Big R Bridge

AZZ Galvanizing Services

Kevin Irving Marketing Manager Northern Ops kevinirving@azzgalv.com 815-693-4242

Tour of the City

Weathering Steel

I-69 Bridge

Ford County 00N, 2350E

New Galvanized Bridges in Chicago

35th Street & Dan Ryan 51 Street & Dan Ryan Douglas Lake Connection 57th Street & Dan Ryan 67th Street & Dan Ryan Michigan Ave over I-94 91st Street & Dan Ryan 26th Street & Dan Ryan

362 Tons 349 Tons 1444 Tons 346 Tons 403 Tons 234 Tons 234 Tons 194 Tons

CTA , IL Toll Road, IDOT & Counties

Over 50 Million Pounds of Bridges were Galvanized in Illinois in last 5 years.

26th Street & the Dan Ryan

Tappenzee Bridge

Tappenzee Bridge

Michigan/MI-102 Bridge Rail

Date Galvanized
2007

Components Galvanized
Guide rails

Environment
Urban

Location
Detroit, MI

Michigan / MI-102 Bridge Rail

Richland County Bridge

Knox County, OH

- Before

Knox County, OH

- After

Seneca County, OH

- Before

Seneca County, OH

- After

Village of Glouster County, OH

- Before

Village of Glouster, OH

- After

Village of Minerva, OH

- Before

Village of Minerva, OH

- After

Corrosion Problem Case Study The Williamsburg Bridge

built in 1903 in New York City

1991 inspection revealed severe corrosion direct cost of repairs was $750 million indirect cost approximately $8.2 billion

40% of Carbon Steel Goes to Replace Corroded Steel

$350 Billion per Year

At a Cost of

Equivalent of Building 562 Willis Towers (Sears) Every Year

Corrosion Process

Law of Entropy

Tendency for metal, after production and shaping, to revert back to its lower, more natural energy state or ore

Definition of Corrosion

Corrosion (n): the chemical or electrochemical reaction between a material and its environment that produces a deterioration of the material and its properties

Bimetallic Couple
Return Current Path

Cathode

+
Anode

Electrolyte

Long-Lasting Zinc Protection

Barrier Cathodic Zinc Patina Metallurgical Bond

Barrier Protection

Cathodic Protection

Galvanic Series of Metals

ZINC = ANODE
STEEL = CATHODE

This arrangement of metals determines what metal will be the anode and cathode when the two are put in a electrolytic cell (arrangement dependent on salt water as electrolyte).

Sacrificial Zinc Anodes

Zinc Patina
Zinc Carbonate

Zinc Hydroxide
Zinc Oxide Zinc

The History of Galvanizing

79 AD

1772

1829

1870

Today

Galvanizing Process

HDG Process: Surface Preparation

Thorough cleaning is necessary as zinc will only adhere to clean steel Degreasing removes dirt, oils, organic residue

We Protect More Than Steel

Degreasing Tank

HDG Process: Surface Preparation

Thorough cleaning is necessary as zinc will only adhere to clean steel Degreasing removes dirt, oils, organic residue Pickling Removes mill scale and oxides

Pickling Tank
We Protect More Than Steel

HDG Process: Surface Preparation

Thorough cleaning is necessary as zinc will only adhere to clean steel Degreasing removes dirt, oils, organic residue Pickling Removes mill scale and oxides Fluxing Mild cleaning, provides protective layer

Flux Tank

We Protect More Than Steel

HDG Process: Galvanizing

Steel immersed in bath of molten zinc (~830 F) > 98% pure zinc, up to 2% additives (Al, Bi, Ni) Zinc reacts with iron in steel to form coating Reaction is complete when steel reaches bath temperature

Galvanizing Bath

We Protect More Than Steel

Hot Dip (Dry) Galvanizing

FHWA Rebar Seminar Providence, RI, 27 March 2008

71

HDG Process: Inspection

Steel is inspected after galvanizing to verify conformance to specs Visual inspection to identify any surface defects Magnetic thickness gauge to check coating thickness

Metallurgical Bond
Eta

100% Zinc 94% Zinc 6% Iron

Zeta Delta Gamma

steel

90% Zinc 10% Iron

75% Zinc 25% Iron

Abrasion Resistance Eta Zeta

Delta Gamma Steel

DPN =70 DPN = 180

DPN: Diamond DPN Pyramid NumberDPN

= 245
= 250

DPN = 159

Edge Protection

Complete Protection
Edges Welds & Seams

Hard to Reach Spots

Typical Spray Application

Hot-Dip Galvanizing

Variety of Sizes & Shapes

Availability

Its a Natural Element

Its Essential

HOT DIP GALVANIZING SAFE

ESSENTIAL FOR LIFE GREEN

Its Recyclable

Sustainability: Galvanizing is Green

Zinc and steel are 100% recyclable

Properties of zinc (and steel) do not degrade with reprocessing Zinc is a natural element in the Earths crust Recycled content contributes to LEED

Galvanizings maintenance-free durability ensures no additional energy, materials, or emissions during use

Hot-Dip Galvanizing & LEED

HDG contributes points under Materials & Resources Credit 4: Recycled Content
Credit

4.1: Use materials with recycled content

(10%)

sum of post consumer recycled content plus one-half of the pre-consumer content equals 10% of the total value of the materials in the project

Credit

4.2: Use materials with recycled content

(20%)

sum of the post consumer recycled content plus one-half of the pre-consumer content constitutes at least an additional 10% beyond Credit 4.1 (total of at least 20%) of the total value of the materials in the project

Other Zinc Coatings

Metallized Hot-Dip Galvanized Zinc-Rich Paint Galvanized

Sheet Electroplated

Zinc Coating Life Predictor

Anticipates service life Program performs calculations

Atmospheric categories

Statistical methods Neural network technology Worldwide corrosion database

Rural Suburban Temperate marine Tropical marine Industrial

Estimated Service Life of HDG

Metallurgical Bond
Eta

100% Zin

94% Zinc 6% Iron

Zeta Delta Gamma
steel

90% Zinc 10% Iron

75% Zinc 25% Iron

Design & Fabrication

Liaison Between...

Design Engineer

Fabricator

Galvanizer

Avoid Combining Different Materials

Welding Procedures and Flux Removal Remove prior to galvanizing

Seal Welding

Viscosity of zinc prevents it from entering gaps less than 3/32 Complete seal-welding or stitch-welding with at least 3/32 gap between surfaces

Galvanizing Oversized Pieces

26th Street & the Dan Ryan

Material Handling

Allowing for Proper Venting & Drainage

Improper Venting

Marking

ASTM A 123

Coatings on Iron & Steel Products

ASTM A 153

Coatings on Iron & Steel Hardware

ASTM A 385

Providing High-Quality Zinc Coatings

ASTM A 767

Zinc-coated Steel Bars for Concrete Reinforcement

132

www.galvanizedrebar.com

133

Advantages of Hot Dip Galvanized Rebar

Corrosion
Low

resistant

cost Tough Long history of performance

1948 Royal Navy Dockyards, Bermuda

Higher

bond strength
134

Stearns Bayou Bridge

ASTM A 780

Zinc-Based Alloys Zinc Dust Paint

Repair of Damaged & Uncoated Areas of Hot-Dip Galvanized Coatings

Metallizing

ASTM D 6386

Standard Practice for Preparation of Zinc (Hot-Dip) Galvanized Coated Iron & Steel Product & Hardware Surfaces for Painting

All commonly practiced welding and cutting techniques can be used on Galvanized Alloyed steel
American Welding Society D 19.0

Welding Zinc Coated Steel

AZZinc Protects

Preparation of Weld Area

weld area should be free of Galvanizing, 1 to 4 inches back, both sides, top and bottom

AZZinc Protects

Preparation of Weld Area

Removing the Galvanizing 1) Grind it off 2) Burn it off 3) Apply Galva Stop before Galvanizing

AZZinc Protects

Weathering of Galvanized Steel

Photo taken 12/18/02

Photo taken 03/28/03

Steel Chemistry
Sandelin Curve

Typical Zinc-Iron Alloy Layers

Irregular Zinc-Iron Alloy Layers

Electrochemical Corrosion Zone

Painting Over Galvanized Steel

Painting Galvanized Steel

Painting Ungalvanized Steel

Synergistic Effect

Safety Marking

Color Coding

Stark County Pro Football Hall of Fame Bridge

Stark County Pro Football Hall of Fame Bridge

Real-world Applications

Stears Bayou Bridge

Stearns Bayou Bridge

Cost Analysis of The Stearns Bayou Bridge

Stearns Bayou Bridge First fully galvanized bridge in the US Built in Michigan 1966 All steel components were galvanized

handrail diaphragms fasteners shear

connectors beams

Stearns Bayou Bridge Options

Preparation costs were not included

Option 1: Paint the steel structure Option 2: Galvanize the structure

Cost Comparison

Initial cost Maintenance

Initial cost

Maintenance
Maintenance Maintenance

What $8,700.00 Bought the Specifier

46 years of: A rust-free surface A spangled appearance A coating thickness of an average of 4.4 mils today 48 more years maintenance free

Spring Lake Bridge MI

Dick Vale Bridge Peru, ME

Montgomery County -Maryland

7th Avenue Light Rail Transit

Date Galvanized
2005

Components Galvanized
Columns, arms, light posts, handrails, benches, hardware

Environment
Urban

Location
Calgary, AB

We Protect More Than Steel

Fallowfield Township Washington County PA

Bryants Bridge Saratoga County N. Y.

Hot-Dip Galvanizing Costs Less Lasts Longer

The Cost of Corrosion Protection

Initial cost will always factor into decision

Life-cycle cost analysis is more complete
Includes all future maintenance costs Provides total cost of the project over its life

Life-cycle cost calculation automated online at www.galvanizeit.org/galvanizingcost/

Quantitative Analysis

Data Sources:

Paint 2008 KTA Tator paper

Nationwide

survey of the paint industry Presented at NACE 2009

Galvanizing 2008 AGA Industry Survey

Project Parameters
Standard mix of steel (structural, tubing, plate) 30,000 ft2 project Moderately industrial environment

Initial Cost Parameters

Paint

Galvanizing

Material (one- or twopack product, number of coats, etc) Shop cleaning labor Shop/field application Field labor

Process is inclusive of all cleaning, material, and labor

Initial Cost
Coating System
Inorganic Zinc Hot-Dip Galvanizing Inorganic Zinc/Epoxy Acrylic WB Primer/ Acrylic WB Intermediate/ Acrylic WB Topcoat Inorganic Zinc Primer/ Epoxy/ Polyurethane Topcoat

$/ft2
$1.35 $1.60 $2.16 $2.55
$3.17

Total
$40,410 $48,000 $64,800 $76,620
$94,950

Life-Cycle Cost

Maintenance costs calculated on a practical maintenance cycle (vs. ideal)

Unique to each paint system Manufacturer recommended cycles provided in the KTA Tator paper

NACE model for NFV and NPV calculations

2% inflation; 4% interest

50-year life Maintenance repaint at 5% rust

Life-Cycle Cost Life

Coating System

2) ($/ft

60-Year
$/ft2
$1.60 $5.16 $8.07 $10.04
$14.82

Hot-Dip Galvanizing Inorganic Zinc Inorganic Zinc/Epoxy Inorganic Zinc Primer/Epoxy Intermediate/ Polyurethane Topcoat Acrylic WB Primer/ Acrylic WB Intermediate/ Acrylic WB Topcoat

Total Cost of 60-Year Project

Coating System
Hot-Dip Galvanizing Inorganic Zinc Inorganic Zinc/Epoxy Inorganic Zinc Primer/ Epoxy/ Polyurethane Acrylic WB Primer/ Acrylic WB Intermediate/ Acrylic WB Topcoat

Total
$48,000 $154,800 $242,100 $301,200
$444,600

Thank You!
Kevin Irving Marketing Manager Northern Ops kevinirving@azzgalv.com 815-693-4242

Knox County, OH

- Before

Knox County, OH

- After

Seneca County, OH

- Before

Seneca County, OH

- After

Village of Glouster County, OH

- Before

Village of Glouster, OH

- After

Village of Minerva, OH

- Before

Village of Minerva, OH

- After

202

www.galvanizedrebar.com

203

Advantages of Hot Dip Galvanized Rebar

Corrosion resistant Low cost Tough Long history of performance
1948 Royal Navy Dockyards, Bermuda

Higher bond strength

204

Stearns Bayou Bridge

Stearns Bayou Bridge

Electrical Utilities

Cellular Clock Tower

Raleigh North Carolina

Piers 1 & 21 Replacement

Date Galvanized
2002

Components Galvanized
Fenders and corner bolsters

Environment
Temperate marine

Location
Norfolk, WA

Texas Motor Speedway

Galvanized

Painted

Corrosion Problem Case Study The Williamsburg Bridge

built in 1903 in New York City

1991 inspection revealed severe corrosion direct cost of repairs was $750 million indirect cost approximately $8.2 billion

Law of Entropy

Tendency for metal, after production and shaping, to revert back to its lower, more natural energy state or ore

Galvanic Series of Metals

ZINC = ANODE
STEEL = CATHODE

This arrangement of metals determines what metal will be the anode and cathode when the two are put in a electrolytic cell (arrangement dependent on salt water as electrolyte).

Zinc is Natural
Air

Water

Soil

Sacrificial Zinc Anode

In an Electrochemical Corrosion Cell, Zinc will sacrifice itself consistently and rapidly as long as all of the Corrosion Elements are present (i.e. Anode, Cathode, Electrolyte & Return Current Path)

(Accelerated Corrosion Testing)

Sacrificial Zinc Anodes

Corrosion of Bare Steel

Microscopic anodic and cathodic areas exist on a single piece of steel As anodic areas corrode, new material of different composition is exposed with different electrical potential

Seal Welding

Viscosity of zinc prevents it from entering gaps less than 3/32 Complete seal-welding or stitch-welding with at least 3/32 gap between surfaces

Electrochemical Corrosion Zone

Chemical Corrosion Zones

AZZinc Touch-up