(continued)
Macroclimate Typically Location Characterised by Surface-specic

corrosion category atmospheric corrosivity
(from External Internal
AS/NZS) 4 1 0 2 : 1 . 2 1 3 2 Exposed Sheltered Wet Dry Damp
More than 20 km to 50 km West and south coasts of
Co
C2 C3 C4
from salt water South Island
C2 East coast of both islands,
py
More than 5 km to 50 km
west and south coasts of inXuence
No marine C2 C3 C4 C3
COPYRIGHT © Standards New Zealand

from salt water
North Island, and all harbours
rig
Inland, more than 50 km from C1
C2 North and South Islands C2 C3
salt water
ht
Close to geothermal source Constant smell of
See note 3 C4
< 50 metres hydrogen sulphide
St
Geothermal zone See note 3
Beyond50 metresto Mild geothermal
- C3
geothermal source
an inXuence
NOTE –
da
(1) Theatmospheric
corrosivity
categories
givenprovide
anindication
of the
environment
corrosivity
toassist
inthe
selection
of a suitable
corrosion
protection
system;taking
into
.
account the macroclimate and where required microclimate effects
rd
(2) For conWrmation
of a site-speciWc
atmospheric
corrosivity
category
(forexample,forsites
that
aresheltered
from marine
inXuence
by the
local
topography)then
, site-speciWc
.
testing is required as described in HERA Report R4-133
sN
(3) For areas
inthe
geothermal
zones, both
the
macroclimate
andthe
surface-speciWc
corrosivity
categories
aredependent
onthe
level
of geothermal
activities
anddistance
from
the
geothermal
source.
Thecorrosivity
category
could
rangeup toCX with
considerable
variation;
thus inthose
areas
site-speciWc
corrosivity
assessment
isrecommended.
For areas
that
aremorethan
50 metres beyondthe
geothermal
source
orboundary
(suchasSulphur
Bay, Rotorua)
and, that
havebeenassessed
ew
usingthe
smell
test
as
having
minimal
ornon-existent
geothermal
inXuence,the
other
corrosion
zonesorcategories
applybasedon distance
from the
sea.
Ze
ala
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19
SNZ TS 3404:2018
SNZ TS 3404:2018
Table 3 – Other atmospheric corrosivity environments
Exposure conditions for steelwork Usesurface-speciccorrosion

category given in Table 2
d
Within the external wall and roof cavity with the steel on the cold Damp
side of the dew point
n
Steel
insubXoorspaces
ala
Steelwork near openings in external walls Sheltered
High humidity and corrosive atmosphere, such as chemical SpeciWc engineering design
required,
processing plant, indoor swimming pools, paper manufacturing refertoAS/NZS 231.:04 and
Ze
plants, boatyard over sea water, composting or pickling plants, AS/NZS 231.:04
foundries, or smelters
Car parks SpeciWc engineering
design required,
ew
refer
toHERA ReportR4-13
NOTE –
(1) The atmospheric corrosivity categories given provide an indication of the environment corrosivity to assist in the
sN
selection of a suitable corrosion protection system; taking into account the macroclimate and where required
microclimate effects
.
(2) For conWrmation
of a site-speciWc
atmospheric
corrosivity
category
(forexample,forsites
that
aresheltered
from
marine
inXuence
by the
local
topography)then
, site-speciWc
testing
isrequired
asdescribed
inHERA Report
R4-13.
rd
(3) For areas
inthe
geothermal
zones, both
the
macroclimate
andthe
surface-speciWc
corrosivity
categories
are
dependent on the level of geothermal activities and distance from the geothermal source The corrosivity category
.
could
rangeup toCX with
considerable
variations;
thus
inthose
areas
site-speciWc
corrosivity
assessment
is
da
recommended For areas that are more than 500 metres beyond the geothermal source or boundary (such as
.
Sulphur
Bay, Rotorua)
and, that
havebeenassessed
usingthe
smell
test
ashaving
minimal
ornon-existent
geothermal
inXuence,the
other
corrosion
zonesorcategories
applybasedondistance
from the
sea.
an
2.3 Selecting a complying corrosion protection system

St
Thesurface-speciWc atmospheric corrosivity

categorydetermined
from 2 2 2 shall be
.
.
usedtoselect a complyingprotectivecoating
systemforthe
required
time tothe Wrst
ht
maintenance in accordance with 1 7

.
.
Table 4 to Table 8 provide a selection of complying coating systems for required time to
rig
Wrstmajor maintenance. RefertoAS/NZS 4 1 0 2 : 1 . 2 1 3 2 andAS/NZS 4 1 0 2 : 2 . 2 1 3 2 formore

coating systemoptions tosuit the required time
toWrstmajor maintenance.
py
For paint and powder coatings, the minimum dry film thickness specified in
AS/ NZS 4:201 .23 andAS/ NZS 2.134: 0 shallcomply with the requirements
of clause 8 3 of AS 3894 3 For other coatings, the minimum coating thickness shall
.
.
.
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comply with the

relevant
standard.
For NZTA steel structures, ifpaints arespecified theyshall be approved by an

independent body such as the Australian Paint Approval Scheme (APAS), the North
East Protective Coating Committee (NEPCOAT), or NORSOK (the Norwegian petroleum
industry standards) For all other types of structures, it is recommended that similar
.
approvals should be considered
.
For the selection of a corrosion protection system in a C5-I or CX environment, the
selectionshall be undertaken by a qualiWed coatingsspecialist.

SNZ TS 3404:2018
With regard to fade resistance, when the colour is something other than white, a paint
topcoat with UV-resistant stable resins and pigments like those used in automotive
coatings, needs to be selected for elements that are exposed to sunlight, and the
allowable glossandcolour shift over time needs tobe speciWedandbe covered by
d
a performance guarantee. Theserequirements couldbe speciWedby referencing a
n
performance standard such as AAMA 2604, used for coated aluminium panels on
buildings, or specifying a colour fade rating to ASTM D2244 or a limit on chalking when
ala
measured to ASTM D4214 Consistent appearance over at least a 10-year period would
.
be considered a reasonable requirement
.
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NOTE – Restrictions
on levels
of glossmay be imposedtoreduce
reXectivity,
whichcan be
hazardous to night-time drivers, or to reduce visual impact of the structure Low-gloss coatings
.
helpdisguise
variations
inproWle
butareless
easily
cleaned
by rain
ormaintenance
washing.
Some softer coatings could have issues with dirt accumulation or biogenic contamination Some
ew
.
paints like epoxy are vulnerable to chalking so where gloss stability appearance is important a
UV-resistant and pigment topcoat paint should be used A clear polyurethane should not be used
.
over an epoxy where exposed to sunlight as the epoxy will still chalk from the UV and clear coat
sN
will then delaminate
.
Batch hot dipgalvanized coatings toAS/NZS 4680 arespeciWedinthat standard to
vary in coating thickness, and hence levels of durability, by the steel thickness being
galvanized The formed coating thickness is largely a function of the steel thickness
rd
.
andsteel chemistry andnotcontrolled by the galvanizer. The speciWedminimum
average coating thickness varies from 45 µm to85 {m 0(32 g/m 2 t o6 0 0 g / m 2) Hot
.
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dipgalvanized coatings thicker than 85 {m arenot speciWed inAS/NZS 4680 butthe

general provisions of that
standard applyand, together with speciWcthickness Wgures,
canform a speciWcation capable of third-party veriWcation.Itisa good idea toknow
an
the composition of the steel to be used and the galvanizer should be consulted before
specifying, as these thicker coatings may not be available for all types of steel Where
.
the steelissuitable, thicker coatings may be speciWed.
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SNZ TS 3404:2018
C2.3
General
Additionalcoatingsystemsandguidanceonthecompatibilityofvariouscoa
d
systemsasanovercoatisgiveninAS/NZS231.:04,AS/NZS231.:04,
n
andHERAReportR4-13.
ala
Coating systems that provide protection in a severe, (for example, C5-M
environment)willhavealongerexpectedtimetorstmajormaintenanceinl
corrosiveenvironmentsfromadurabilitypointofview.Thisdoesnotinclud
expectationofglossandcolourretention.
Ze
Forothertypesofcorrosionprotectionsystems(includingprotectivecoat
not included herein, their use may be considered by the project engineer or
qualiedcorrosionspecialistwhoiseitheranAustralasianCorrosionAss
ew
(ACA) technician or technologist, with a relevant qualication, such as ACA’
Coating Selection and Specication Certicate or NACE Coating Inspection
Program (CIP) certication (minimum level 2), or is a certied NACE protective
sN
coatingspecialistorNACEcorrosionspecialist.
A galvanized coating will typically develop a matt grey colour, consistent o

theentiresurface,irrespectiveofwhethertheinitialappearanceisshin
dull, and shiny or fully dull. This dulling will usually occur within 6 – 12 months
rd
ofinstallation.
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Galvanized coatings
Continuous galvanized coatings complying with AS 1397, such as those used
for roll-formed purlins, have a coating thickness that is designated as th
an
massofthecoatingonbothsidesofthesubstratemetal.Forexample,apurlin
made from AS 1397 Z350 grade material has approximately 175 g/m 2
coating
massoneachsideµm(24 coatingthickness)Tube . suppliedtoAS/NZSwill 4792
St
bedesignatedwiththecoatingmassoneachface.Forexample,AS/NZS4792
ZB135/1 will have at least 135 g/m 2
coating mass (24 µm coating thickness)
oneachfaceofthetube(internalandexternal).
ht
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SNZ TS 3404:2018
Table4–Internalsteelwork–Coatingrequiredonlyforappearance,surface-speciccorrosivity
category C1 and temporary protection during construction
System Surface Number of Typical colour Initial gloss Allowable
d
designationa preparation coats surface-specic
corrosivity during
n
constructionb
ala
ALK6 3 Flat to full gloss
Sa 2½ C4
IZS1 1 Flat
Wide range
Ze
Semi-gloss to
PUR1 St 3 2 C4
full gloss
ALK1c 1 Limited range C2d
St 3/Sa 2 Flat to full gloss
ew
ALK3 2 Wide range C3
NOTE – All galvanized coatings are suitable for internal steelwork
.
a BasedonAS/NZS 231.:04
c
Basedona maximum of 1 year’s
exposure
during
construction.
sN
The alkyd primer system ALK1 should not be used in grey colour because the breakdown of the system will be

highly visible Red oxide colour is preferred to reduce the visual impact of minor and structurally acceptable rusting
rd
.
that may occur on the ALK1 system in a few years
.
d Basedona maximum of 4 weeks’
exposure
during
construction.
da
Table5–Coatingsforsurface-speciccorrosivitycategoryC2
an
Years System Surface Number Typical colour Initial gloss

designationa preparation of coats
EPM3 Sa 2 Low to semi-gloss
St
15 ACC2 2 Wide range

Sa 2½ Semi-gloss to full gloss
PUR2
MCU2 Limited range Semi-gloss
ht
3
25 PUR3 Wide range Semi-gloss to full gloss
Sa 2½
IZS2 1 Mostly grey Flat
rig
PUR5 3 Wide range Semi-gloss

40 HDG390 See AS/NZS 4680 1 Flat to semi-gloss
Greyb
TSZ10 Sa 2½ 1 Flat
py
NOTE – All
galvanized
coatings
provide
15 years’
corrosion
protection,
forgalvanized
coatings
>18 µm provide
25 years’
corrosion protection, and galvanized coatings >28 µm provide 40 years’ corrosion protection
.
Co
a BasedonAS/NZS 231:0.
b Wide range when coloured sealer/topcoat is used

.
SNZ TS 3404:2018
Years System Surface Number Typical colour Initial gloss

designationa preparation of coats
d
IZS2 1 Mostly grey Flat
n
PSL1 2
15 PUR4 Wide range Semi-gloss to full gloss
ala
Sa 2½
ACC4 3
MCU2 Limited range Semi-gloss
PUR5 3 Wide range Semi-gloss
25
Ze
HDG390 See AS/NZS 4680 1 Greyb Flat
IZS4 Mostly grey
Sa 2½
TSZ10 c
1 Flat
Greyb
ew
HDG600 See AS/NZS 4680
40
Sweep abrasive blast
HDG600-5D toAS/NZS 4680 or 2 Wide range Semi-gloss to full gloss
sN
etch prime
NOTE – All galvanized coatings > 32 µm provide 15 years’ corrosion protection Galvanized coatings can be topcoated,
.
knownasa duplexcoating,
toprovide
notonlycolour
but
also
enhanced
corrosion
protection.
See AS/NZS 231.:04
for additional guidance
.
rd
b Wide range when coloured sealer/topcoat is used

da
.
c TSZ10 canbe sealed
orremain
unsealed.
an
Years System Surface preparation Number Typical colour Initial gloss

St
designationa of coats
TSZ10 b
1 Greyc Flat
PUR5
Sa 2½ 3 Wide range Semi-gloss to full gloss
ht
15 ACC6
IZS4 1 Mostly grey
rig
HDG500 Flat
See AS/NZS 4680 1 Grey
HDG900
HDG500-5D or 5I Sweep abrasive blast
25
py
toAS/NZS 4680 or 3 Wide range Semi-gloss to full gloss

HDG600-4D or 4I
etch prime
TSZ150S Sa 2½ 2 Greyc Flat
Co
Sweep abrasive blast

40
HDG600-5D or 5I toAS/NZS 4680 or 3 Wide range Semi-gloss to full gloss
etch prime
b TSZ10 canbe sealed

orremain
unsealed.
c Wide range when coloured sealer/topcoat is used

.
SNZ TS 3404:2018
Table8–Coatingsforsurface-speciccorrosivitycategoryC5 -M
Years System Surface preparation Number Typical colour Initial gloss

designationa of coats
d
EHB6 Limited range Flat to semi-gloss
3
n
PUR5 Sa 2½ Wide range Semi-gloss to full gloss
15
TSZ150S b
2
ala
HDG900 See AS/NZS 4680 1 Greyc Flat
TSZ20S b
2
Sa 2½
TEC1d 1 Limited Gloss
Ze
25 Sweep abrasive blast
HDG600-5D or 5I toAS/NZS 4680 or 3 Wide range Semi-gloss to full gloss
etch prime
ew
TSZ30S b, e
Sa 2½
40 2 Greyc Flat
TSA225S e
Sa 3
sN
b Only zinc/aluminium alloy (85% zinc, 15% aluminium) to be used in C5-M environment
.
c Wide range when coloured sealer/topcoat is used
.
d Thermoplastic ethylene copolymers with DFT > 300 µm
rd
.
e Thermal aluminium spray is mostly used for structures within 100 m from the sea due to the high corrosivity category

and abrasiveness of the environment, while thermal zinc spray is used for structures in the < C5 categories
.
da
2.4 Average steel loss over the design life of the structure
an
ISO 9224 outlines the methodology for determining the steel section loss over the design
life of the structure
.
St
NOTE – In ISO 9224 the corrosion rate for steel is considered to be appropriate for up to 20 years,
and beyond that period the corrosion rate is considered to be only indicative
.
ht
2.5 Assessing the remaining steel loss at the end of the design life
For both atmospheric and non-atmospheric environments, when assessing the average
rig
steel loss on a surface that is not maintained after a given point in time (this period is
taken as ,) takinginto account the corrosion protectionsystem,useEquation 1
inconjunction with the surface-speciWc corrosivity category determined from 2 2 2
py
.
.
.
Eq 1
...............................................................................................................
.
Co
where
Steel thickness loss in µm/steel surface
Steelwork design life in years
Total time toWrst

major
maintenance
of initial
andsubsequent
coating
systems
applications

SNZ TS 3404:2018
Steel corrosion rate, in µm/annum, for steel in:

atmospheric environments – determine the surface-specific atmospheric
corrosivity category using Table 2 and then determine from Table 9, based
d
on or as appropriate; or
n
non- atmospheric environments – determine
theexposure classiWcation from
Table 0 1 to Table 12 and then determine which in this case is the uniform
ala
corrosion allowance from Table 13
.
NOTE – Equation 1 does not account for localised pitting corrosion so is only applicable to a
Ze
minimumsteel
thickness
of 01 mm forsteel
inmaritime
environments
orembedded
insoil,
and
a minimum steel
thickness
of 8 mm forsteelwork
located
elsewhere.
Table 9 outlines the average carbon steel corrosion rate in different atmospheric
ew
environments These are given as average corrosion rate for up to 10 years that
.
correspond to the initial period of exposure ( ), and as the average corrosion rate during
the Wrst
30 yearsthat aretaken asbeingsteady-state corrosion rates ( )
.
Table 9 – Average corrosion rate (µm/annum) of carbon steel in different environments
Surface-specic Average corrosion rate, ,

sN
Steady-state corrosion rate, , estimated as the
rd
corrosivity category duringtherst10years averagecorrosionrateduringtherst30 years
C1 p 0.4 p 0.3
da
C2 04< p 8.3 03< p 4.9

.
.
C3 83< p 17 49< p 10
.
.
C4 17 < p 27 10 < p 16
an
C5 27 < p 67 16 < p 39
CX 67 < p 23 39 < p 138
St
C2.5
Example:
ht
Steel sections supporting a roof canopy will be recoated after 15 years with a
rig
15-yeartimetorstmajormaintenancecoatingsystem.Nofurtherrecoatswillbe
applied.Thedesignlifeofthestructureisyears.
50 Thesurface-speciccorrosivit
categoryisassessedasC3from
TableThe
2. extentofsteelthicknessloss,using
asµm/
10 annumfrom Tableat
9, theendofthedesignlifeiscalculatedusing
py
Eq.1asfollows:
=10(5–(15+)=20µm/steelsurface.
Co
Thesteelcorrosionrate of
wasused,
astheexposureperiodwasgreaterthan
years.
10 Ifthatperiodwasequalorlessthanyears,
10 then the would
value
havebeenused.

SNZ TS 3404:2018
3 CORROSION OF STEEL IN NON-ATMOSPHERIC ENVIRONMENTS
3.1 Exposure classification
d
Theexposure classiWcation of thesurface of steel
inanon-atmospheric environment shall
n
be determined from Table 10 to Table 12 For the range of chemical conditions at steel
.
surfaces in soil, the condition leading to the most severe condition shall be allowed for
ala
.
Consideration shall be given to possible changes in groundwater levels For embedded
.
steel immersed in sea or fresh water, use Table 12
.
Ze
Table0–1 Exposureclassicationforsteelinwater
Water type Exposure condition Exposureclassication

Sea water Submerged Severe
ew
Tidal/splash zone Very severe
Accelerated low water corrosion Extreme
Fresh water Soft running water Moderate
NOTE –
(1)
Microbial
inXuenced
corrosion
sN Very severe
Accelerated low water corrosion is a form of rapid pitting corrosion that typically occurs on marine piling in the
rd
aerated
zoneat
orjust
belowthe
lowtide
level
andisassociated
withmicrobial
induced
corrosion
(MIC). Thisisdue
to the conversion of sulphates in the steel to hydrogen sulphide and sulphuric acid by bacteria
.
da
(2) MIC can occur on steel components in fresh water It has been observed on sheet piles with sulphur inclusions in the
.
steel; therefore, it is recommended that good quality steel with no sulphur inclusions be used
.
an
Table1–Exposureclassicationforsteelinrefusell
Exposure condition Exposureclassication

St
Domestic waste Severe

Industrial waste Very severe
NOTE – Contamination by the tipping of mineral and domestic waste or by spillage from mining, processing, or
ht
manufacturing industries presents special durability risks due to the presence of certain aggressive acids (both organic
andinorganic)
salts,
, andsolvents,
whichcanchemically
attack
steel.
In the
absence
of site-speciWc
chemical
information,
rig
the
exposure
classiWcation
should
be assessed
asgiven.Chemical
andmicrobiological
analysis
of the
latter
could,
however,
lead
toa lower
risk
classiWcation.
py
Co

SNZ TS 3404:2018
Table2–1 Exposureclassicationforsteelinsoil
Exposure conditions Exposureclassication

Soil pH Chlorides Resistivity Soil Soil
d
In soil In groundwater (ohm-cm) Condition Aa Condition Bb
n
(ppm) (ppm)
>5 < 5000 < 1000 > 5000 Non-corrosive Non-corrosive
ala
4–5 50 – 20 0 10 – 10 0 2000 – 5000 Non-corrosive Mild
3–4 20 0 – 50 0 10 0 – 20 0 1000 – 2000 Mild Moderate
<3 > 50 0 > 20 0 < 1000 Moderate Severe
Ze
NOTE –
(1) Where high levels of sulphates exist (> 1000 ppm), sulphate-reducing bacteria may be present and active, sometimes
leading to MIC In such cases, classify as ‘mild’ for low permeability soils and ‘moderate’ for high permeability soils
.
.
ew
(2) For steel
indisturbed
soil,
consider
theassumption
of soil
condition
B whereaccelerated
corrosion
ispossible.
(3) Thenatural
pH of mostNew Zealand
soils
ranges
from 4 to6, with
mosthaving
pH > 5 (Edmeades et
al190).
Any soil
modiWcation
foragriculture
purposes
raises
thepH tobetween
6 and7. Studies
of New Zealand
subsoils
sN
down to 0 9 m depth have been undertaken by Penhale (Penhale 1971; Penhale 1984), focusing on determining
.
corrosion
the performance
of mildsteel
elements
ina rangeof New Zealand
subsoils.
Thetypesof soil
that
have
pH below4 include:
(a) Geothermally affected soils (where it can be < 3);
rd
(b) Peat layers which occur in some swampy, low-lying areas;
(c) Highlyweathered
clayssubject
toalternate
wetting
anddrying.
(4) Chloride ion concentration is related to distance from the sea but is very variable Once this distance reaches or
da
.
exceeds 20 km the chloride content is typically low
.
(5) Resistivity is a measure of the moisture and chemical content of a soil and its porosity; within each pH band the
resistivity is related to the porosity Silts and clays have lower porosity than sands and gravels and therefore have
an
.
higher resistance to corrosion currents
.
(6) Site-speciWc
soil
testing
forpH, chlorides
andresistivity
canbe doneby a numberof New Zealand
laboratories,
and
St
should be determined as part of the geotechnical investigation when required This should be determined down the
.
length of the soil column into which the steel is to be located at intervals as advised by the testing organisation or
geotechnical engineer
.
ht
(7) Determine
thesoil
pH from site-speciWc
study
orconsult
a geotechnical
engineer.
Thisgives
the
appropriate
line
in
the
table
toread
from fordetermining
theexposure
classiWcation.
(8) If the
chloride
concentration
isavailable,
usethat
todeWnethe
uniform
corrosion
allowance
within
thegiven
rig
pH band.
(9) If the
resistivity
isavailable,
usethat
todeWnethe
uniform
corrosion
allowance
within
thegiven
pH band.
(10) Usingthis
information,
determine
theexposure
classiWcation
andthe
value
of uniform
corrosion
allowance
from
py
Table 13 ; this can include interpolation from Table 13 for determining the uniform corrosion allowance
.
a Soil condition A: Low permeability soils (such as silts and clays) that are in groundwater
Co
.
b Soil
condition
B: High permeability
soils
(suchassands
andgravels)
that
areingroundwater
orall
soils
above

groundwater
.
3.2 Corrosion rate of steel in non-atmospheric environments
Where no corrosion protection system or cathodic protection is applied, allowance shall
be made for loss of section during the design life of the steel structure or component
.
Where a corrosion protective system (such as a protective coating) is provided,
consideration shall be given to the likely life of the coating and allowance made for loss
of steel section thereafter, as per 2 5
.
.
SNZ TS 3404:2018
Where no corrosion protection systems are to be applied to steel in non-atmospheric

environments, allowance shall be made for uniform corrosion and loss of section In the
.
absence of other information, the corrosion rates given in Table 13 shall be used If the
.
site-speciWc corrosion rates are known,those site-speciWc ratesmay beused.Corrosion
d
on the internal faces of a fully sealed closed-form pile may be assumed to be negligible
n
.
Where steel components are electrically connected to a dissimilar metal, the resultant
ala
beneWcialoradverse galvanic effect shall be takeninto consideration.
Table 13 – Corrosion allowance for steel in non-atmospheric environments
Ze
Exposureclassication Uniform corrosion allowance (µm/annum)
Non-corrosive < 10
Mild 10 – 20
ew
Moderate 20 – 40
Severe 40 – 100
Very severe 100 – 200
Extreme
NOTE –
(1)
> 200
sN
The allowances may be reduced, as appropriate, where adequate corrosion protection systems (such as coatings
rd
or cathodic protection) are to be used Coatings will reduce corrosion allowance while they remain in good
.
condition Coating damage, deterioration, and breakdown will result in the corrosion rate increasing and, in such
.
circumstances, the corrosion allowances in this table shall apply
da
.
(2) To allow
forfuture
retroWtting
of cathodic
protection
it
isgood practice
toprovide
electrical
continuity
throughout
the piled system at the time of construction In providing electrical continuity, consideration shall be given to the
.
an
of stray
likelihood current
corrosion,
especially
ifthe
completed
structure
isof signiWcant
length
andadjacent
toa
cathodically
protected
systemorwithin
close
proximity
todirect
current
electriWed
traction
orpowersupplysystems.
(3) For verysevere
andextreme
conditions
a site-speciWc
assessment
should
be sought.
St
(4) Thenatural
pH of mostNew Zealand
soils
ranges
from 4 to6, with
mosthaving
pH > 5 (Edmeades et
al190).
Any soil
modiWcation
foragriculture
purposes
raises
thepH tobetween
6 and7. Studies
of New Zealand
subsoils
down to 0 9 m depth have been undertaken by Penhale (Penhale 1971; Penhale 1984), focusing on determining
.
ht
the
corrosion
performance
of mildsteel
elements
ina rangeof New Zealand
subsoils.
Thetypesof soil
that
have
pH below4 include:
(a) Geothermally affected soils (where it can be < 3);
rig
(b) Peat layers which occur in some swampy, low-lying areas;

(c) Highlyweathered
clayssubject
toalternate
wetting
anddrying.
(5) Chloride ion concentration is related to distance from the sea but is very variable Once this distance reaches or
py
.
exceeds 20 km the chloride content is typically low
.
(6) Resistivity is a measure of the moisture and chemical content of a soil and its porosity; within each pH band the
resistivity is related to the porosity Silts and clays have lower porosity than sands and gravels and therefore have
Co
.
higher resistance to corrosion currents
.
(7) Site-speciWc
soil
testing
forpH, chlorides,
andresistivity
canbe doneby a numberof New Zealand
laboratories,
and
should be determined as part of the geotechnical investigation when required This should be determined down the
.
length of the soil column into which the steel is to be located at intervals as advised by the testing organisation or
geotechnical engineer
.
SNZ TS 3404:2018
C3.2
Corrosion rates of 30 µm/annum to 80 µm/annum due to accelerated low
watercorrosioninseawaterandMICinfreshwaterhavebeenrecorded.Insuch
d
circumstances,additionalcorrosionprotectionisrequired.
n
Localisedcorrosioncanalsobefoundinthesteelcomponentsembeddedzone
ala
close to the soil-water or soil-air interface where microbial activity is h
wherescouringcanmaintainhighcorrosionactivity.Suchlocalisedcorrosi
notcoveredbythecorrosionallowancesgiveninthisclause,whichareavera
ratesforsituationswheregeneralcorrosionoccurs.
Ze
A cathodic protection system for steel that is either buried or immersed
fullyeffectiveuptoapproximatelymid-tidelevelinseaortidalwaters,andu
groundlevelinsoils.
ew
3.3 Selecting a complying corrosion protection system
sN
Protective coating systems may be used to increase the design life of the buried
or immersed surfaces of steel components (such as piles) For steel surfaces that
.
are exposed to the atmosphere, these should be treated as steel in atmospheric
rd
environments
.
Table 14 describes a selection of suggested options
da
.
Table 15 states the corrosion rate of zinc (such as galvanizing) in soil
.
an
C3.3
St
AS/ NZS 2 0 4 1 . 1 , AS/ NZS 2 3 1 2 . 1 : 2 0 1 4 , and AS 2 1 5 9 have additional

recommendationsforprotectivecoatingsforpiles.Anumberofmethodscanbe
usedtoincreasethesteelpilesdesignlife.Thesemethodsare:
ht
(a) Useofaheaviersection;
(b) Useofahighergradesteelatmildsteelstresslevels;
rig
(c) Useabarriertapesystem;
(d) Applyaprotectivecoating;
py
(e) Applycathodicprotection;and
(f) Useconcreteencasementwherepracticable.
Co
In practice, a combination of protective coatings (or barrier tape) and catho

protectionislikelytoprovidethemostcosteffectivelong-termsolution.C
protectionsystemsshouldbedesignedandinstalledinaccordancewithAS.4238

SNZ TS 3404:2018
Table 14 – Suggested protective coating systems for steel piles in non-atmospheric environments
System Coating Surface No. Total Typicalareasof use Typical time

designationa preparation coats nominal to loss of
d
drylm corrosion
thickness protection
n
(µm) system (years)
ala
Very high
Piers,jetties, bearing
EVHB2 build 1 400 20+
piles in corrosive soils
epoxy
Ze
piles in corrosive
Glass Xake soils For soils and
EVH3 2 500 20+
.
epoxy immersion conditions
ew
Sa 2½ that also require
abrasion resistance
sN
piles in very corrosive
Glass Xake
soils where abrasion
PES1 polyester/ 1 1000 20+
resistance and
vinyl ester
chemical resistance
rd
area required
Retaining walls
Hot dip See
da
HDG600 1 85 in non-marine 10 – 20
galvanizing AS/NZS 4680
environments
a BasedonAS/NZS 231.:04 andAS/NZS 231.:04
an
St
ht
rig
py
Co

SNZ TS 3404:2018
Table 15 – Average zinc corrosion rate (per side in contact) versus soil water, pH, or resistivity
Soil pH Range of average zinc corrosion rate (µm/annum)
d
Drained soils Undrained soils
<4 >65 > 20
n
.
4–49 26–52 6 7 – 13 3
ala
.
.
.
.
.
5–79 22–43 5 5 – 11
.
.
.
.
8–9 33–65 6 1 – 12 1
.
.
.
.
>9 >86 > 17 2
.
.
Ze
Soil resistivity (ohm-cm) All soils
< 500 >35 .
500 – 1000 15–35
.
.
1000 – 2000 13–15
ew
.
.
2000 – 5000 09–15
.
.
> 5000 <09
.
NOTE –
(1)
sN
The loss rates shall be calculated from the worst-case loss for either pH or resistivity The loss rates for pH and soil
.
resistivity shall not be added together
.
(2) In fully submerged conditions where oxygen levels are low, reduced metal loss rates can be expected
rd
.
(3) In marine splash zones, metal loss rates will exceed those given for severe coastal conditions
.
da
an
St
ht
rig
py
Co

SNZ TS 3404:2018
4 MISCELLANEOUS
4.1 Inspection of coatings
d
Inspection of protective coating systems shall be carried out in accordance with the
n
recommendations inAS/NZS 4 102: .2 1 3 andAS/NZS 4 102.: 32 orAS/NZS . 1 3 5
ala
C4.1
CoatinginspectionrecommendationsarecoveredindetailinAS/NZS,4102:.132
Ze
AS/ NZS 2 3 1 2 . : 2 0 1 4 , and AS/ NZS 5 1 3 . These include conrmation of
requirementsandachievementof:specications,standardsofworkmanshipfor
eachstepinthesystem,surfacepreparation,methodofapplication,suitabili
equipment,dryingandcuringtimeintervalsbetweencoatsandhandling,coati
ew
thickness,methodofhandling,andreporting.
Itisrecommendedthatinspectionofprotectivecoatingsystemsinlocations
surface-speciccorrosivityofC3toCXbeperformedbyaCerticationBoardfor
hotdipgalvanizedcertiedinspector. sN
InspectionPersonnelorNACEinternationalcertiedcoatingsinspector,orA
Inallsurface-speciccorrosivitycategories,theperformanceofcoatingsystems
rd
requiringsteelsurfacepreparationtoISOor8501- ASof
1627.4 Saor
2½ higher
isverydependentonthatqualityofpreparationbeingachieved.Aswellasremov
da
ofdeleteriouscontaminates,thisincludesattainingaspecicsurfacerough
whererequiredforaparticularcoating(forexample,thermalmetalspraysrequi
asharpangularproletoaspeciedroughnessdependingonthetypeofmetal
an
spraybeingdeposited).
St
4.2 Inaccessible surfaces

Surfaces in contact or near contact after fabrication or erection shall receive their
ht
speciWedsurface preparation
andtreatment prior toassemblyinaccordance with
AS/NZS . 1 3 5 In the
caseof paintcoatings these shallbe cured beforeassembly.
rig
This requirement does not apply to the interior of sealed hollow or sealed box sections,
orconnection faying)
( surfacesforjoints with friction typebolting category where bare
steel interfacesarespeciWed.
py
4.3 Protection during transport and handling after corrosion protection

Co
Structural members shall be adequately protected during handling and transport to

minimise damage tothe corrosion protectioninaccordance withAS/NZS . 1 3 5
Units that are transported in nested bundles should be separable without damage to
the units or their coatings Consideration shall be given to the use of lifting beams with
.
appropriately spaced lifting points and slings, or to lifting with properly spaced and
protected forklift tines
.
SNZ TS 3404:2018
4.4 Repairs to corrosion protection

A corrosion protection system that has been damaged by welding, erection, bolting, or
other causes shall be fully reinstated before the structure is put into service in accordance
d
with AS/NZS . 1 3 5
n
The damaged area shall be dry and clean, free from dirt, grease, and loose or heavy
ala
scale or rust before the corrosion protection is applied The corrosion protection shall
.
be applied as soon as practicable and before noticeable oxidation of cleaned surfaces
occurs Damaged zinc coatings shall be restored by applying an equivalent thickness of
.
a suitable zincpaint conforming toAS/NZS 9.05 73 orAS/NZS ,5 1 .05 73 orwiththermal
Ze
zinc spray
.
Damaged galvanized
coatings
shall
be repaired
inaccordance
with
AS/NZS 4 6 8 .0
ew
4.5 Coatings reference areas and test coupons
sN
To assist with determining the responsibility for coating failure between coating
speciWcation, coatingmaterial andworkmanship; referenceareas ortest couponsmay
be used These shall be located on the structure itself, and are prepared, installed, and
.
the location recorded during the application of the protective coating systems, or in the
rd
case of hot dip galvanizing, at the time of installation
.
For the
useof reference
areas,
refer
toAS/NZS .4 102: .2 1 3
da
For the
useof test
coupons,refer
tothe
NZTA Protectivecoatingsforsteelbridges
.
an
St
ht
rig
py
Co

NOTES
n d
ala
Ze
ew
sN
rd
da
an
St
ht
rig
py
Co
NOTES
n d
ala
Ze
ew
sN
rd
da
an
St
ht
rig
py
Co
SNZ TS 3404:2018
n d
ala
Ze
ew
sN
rd
da
an
St
ht
rig
py
© 2018 CROWN COPYRIGHT ADMINISTERED BY THE NEW ZEALAND

Co
STANDARDS EXECUTIVE
Approved by the New Zealand Standards Executive on 19 December 2017 to
be a New Zealand technical specification.
First published: 22 February 2018
The following references relate to this technical specification:

Project No. P3404
Draft for comment No. DZ TS 3404
Typeset by: Standards New Zealand
n d
ala
Ze
ew
sN
rd
da
an
St
ht
rig
py
Co

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SNZ TS 3404:2018

Standards New Zealand Technical Specification

Durability requirements for

Cover photograph of Haast Bridge courtesy of Raed El Sarraf, WSP Opus.

Copyright Act 1994.

content remains with Standards Australia Limited.

Published by Standards New Zealand, PO Box 1473, Wellington 6140.

No. Date of issue Description Entered by, and date

ISBN (Print) 978-1-77673-253-1

2 CORROSION PROTECTION OF STEEL IN ATMOSPHERIC ENVIRONMENTS �����8

4 Wellington corrosivity zone map 13

iv COPYRIGHT © Standards New Zealand

AS/NZS 02: 1 3 Glossary of paint

AS/NZS -:2 1 3 Guide tothe protectionof structuralsteel against

AS/NZS 4 6 80 2 : Hot-dip galvanized

AS/NZS 02: 9 7 6 4 Hot-dip galvanized zinc)

AS/NZS -0 : 1 5 Bridge design

AS/NZS 6 1 02: 3 1 5 Structural

and related products – Visual assessment of surface

substrates and of steel substrates after overall removal of

ISO 9223:2012 Corrosion of metals and alloys – Corrosivity of

ISO 9224: 2012 Corrosion of metals and alloys – Corrosivity of

COPYRIGHT © Standards New Zealand v

AS 2159:2009 Piling – Design and installation

AS 3894:---- Site testing of protective coatings

American Architectural Manufacturers Association AAMA 2604-05 – Voluntary

organiccoatingsonaluminiumextensionand panels Illinois, USA:

Edmeades, D C andWheeler,D M. ‘Measurement of pH inNew Zealand Soils,an

vi COPYRIGHT © Standards New Zealand

New Zealand legislation

COPYRIGHT © Standards New Zealand vii

This technical specification provides an advanced framework for specifying the

Thistechnical speciWcation hasbeenprepared foruseby asset owners,designers

Bridge manual , andthe NZTA Protective coatings for steel ; as bridges

of NZS 4 0 4 3 areinthe processof beingsuperseded by AS/NZS 1 3 1 5 andAS/NZS, 6 . 0 1 5

SNZ TS 340 supersedes

viii COPYRIGHT © Standards New Zealand

Durability requirements for

Clauses preWxedby ‘C’andprinted initalictypeareincluded ascommentson the

For the purposes of this

Asset owner The owner of the structure being constructed or maintained,

Contractor A person orWrm that undertakes a contracttoperformthe

of a steel structure or component

Corrosivity A measure of the ability of an environment to cause

Damp Internal environment where condensation may occur, such

COPYRIGHT © Standards New Zealand 1

Designer An engineer or architect with relevant experience and

Design life Period over which a structure or structural element is

Environment Surrounding region which contains one or more corrosive

Inspector A person who, onthe basis

the requirementsof this

Internal Protected from the weather by being located inside the

Nominaldrylm Thickness speciWed foreachcoat orforthe whole

Protective coatings The organisation that manufactured and supplied protective

Sheltered Open to airborne salts but unwashed by the rain, such as

Specier A person,who onthe basis of experience andqualiWcations,

is competent to specify a corrosion protection system for

Wet Often wet for extended periods of time, such as crevices,

2 COPYRIGHT © Standards New Zealand

2 CORROSION PROTECTION OF STEEL IN ATMOSPHERIC ENVIRONMENTS ��8