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Duplex coatings are used to protect galvanizing in harsh environments, provide aesthetics, and enhance corrosion protection. Surface preparation is critical to achieving long term performance, and abrasive blasting was found to be the most effective surface preparation technique.
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Galvanized mast arms support uncounted numbers of traffic signals and signage throughout the United States. The proportion of these that have a “duplex” coating system (both galvanizing and organic coatings) is unknown. However, the number is surely significant, and the number of coating system failures is also significant.
The 2014 US bridge inventory lists over 610,000 highway bridges. Industry experts believe that the cost of maintaining those bridges for repairs due to corrosion is at least $30 billion annually. Bridge owners do not have the resources to maintain bridges in good condition. New bridges are being constructed, at the rate of approximately 3,000 nationally each year. Those new bridges must not pose additional maintenance burdens on the already inadequate bridge maintenance budgets.
Steel structures are often galvanized to ensure durability in harsh environments. However, on occasion, incidents of cracking have occurred in galvanized structures that appear to be induced during the galvanizing process. Such cracking incidences produce a significant cost to the industry, in that repair procedures are often necessary to eliminate any flaws present directly after galvanizing.
The first written record of galvanizing describes how a French chemist named Melouin presented a method of coating iron by immersing it in molten zinc to the French Royal Academy in 1742. Sorel, another French chemist patented a process for coating iron with zinc after preparing it with 9% sulfuric acid followed by fluxing with ammonium chloride. Great Britain granted a patent for a similar process in 1837. By 1850, galvanizing had become a generally accepted practice for the protection of iron and steel with 10,000 tons of zinc per year used for the protection steel.
Life safety is the mantra of National Fire Protection Association (NFPA) 101 which is embraced by all in the fire protection industry. The approach to life safety has disseminated now into steel protection. Hot dipped galvanized members are being used more frequently in commercial buildings which require hourly ratings for fire protection.
Hot-dip galvanizing is one of the most economical, maintenance-free corrosion protection systems available. Like any other manufacturing process, hot-dip galvanized steel requires an inspection of the finished product to ensure compliance with applicable specifications. In this presentation, we will discuss the inspection process completed at galvanizing facilities prior to final shipment.
This paper provides an introduction to the hot-dip galvanization process as an effective and important coating option and the necessary surface preparation steps for successful painting over hot-drip galvanized steel, also known as a duplex system. Proper practices and procedures must be used to prepare new and weathered zinc-coated surfaces on after-fabrication steel products for painting to improve the bond of paint to the zinc surface and provide long-term protection against corrosion.
The nuts of galvanized fasteners used on bridges are coated with a wax-based lubricant that contains a dye. Once installed, the fasteners are cleaned to remove the wax prior to painting. Cleaning is typically accomplished using a combination of solvents and hand tools, but questions are often raised as to how much residual dye on the surface is acceptable for painting.
This paper will cover understanding the hot-dip galvanizing process and coating benefits, Identify the benefits of utilizing paint/powder coating with hot-dip galvanizing in a duplex system, Recognize the importance of communication and clear assignments of responsibility in the specification of successful duplex systems and differentiate between HDG surface conditions in order to properly prepare the zinc coating for paint/powder.
The “Weakest Link” on any structure is found at the nut and bolt assemblies. Nuts and bolts are found on every structure. “The fate of any complex steel assembly may be determined by the vulnerability of its smallest and least considered components”. “The bolts or fasteners holding the assembly together are often the areas where corrosion starts first and where the effects of corrosion may have the most serious consequences”.
Duplex Coating systems refers to the application of a protective coating system (liquid or powder) over hot-dipped galvanized steel. These systems are often specified and are considered very robust in a wide variety of corrosive environments.