Chemical Engineering Course (undergraduate)

Bahan Konstruksi dan Korosi

(Construction Material and Corrosion)

Presented by:
Achmad Chafidz M. S., S.T., M.Sc.
Department of Chemical Engineering, Universitas Negeri Semarang

Universitas Negeri Semarang (UNNES)

Semester Ganjil 2016/2017
GALVANIC ZINC APPLICATION
Corrosion Protection
Steel is a proven durable and efficient building material that has been used
since the Industrial Revolution.

It is cost effective, aesthetically pleasing, sustainable, and strong.

However, like all metals, steel corrodes when exposed to the

atmosphere. Therefore, it is important to consider corrosion protection
methods when constructing projects with exposed steel. There are a number
of different corrosion protection systems to consider including:

•Hot-Dip Galvanizing
•Duplex Systems
•Zinc Coatings
•Protective Coatings
•Special Steels
•Sacrificial Anodes
Hot-Dip Galvanizing
Hot-dip galvanizing (HDG) is the process of immersing fabricated steel or iron into a
kettle (bath) of molten zinc. While in the kettle, iron in the steel metallurgically
reacts with the zinc to form a tightly-bonded alloy coating that provides superior
corrosion protection to steel.. For more than 150 years, hot-dip galvanizing after
fabrication has been specified to combat steel corrosion in the harshest
environments throughout various markets. However, new technologies and
creative chemistries evolve the specification and use of hot-dip galvanized steel
constantly as new markets emerge. Once considered only as a means of corrosion
protection, hot-dip galvanizing is now specified for an array of reasons including
lower initial cost, durability, longevity, availability, versatility, sustainability, and
even aesthetics.

Hot-dip galvanizing resists corrosion by providing barrier and cathodic protection,

as well as through the development of the zinc patina. These three levels of
corrosion protection provide galvanized steel with maintenance-free longevity for
decades.

The term “galvanizing” is often incorrectly used to describe various zinc

coatings for steel.
Hot-dip galvanizing (HDG) is often used to protect steel from corrosion in some
of the harshest environments imaginable, yet it provides maintenance-free
longevity for decades. The corrosion resistance of hot-dip galvanizing varies
according to its surroundings, but generally corrodes at a rate of 1/30 of bare
steel in the same environment. Measurements of the actual consumption rate
of the coating during the first few years of service provide good data for
projecting a conservative estimate for the remaining life to first maintenance,
because as zinc corrosion products build on the surface, which in most
environments are adherent and fairly insoluble, the corrosion rate often slows
as time progresses.

The corrosion resistance of zinc coatings is determined primarily by the

thickness of the coating but varies with the severity of environmental
conditions. Each environment affects hot-dip galvanizing differently based on
a unique set of corrosion variables. The predictability of the lifetime of a
coating is important for planning and budgeting for required maintenance.

Whether exposed in the atmosphere, subjected to blazing UV rays, snow,

and/or other elements, submerged in water, embedded in soil or concrete, or
various other environments, hot-dip galvanized steel can withstand the
different corrosive elements and fulfill the intended design life.
Duplex Systems

Though many specifiers are familiar with one type of corrosion protection or
another, few realize the intrinsic value of utilizing two corrosion protection
systems together, known as a duplex system. A duplex system is formed by
painting or powder coating over hot-dip galvanized steel. When used together,
the corrosion protection of the two systems combined is far superior to either
protection system used independently.

Painting or powder coating hot-dip galvanized steel requires careful

preparation and a good understanding of both systems. Many products have
utilized a duplex system successfully for decades; automobiles and radio
towers are two examples. When the galvanized surface is prepared
correctly, paint and powder coating adhesion is excellent, and the duplex
system will provide corrosion protection well into the future.
Duplex systems are most commonly specified for aesthetic reasons. Hot-dip
galvanizing alone provides an attractive, metallic-gray finish many specifiers
have come to appreciate. However, when the industrial finish of galvanizing
does not suit a particular project, painting or powder coating can offer an
aesthetic alternative. Whether the architect prefers a vibrant color, or the owner
prefers the project blend with its surrounding environment, painting or powder
coating over galvanized steel provides superior corrosion protection along with
the color preference.
Zinc Coatings
Zinc, a natural, healthy, and abundant element was first used in construction in
79 AD. Zinc metal has a number of characteristics that make it a well-suited
corrosion protective coating for iron and steel products.

Zinc’s excellent corrosion resistance in most environments accounts for its

successful use as a protective coating on a variety of products and in many
exposure conditions.

This proven corrosion resistance is a result of zinc’s

ability to form dense, adherent corrosion byproducts,
which leads to a rate of corrosion considerably lower
than ferrous materials – 10 to 100 times slower,
depending on the environment.

While a fresh zinc surface is quite reactive when

exposed to the atmosphere, zinc corrosion products
develop rapidly on the surface as the coating is exposed
to natural wet and dry cycles in the atmosphere. These
corrosion products, collectively known as the zinc patina,
act as an additional barrier between the steel and the
environment.
Zinc Coatings
A number of different methods of applying zinc coatings to steel are
commercially available, each of which has unique characteristics.

Often all of these coatings are incorrectly labeled “galvanizing,” but it is

important to understand the differences.

The products produced by each of these processes have different uses

depending on their applicability, relative economics and expected service life.
This section will explore each of these coatings in more detail.

• Batch Hot-Dip Galvanizing

• Metallizing
• Zinc-Rich Paint
• Continuous Sheet Galvanizing
• Electroplating
• Mechanical Plating
• Zinc Plating
Selection of Zinc Coatings

Once the decision is made to use a zinc coating for corrosion protection, a
few additional factors must be considered to ensure the proper coating is
selected for the application and service environment.

Each zinc coating covered in this section provides varying degrees of

corrosion protection and it is important to identify the corrosiveness of the
exposure environment to determine if the coating selected will provide
adequate service life.

Some zinc coatings will be eliminated by the nature alone, (zinc coating
processes limited to small parts or sheet steels cannot be considered for the
protective coating of structural steel members); others may be ruled out
based on cost, appearance, availability, etc.
Selection of Zinc Coatings
Coating Thickness vs. Coating Weight

The service life of zinc coatings is a linear function of the zinc coating
thickness. However, zinc coating thickness alone can be deceiving when
evaluating zinc applied by different processes. In addition to thickness, the
amount of available zinc per unit volume, or density, is also important.

Various ASTM and/or other specifications require different weights or

thicknesses, so it is imperative to convert all coatings to a common
denominator for comparison. While coating densities for some types of zinc
coatings are nearly identical, others differ considerably. The coating densities,
in terms of thickness required to equal 1 oz of zinc per square foot of surface,
are:

Coating Thickness to reach 1 oz/ft2

Hot-dip galvanizing (batch or continuous),
1.7 mils (43 µm)
electroplating, zinc plating
Metallizing (zinc spraying) 1.9 mils (48 µm)
Mechanical plating 2.2 mils (55 µm)
Zinc-rich paint 3-6 mils (75-100 µm)
Each of these thicknesses, representing the same weight per unit area of zinc,
would be expected to provide equivalent service life; i.e. 1.7 mils of hot-dip
galvanized would give about the same service life as 2.2 mils of mechanical
plating or 3-6 mils (depending on the paint formulation) of zinc-rich paint,
assuming bond strength and edge protection are not factors.

It is also important to remember for all continuous galvanized sheet materials,

including electrogalvanized, the coating weight is given for the total for both
sides of the sheet. To obtain the amount of zinc per unit area of surface, the
weight given must be divided in two, assuming equal distribution on both
sides. For example, an ASTM A653 Class G90 sheet contains 0.90 oz/ft2 of
zinc or about 0.45 oz/ft2 per side.
1. Batch Hot-Dip Galvanizing

Batch hot-dip galvanizing, also known as general galvanizing, produces a zinc

coating by completely immersing the steel product in a bath (kettle) of molten
zinc. Prior to immersion in the zinc bath, the steel is chemically cleaned to
remove all oils, greases, soil, mill scale, and oxides. Surface preparation is
critical as zinc will not react with unclean steel.

After surface preparation, the steel is immersed in the molten (830 F) zinc
bath. The bath consists of more than 98% pure zinc and the remaining 2% or
less consists of additives – most commonly aluminum, nickel, and
bismuth. These additives help with zinc fluidity and consumption, coating
appearance, and other efficiencies. While in the galvanizing kettle, the molten
zinc metallurgically reacts with the iron in the steel to form the coating.
Hot-dip galvanized coatings are used on many materials in myriad construction
sectors from electric utility to artistic sculptures. Ranging in size from small
parts such as nuts, bolts and nails to large structural shapes, galvanizing is
integral to North American infrastructure. Most commonly batch hot-dip
galvanizing is used in atmospherically exposed steel; however, it is also used
in fresh and salt water applications, buried in soil, embedded in concrete, and
much more.

Size can be a limitation to the application of hot-dip galvanizing; however, the

average length of zinc baths in North America is 40 feet and 55-60 foot kettles
are common. Utilizing progressive dipping – immersing one portion of the
product and then the other – significantly increases the maximum size that can
be accommodated to nearly double the bath size.
Coating Characteristics

The batch hot-dip galvanized coating consists of a series of zinc-iron alloy

layers with a surface layer of pure zinc. The unique intermetallic layers are
tightly bonded (3,600 psi) to and harder than the base steel, offering
excellent abrasion resistance. The zinc-iron alloy layers, metallurgically
bonded to the steel, become an integral part of the steel rather than just a
surface coating. Because zinc is anodic to steel, even if the durable
intermetallic layers of the hot-dip galvanized coating are damaged (up to 1/4
inch in diameter) adjacent zinc will sacrificially protect the exposed steel until
all of the surrounding zinc is consumed.

Another unique characteristic of the batch hot-dip galvanized coating is

its uniform, complete coverage. During the diffusion reaction in the kettle, the
zinc-iron alloy layers grow perpendicular to all surfaces, ensuring edges,
corners, and threads have coating equal to or greater than flat surfaces.
Additionally because hot-dip galvanizing is a total immersion process, all
interior surfaces of hollow structures and difficult to access recess of complex
pieces are coated. This complete, uniform coverage ensures critical points
where corrosion commonly starts have the same protection as accessible,
flat exterior surfaces.
2. Metallizing

Zinc spraying, or metallizing, is accomplished by feeding zinc wire or powder into

a heated gun, where it is melted and sprayed onto the part using combustion
gases and/or auxiliary compressed air to provide the necessary velocity. Prior to
metallizing, the steel must be abrasively cleaned.

The 100% zinc coating can be applied in the shop

or field, but is more commonly done in the shop
where heat for melting is more readily available.

Zinc spray is often used as an alternative to hot-dip

galvanizing when the part is too large for immersion
in the kettle, and is also a great option for
extending the life of already erected galvanized
structures. The biggest limitations to metallizing
applications are availability of skilled operators and
equipment and a significant cost premium
Coating Characteristics
The metallized zinc coating is rough and slightly porous, with density about
80% that of hot-dip galvanizing. As the metallized coating is exposed to the
atmosphere, zinc corrosion products tend to fill the pores providing consistent
cathodic protection. The mechanically-bonded, pure zinc coating covers
welds, seams, ends and rivets well and can be applied in excess of 10 mils
(254 µm). Coating consistency is dependent on operator experience and
coating variation is always a possibility. Coatings tend to bethinner on corners
and edges and no coating is applied to interior surfaces or difficult to access
recesses and cavities.
3. Zinc-Rich Paint

Zinc painting, commonly referred to by the misnomer “cold galvanizing,” is the

application by brush or spray of zinc dust mixed with organic or inorganic
binders. Prior to application, the steel must be cleaned by sand blasting to
near white metal (SSPC-SP 10), commercial blast cleaning (SSPC-SP 6) or
white metal (SSPC-SP 5). The zinc dust must be mixed with a polymeric-
containing vehicle and constantly agitated during application to produce a
homogenous mixture and proper adhesion.

Zinc-rich paints contain 65-95% metallic zinc in dry film, with 92-95% being
common. The paints can be brushed or sprayed on to the steel. When spray
applying, feed lines should be kept as short as possible to prevent settling of
zinc dust and uneven film coats. Zinc painting can be applied in either the
shop or the field.
Zinc-rich paint can be applied to steel of any size and shape, though
application is difficult on more complex fabrications. Zinc-rich paints are also
widely used as primers to high-performance two and three coat systems and
for repair of batch hot-dip galvanized coatings. In mild environments,
inorganic zinc paint may be used independently for corrosion protection, but
should be top coated in more severe environments to extend service life.
Limitation to zinc-rich paint include life-cycle cost, difficulty in applying, lack of
coating uniformity (particularly at corners and edges) and the requirement for
a clean steel surface.

Coating Characteristics
Like all paint coatings, zinc-rich paint is a surface coating, mechanically
bonded to the steel at a few hundred pounds per square inch (psi). Zinc-rich
paints are either organic, consisting of epoxies, chlorinated hydrocarbons,
and other polymers; or inorganic based on organic alkyl silicates. The
organic or inorganic paints are applied to a dry film thickness of 2.5 to 3.5 mils
(64-90 µm).
One commonality of all zinc coatings is the cathodic protection
afforded. However, zinc-rich paint coatings are different than the others as there
is a binding material used to adhere zinc particles. For cathodic protection to be
possible, the zinc dust must be at a concentration high enough to provide for
conductivity between the zinc particles and the steel. This is another reason
constant agitation and homogenous mixture is important during application.
There is some question as to whether cathodic protection is possible at all if the
zinc particles are encapsulated in the binder and the binder is non-conductive.

Inorganic and organic zinc-rich paints vary

somewhat in their performance. Inorganic
zinc-rich paints, which adhere to the steel
with mild chemical reactivity, have good
solvent resistance and can withstand
temperature up to about 700 F (375
C). Inorganic zinc-rich paints do not chalk,
peel, or blister readily, are easy to weld
and provide simpler cleanup than
organics. The density of inorganic zinc-
rich paints is about half the density of zinc
per mil of batch hot-dip galvanized
coatings.
The properties of organic zinc-rich paints depend on the solvent
system. Multiple coats may be applied within 24 hours without
cracking. Organic zinc-rich paints do not have the same temperature
resistance of inorganic zincs, as they are limited to 200-300 F. They are
also subject to ultraviolet (sunlight) degradation, and are not as effective as
inorganics in corrosion resistance.
4. Continuous Sheet Galvanizing

Continuous sheet galvanizing is also a hot-dip process, but is only applied to

steel sheet, strip, and wire. A coil-to-coil process, steel sheets from 0.010 to
1.70 inches (0.25 mm to 4.30 mm) thick and up to 72 inches (1,830 mm)
wide is passed as a continuous ribbon through cleaning baths and molten
zinc at speeds up to 600 feet per minute.

Preparing the steel for the continuous galvanized coating begins with
cleaning in an alkaline liquid combined with brushing, rinsing, and
drying. Then the steel passes into the heating or annealing furnace to soften
it and impart the desired strength and formability. In this annealing furnace,
the steel is maintained under a reducing gas atmosphere, composed of
hydrogen and nitrogen, to remove any oxide that may be on the
surface. Just as in the batch hot-dip process, the steel must be completely
clean of oxides and contaminants for a successful coating.
As the steel exits the furnace, it enters into a vacuum chamber, or snout,
before entering the molten zinc bath to prevent and air from reoxidizing the
heated steel product. The steel is then sent around a submerged roll in the
molten bath to create the bonded coating and removed in a vertical
direction. As the product is withdrawn from the bath, precisely regulated,
high-pressure air (air knife) is used to remove any excess zinc to create a
closely controlled coating thickness. The steel is then allowed to cool and
solidify before contacting another roll to avoid transferring or damaging the
coating.

Today, this continuous process is used to make seven

different types of sheet products including:
• galvanized (zinc)
• galvannealed (90-92% zinc/8-10% iron alloy)
• two alloys of zinc and aluminum (55% aluminum/45%
zinc alloy and 95% zinc/5% aluminum alloy)
• two aluminum based alloys (100% aluminum, 89-95%
sluminum/5-11% silicon alloy)
• terne coating (85-97% lead/3-15% tin alloy)
Coating Characteristics
Because both are hot-dip processes, continuous sheet and batch hot-dip
galvanizing are often confused. One major difference in the two coatings is
the thickness. The continuous sheet galvanizing process has greater control
and preciseness when it comes to zinc thickness as the air knife used after
galvanizing ensures a uniform thickness across the steel sheet. The coating
is mostly unalloyed zinc, though minimal alloy layers are present, and is
ductile and able to withstand deep drawing or bending without damage. This
is important as the coating is applied prior to final fabrication such as
punching, bending, and cutting.

Because of the precise control of coating thickness, continuous sheet is

stocked in a variety of coating weights. One of the most common zinc
coatings is Class G90, which has 0.9 oz/ft2 of zinc (total both sides) or about
0.80 mils (20 μm) per side.

Service life for all zinc coatings is linear to zinc thickness; however, because
the continuous sheet coating is applied pre-fabrication, final forming and
placement often includes punching holes, bending, cutting, etc. which
creates uncoated areas. Like batch hot-dip galvanizing, the surrounding zinc
will provide cathodic protection to these uncoated areas, but as there is
much less zinc present, best practice is to touch-up any exposed areas after
fabrication to extend service life.
5. Electroplating

Electrogalvanized (electroplated) coatings are created by applying zinc to steel

sheet and strip by electro-deposition. Similar to sheet galvanizing, the operation
is continuous and coating thickness is minimal. Applied in a steel mill, sheet or
strip is fed through entry equipmentinto a series of washes and rinses then into
the zinc plating bath.

The most common zinc electrolyte-anode arrangementuses lead-silver, or other

insoluble anodes and electrolytesof zinc sulfates. Soluble anodes of pure zinc
are also used.The coating develops as positively charged zinc ions inthe solution
are electrically reduced to zinc metal anddeposited on the positively charged
cathode (sheet steel). Grain refiners may be added to help produce a smooth,
tight-knit zinc coating on the steel.

Electrogalvanized coatings are applied to sheet steels and wire; and therefore,
are used in similar applicationsto continuous sheet galvanizing or wire
galvanizing.The most common applications are in automobile andappliance
bodies and fasteners. Furthermore, to extendthe service life, electrogalvanized
coatings can be treatedto make them suitable for painting, and this is often
recommended due to the extremely thin zinc coating.
Coating Characteristics

This electro-deposited zinc coating consists of pure zinc tightly adherent to the
steel. The coating is highly ductile remaining intact even after severe
deformation. Produced on strip and sheet materials, the coating weight ranges
up to 0.2 oz/ft2 (60 g/m2), or thicknessesup to 0.36 mils (9.1 μm) per side,
while on wire, coating weights may reach up to 3 oz/ft2 (915 g/m2). The coating
of pure zinc is thinner than continuous sheet galvanizing, mechanically-
bonded, and there are no alloy layers, but provides a smoother finish. Heat-
treated and electro-coated wire can be cold drawn to about 95% reductionin
area, depending on the chemical composition of the wire, heat treatment, and
diameter.
6. Mechanical Plating

Mechanical zinc plating is accomplished by tumbling small parts in a drum

with zinc and proprietary chemicals. Small iron and steel parts – usually
limited in size to about 8-9 inches (200-300 mm) and weighing less than one
pound (0.5 kg) – are cleaned and flash coppercoated before loading into a
plating barrel. The barrel is then loaded with proprietary chemicals, glass
beads and zinc powder and tumbled. During tumbling, the glass beads peen
zinc powder onto the part. Once finished, the parts are dried and packaged,
or post-treated with a passivation film, dried, and packaged.

As mentioned, mechanical plating can only be applijedto small parts limited

to the capacity of the drum. Furthermore, the materials must be simple in
design to ensure peening to all surfaces. Mechanical zinc plating is most
commonly used on high-strength fasteners and other small parts not suitable
for hot-dip galvanizing.
Coating Characteristics

Mechanical plating consists of a flash coating of copper followed by the zinc

coating. Coating thickness requirements contained in ASTM Specification
B695 range from 0.2-4.3 mils (5 to 110 µm). While thicker coatings are
possible, the common thickness on commercial fasteners is 2 mils (50 µm).
The coating density is approximately 0.45 oz/ft2/mil compared to the hot-dip
galvanized coating density of about 0.6 oz/ft2/mil. The hot-dip coating has over
30% more zinc per unit volume than the mechanical coating.

The coating, upon micro cross-section, appears to consist of flattened particles

of zinc loosely bonded together. The bond between zinc and steel, and zinc-to-
zinc, being mechanical in this process, is weaker than the metallurgical bond
found in hot-dip galvanizing. Edge, corner and thread coating thicknesses are
usually lower at these sharp radii areas due to minimal peening action at these
locations.
7. Zinc Plating

Zinc plating is identical to electro-galvanizing in principle because both are

electro-deposition processes. However, zinc plating is used on small parts such
as fasteners, crank handles, springs and other hardware items ratherthan sheet
metal. The zinc is applied as an expendable electrode in a cyanide, alkaline non-
cyanide, or acid chloride salt solution. Cyanide baths are the most operationally
efficient but can potentially create pollutionand are hazardous.

After alkaline or electrolytic cleaning, pickling to remove surface oxides, and

rinsing, the parts are loaded into a barrel, rack, or drum and immersed in the
plating solution. Various brightening agents may be added to the solution to add
luster, but careful control is needed to ensure a quality product. Post-plating
treatments may be used to passivate the zinc surface as well as impart various
translucent colors or to extend the life of the coating.

Zinc plating is typically used for screws and other small fasteners, light switch
plates, and various small parts that will be exposed in interior or mildly corrosive
conditions. For use in moderate or severe environments,the materials must be
chromate-conversion coated for additional corrosion protectio