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Duplex coatings Preparing a hot dip galvanized surface for painting Painting over a hot dip galvanized surface known commonly as a “Duplex System” was introduced into the world by a knighted engineer Jan van Eijnsbergen in the early fifties. Jan found that when an appropriate paint system of reasonable thickness was applied over a hot dip galvanized surface one achieved a synergistic performance from the sum of the two individual coating systems. His further developments assured that increased factors of a minimum of 1,5 to 2,3 times the sum of the individual coating lives, in varying conditions, would be achieved. Due to some duplex failures, where the paint peels off prematurely, some people feel that the concept of the system does not work. Paint, like any mechanically applied coating has to be applied to a suitably prepared surface and while this is essential for painting onto carbon steel, it also equally applies to painting over hot dip galvanized steel. In most applications when steel is hot dip galvanized, the process following hot dip galvanizing is a quench bath containing a passivation. This reduces the component temperature and passivates the freshly galvanized component, providing temporary protection against the incidence of white rust. In most instances when a duplex coating is required, the passivation is omitted, particularly if the galvanizer is aware of this requirement. Should this not happen, the passivation must be comprehensively removed prior to painting. A simple test indicating the presence of the passivation can be done. See ASTM B201-80. Preparation of the hot dip galvanized substrate can include a chemical washing procedure, a high pressure water blast or a sweep blast. Sweep blasting which is done at less than 300kPa using a micro-grit at the correct angle and distance from the surface, removes surface imperfections and zinc ash and will also comprehensively remove all passivation from accessible surfaces. This means that in the case of tubular components the inside of the tube (where it is unlikely to be painted), will still be passivated and therefore protected against the formation of possible white rust. Galvatech (Pty) Ltd a member of the Association swears by sweep blasting for duplexing. As Christof Krugmann, current Production Manager, says, “Paint coatings are only as good as the surface preparation prior to painting. If you do not go this route it is almost like plastering a wall without "chipping" it before hand. Correct sweep blasting provides an excellent key for subsequent painting.” Krugmann also says, “Utilizing sweep blasting as a surface preparation might be a little more costly to start off with, but at the end of the day ensures no unforeseen expenses. Even site work like "touch up's" are minimized by proper adhesion of the paint on galvanized structures. Paint is not nearly as prone to chipping, not even when bolts are tightened when structures are put together on site. This observation was made by one of our clients who used to "chemically clean" galvanized steel, instead of sweep blasting before applying paint.” 32 Hot Dip Galvanizing Today Volume 10 Issue 2 2013
Education 3 CPD POINTS 3-day Galvanizers Inspectors Course Hot dip galvanizing is one of the most widely used methods of protecting steel from corrosion. During and after fabrication and after hot dip galvanizing the coating is inspected for compliance with the relevant specifications. The course commences at the selected venue where course material is presented and reviewed, the lecturer encourages discussions between delegates and himself. Each lecture is preceded by a number of pertinent questions on the previous lecture. Once the delegates have a reasonable knowledge of the coating, including its inspection criteria, the venue moves to a selected galvanizer where a batch of incoming components are discussed en-group and then in teams, preselected hot dip galvanized components are inspected and reports are required to be completed. If available at the galvanizer or other venue, preparation by sweep blasting and/or chemical treatment is demonstrated and duplex coatings are discussed. The course will provide delegates with sufficient knowledge to advise on fabrication for successful hot dip galvanizing and also test, inspect and interpret test results after hot dip galvanizing. COURSE DURATION AND CONTENTS Day 1 (08h00 to 16h00) Lecture 1 Introduction to the Environment, Steel & Corrosion Lecture 2 Understanding Zinc Coatings (How does Zn protect) ISO 9223 & 12944 Lecture 3 Designs, Fabrication and Inspection before hot dip galvanizing SANS (ISO) 14713:1999 Lecture 4 General Hot Dip Galvanizing Processes SANS 121 (ISO 1461:2009) Batch type galvanizing SANS 32 (EN 10240: 1997) Automatic T & P SANS 10684:2004 HDG of Friction Grip <strong>Fasteners</strong> Day 2 (07h00 to 16h00) Hot Dip Galvanizing Plant Visit and Inspection Lecture 5 Duplex Coatings and HDG Reinforcement in Concrete Day 3 Lecture 6 Lecture 7 (08h00 to Completion of Exam) Inspections after Hot Dip Galvanizing Quality Assurances in Coating Applications Application of specifications Control documentation for a QA System Examination on Course Effectiveness DATE AND TIME Courses commence at 08h00 sharp and end at 16h30 (or as otherwise instructed). Lunch and refreshments will be provided. Comprehensive course notes can be collected from our offices two weeks before the course (this is highly recommended). Johannesburg: 26 to 28 February; 12 to 14 March; 14 to 16 May; 9 to 11 July; 13 to 15 August; 8 to 10 October; 26 to 28 November. Cape Town: 5 to 7 March; 4 to 6 June; 10 to 12 September. Special courses can be arranged for a minimum of 6 delegates at appropriate venues in South Africa. COURSE COST AND PAYMENT TERMS R4 200.00 per person exclusive of VAT. Should you have two or more delegates from the same company, course costs will be R4 000.00 per person exclusive of VAT. Please note that payment is due on the first day of training. Cheques are to be made out to “Hot Dip Galvanizers Association SA”. Members qualify for a discount. CONTINUOUS PROFESSIONAL DEVELOPMENT (CPD) By attending the Association’s 3 day course Galvanizing Inspectors Course, you will obtain 3 points (accredited by ECSA). Course schedule may be altered and interesting activities added for the benefit of delegates. Following the course and successful result in a three part exam, the delegate will be issued with a certificate and if required, registered as an approved HDGSA Galvanizing Inspector. Registration will be confirmed on an annual basis. Successful galvanizing inspectors will become Affiliate Galvanizing Inspector Members of the HDGASA for the year. VENUE AND NUMBER OF DELEGATES The courses are usually run in Johannesburg from the Hot Dip Galvanizers Association in St Andrews, Bedfordview and also from a suitable venue in Cape Town. Bookings are limited to 10 people per course on a first come first serve basis. Courses in other areas are possible, contact HDGASA. SHOULD YOU BE INTERESTED, KINDLY CONTACT SASKIA SALVATORI OR MARJORIE MONTGOMERIE AT THE ASSOCIATION Volume 10 Issue 2 2013 Hot Dip Galvanizing Today 33
Page 1: 2013 Volume 10 Issue 2 HOT DIP GALV
Page 4: Comments Executive Director’s Com
Page 7 and 8: Fasteners Pre lubricated nuts (with
Page 9 and 10: Fasteners weakening Rand and the co
Page 11 and 12: Fasteners Fastener availability mat
Page 14: Fasteners TYPE OF COMPANY STEEL GRA
Page 17 and 18: Fasteners TYPE OF COMPANY STEEL GRA
Page 19 and 20: Case history Lion's Den, disused ol
Page 22 and 23: Misconceptions MISCONCEPTIONS Miss
Page 24 and 25: Technical Appropriate (A) Less appr
Page 26 and 27: Bob’s Banter Natural networking c
Page 28 and 29: Duplex coatings Cape Town’s MyCit
Page 30 and 31: Duplex coatings Two different bus s
Page 32: Duplex coatings OBITUARY Andrew Dip
Page 37 and 38: Education New coating thickness gau
Page 39 and 40: Education ◆ ◆ particular areas
Page 41 and 42: General maintenance periods would b

Fasteners - hdgasa

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