HDGASA V7E1.pdf

2010 Volume 7 Issue 1HOT DIP GALVANIZERS ASSOCIATION Southern Africa42Featuring:Pictorial review of the galvanizing in four of the Soccer World Cup StadiaAnnual Fastener Availability MatrixCase History – Newlands Rugby StadiumGalvanized rebar for concrete & introduction to Professor Stephen YeomansWamosha & Bob's Banter

Trident Steel is an AVENG Group company with our mainoperation centrally situated in Roodekop, Germiston with otherfacilities in Alrode, Durban, Port Elizabeth, Rosslyn and Cape Town.We supply a wide product range to the steel industry inSouth Africa as well as internationally from our extensivesteel yards, modern and comprehensive steel processing andsteel service centres, speciality steel division andtube manufacturing plant.We offer our customers a quality product, delivered on timeat a competitive price.Our growth is guaranteed by the contribution we make to thesuccess of our customers.TRIDENT STEEL (PTY) LTD■ Marthunisen Road, Roodekop, Germiston ■ PO Box 124054, Alrode 1451■ Tel: (011) 861 7111 ■ Fax: (011) 865 3035 ■ Website: www.trident.co.za■Email: trident@trident.co.za / export@trident.co.za1348 CBT (011) 868 3408

The Associationis an informationcentre establishedfor the benefitof specifiers,consultants, endusers and itsmembers.HOT DIPGALVANIZINGOfficial journal of the Hot Dip Galvanizers Association Southern Africa • 2010 Volume 7 Issue 1CONTENTSISSN 1023/781XTODAY42CAPE TOWN JOHANNESBURGExecutive Director: Bob WilmotCell: 082 325 8840Email: bob@hdgasa.org.zaOffice Manager: Saskia SalvatoriEmail: hdgasa@icon.co.zaTechnical MarketingConsultant:Hendrik SteenkampCell: 082 891 5357Email: hendrik@hdgasa.org.zaReceptionist: MarjorieMontgomerieEmail: info@hdgasa.org.zaPUBLISHED BY:Hot Dip GalvanizersAssociation Southern AfricaQuality House, Unit U4,St. Christopher Road,St.Andrews, BedfordviewP.O. Box 2212 Edenvale 1610Tel: 011 456-7960Fax: 011 454-6304Email: hdgasa@icon.co.zaWebsite: www.hdgasa.org.zaEditor and Technical MarketingDirector:Terry SmithTel: 021 797 4735Fax: 086 612 7284Cell: 082 893 3911Email: terry@hdgasa.org.zaSub-Editor,Advertising and Sales:Anne van VlietTel: 011 462 5073Cell: 082 775 0711Email: mwvliet@mweb.co.zaDesign and Layout: Sandra AddinallTel: 011 868 3408Fax: 011 900 1922Email: cbtdesign@adcot.co.zaReproduction and Printing:Camera PressTel: 011 334 3815Fax: 011 334 3912Email: cpress@iafrica.comViews expressed in articles andadvertisements are not necessarily theviews of HDGASA.Articles or extracts thereof may bereproduced provided full acknowledgementis given.Advertisers’ Index.................................................................................................................................................... 30RegularsExecutive Director’s Comment........................................................................................................................................ 2Note from the Editor ........................................................................................................................................................ 2Case History No. 19 .......................................................................................................................................................... 25Bob’s Banter .......................................................................................................................................................................... 27WamoshaCapricorn Park – “Are the two coatings the same?” ............................................................................................ 27Member’s News.................................................................................................................................................................... 32AwardsThe 2010 Hot Dip Galvanizing Awards – Call for nominations .............................................................................. 22FastenersFastener availability matrix and participating fastener suppliers .............................................................................. 4SANS 1273 – setting a new standard for roofing fasteners...................................................................................... 11Continuous Wire GalvanizingThe introduction of Galfan coated wire at Cape Gate,Vanderbijlpark .................................................................. 13SANS 675:2009 Zinc coated fencing wire, has been revised .................................................................................... 162010 Soccer World Cup StadiaReviewing the corrosion protection provided by hot dip galvanizing of the stadia for the 2010 SoccerWorld CupMoses Mabhida Stadium.............................................................................................................................................. 17Cape Town Stadium...................................................................................................................................................... 18Port Elizabeth Stadium ................................................................................................................................................ 19Soccer City .................................................................................................................................................................... 20Innovative use of Mentis grating at Soccer City .......................................................................................................... 21Education and TrainingThe new features for the Elcometer 456 Coating Thickness Gauge ...................................................................... 23Coating Inspector’s Course .............................................................................................................................................. 24GeneralProfessor Stephen R Yeomans’ series of presentations and seminars on hot dip galvanizedrebar for concrete in South Africa .................................................................................................................................. 31The merits of using hot dip galvanized steel reinforcement in concrete structures .......................................... 28Hot Dip Galvanizers Association Executive Committee 2010 ................................................................................ 39Front Cover: A kaleidoscope of photographs showing some galvanized components in the four larger stadia, with their verydifferent seating colouring arrangements and some bolt and nut photos.Hot Dip Galvanizing – Adding value to Steel

CommentsExecutive Director’sCommentThe year 2009 has beenassigned to history andwe are already 1/6th ofthe way through 2010.The year ahead is fullof promise with a focuson a number of newprojects andprogrammes as well asthe continuation ofothers.Education and training of people that aredirectly or indirectly involved in hot dipgalvanizing of carbon steel for corrosioncontrol will continue with the introduction ofa revamped and upgraded inspector’s course.We plan to introduce a new, more practical,entry level course for candidates that find themain course too technically difficult. Inaddition, a computer based interactive courseis to be launched in order to cater for plantoperators who have or could be given accessto a computer. This course will allowcandidates to progress at their own pace andat the same time not interfere with their dailywork attendance.During the month of February we werefortunate to be visited by Prof. StephenYeomans from New South Wales - Australia.Together with Association staff, the professorvisited Gauteng, Durban and Cape Town andengaged with numerous specifiers anduniversity students via a series of seminarsand presentations on hot dip galvanized rebarfor concrete. The country-wide market for hotdip galvanized reinforcing steel is growing andthe visit by the professor was most welcome.Corrosion investigations and reports continueto be an area that will receive our attention.Each case study is a learning experience thatis used to support future hot dip galvanizedsteel applications. An area of particularinterest for us at the Association is thecorrosive conditions found in many of ourmines. Corrosion of carbon steel within themining industry is particularly severe, wherehot dip galvanizing and duplex systems doprovide economical solutions.Readers of our magazine are encouraged touse the corrosion investigative services of theAssociation as we are committed to providingcritical, unbiased and objective reportswhenever galvanized and duplex coated steelsare used.Bob WilmotNote from theEditorIt was extremely gratifying to me that where hot dipgalvanizing had been used in the four stadiums that we havepictorially reported on, in many instances the boltedconnections used are mainly hot dip galvanized bolts, wherein the past due mostly to inappropriate, inconcisespecifications and non-availability of hot dip galvanizedfasteners, more zinc electroplated fasteners were used. Our feature on fasteners againaddresses this essential requirement.Also we wish to compliment the designers and fabricators of the various hot dipgalvanized componentry (in the stadiums) that they have to a large degree, understoodthe requirements of the hot dip galvanizing process, using modular design, with itsbenefits of appropriate sizing, ease of handling, minimisation of site coating repairs, etc.With the rigorous paint coating systems and guarantees now in place for some of thestadia, it goes without saying that we will be monitoring the performance of the tworespective corrosion control systems, over the next decade or so, particularly as the "allpaint coating system" has been applied to roof steelwork, which is relatively inaccessiblein most instances for future maintenance.At the Association we pride ourselves in providing cost effective advice in the use of ourcoatings and are always happy to be involved in the evaluation and inspection ofpreviously exposed and weathered hot dip galvanized or duplex coated components.Should a reader require this evaluation and inspection service, kindly contact Bob,Hendrik, myself or a number of our qualified Galvanizer Inspectors throughout thecountry (list available from the Association).Our features for this issue include, a pictorial review of the hot dip galvanizedcomponents installed at four of the major stadiums. Our regular Fastener AvailabilityMatrix, with some new fastener categories - we had hoped to have incorporated a seriesof shackles and turnbuckles that are either hot dip galvanized or appropriatelymechanically plated to achieve reasonable durability in corrosive atmospheres but wewill have to work on this for future issues.In our continuous wire feature we include a short account with respect to corrosionprotection on the 2009 version of SANS 675 versus the 1993 version. Also in this featureis an account on “Galfan” wire and its attributes.“Wamosha” includes a story of inappropriately used continuously hot dip galvanizedpurlins fixed to generally hot dip galvanized rafters in a corrosive marine atmosphereand the effects after nearly three years.We report on a recent brief tour by Prof. Stephen Yeomans from the University of SouthWales, Australia. Stephen, a world renowned authority on hot dip galvanizedreinforcement for concrete, who together with Association staff and Rob White of IZASAtoured the major centres and presented his ideas.Case History includes an evaluation and inspection of the hot dip galvanized seatingbrackets and handrails at Newlands Rugby Stadium after 31 years!Education and Training, expands on our certificated coating inspectors course, anessential requirement in any coating inspectors portfolio.Other regular articles include, Bob’s Banter, where Bob Andrew chats about “Likebacteria, the business community needs a common immune system”, Members News,where some members report on their involvement in the stadia.Should a reader wish to express an opinion or provide us with an article, or comment onour articles, kindly contact me –Due to lack of space Duplex Coatings, Coating Report, Guest Writer, “On the Couch”and Misconceptions are not included in this issue but will resume in subsequent issues.Enjoy the “magazinc”.Terry Smith2 Hot Dip Galvanizing Today Volume 7 Issue 1 2010

Since1988 we have excelled as a high quality manufacturer of steelfasteners, specialising in hot dip galvanised bolts and nuts. Ourfasteners come in mild steel and hi-tensile and range from M6 up toM30 in diameter. They are also available as zinc plated and cadmiumplated.We supply all sectors of the engineering, automotive and miningindustries. Using state-of-the-art quality testing equipment, ourproducts are quality monitored throughout the process fromaccepting the delivery of steel to sending out the finished product.Our large range of standard products is available from ourGermiston-based warehouse. We also offer specialised servicestailored to individual applications and pride ourselves on speed ofmanufacture and delivery.

FastenersFastener availability matrix and participating fastener suppliersFrom experience it has been shown that on many occasions at building sites, alternatives such as zinc electroplated fasteners aremistakingly used. In order to provide a similar service life to that of the hot dip galvanized structure, it is important to specify and usehot dip galvanized fasteners. To this end we provide the following "Fastener Availability Matrix", indicating the feasibility and availability ofa range of hot dip galvanized fasteners, etc. Should a particular fastener that you require not be listed, kindly contact one of theparticipating fastener suppliers at the end of this matrix or the Association.TYPE OFFASTENERCOMPANY STEEL GRADE SPECIFICATION SPECIFICATIONLOCKING NUTSAVAILABLESIZESHalf Lock Nuts Bolt Fast MS M8 – M30 YesHOT DIPGALVANIZEDTO ORDERImpala Bolt & Nut MS/HT M8 – M36 Yes YesNew Aloe Fastening Systems MS/HT M8 – M48 YesTel-Screw Products MS/HT M8 – M48 Yes YesWLS Fastener Manufacturing Co. cc MS/HT M8 – M36 Yes YesHard Lock Nuts Bolt Fast Gr: 8 M8 – M30 YesCastle Nuts Bolt Fast MS/Gr:8 M8 – M30 YesNew Aloe Fastening Systems MS/Gr:8 M8 – M100 YesTel-Screw Products MS/Gr: 8 M8 – M100 YesSteel Hex Lock Bolt Fast MS M8 – M100 YesNuts New Aloe Fastening Systems MS/HT M8 – M100 YesTel-Screw Products MS/HT M8 – M100 YesWLS Fastener Manufacturing Co. cc MS YesCrimped Nuts Impala Bolt & Nut MS YesTel-Screw Products MS M8 – M48 YesLocking Washers Bolt Fast MS M8 – M52 YesNyloc NutsNew Aloe Fastening Systems MS/HT YesNyloc nuts are currently not available in hot dip galvanized form, some other form of bolt locking device is necessaryCleeve Lock Nuts Bolt Fast Gr: 8 M8 – M30 YesPrevailing Torque Tel-Screw Products Gr: 8 & 10 DIN 980V YesHex Lock NutsNORMAL NUTSHex OS Nuts Bolt Fast MS/Gr: 8 & 10 M8 – M64 Yes YesCBC Fasteners Gr: 8 DIN 934 ISO 4032 M8 – M30 Yes YesImpala Bolt & Nut Gr: 8 DIN 934 M8 – M30 Yes YesNew Aloe Fastening Systems Gr: 8 & 10 M8 – M24 YesTel-Screw Products Gr: 8, 10 & 12 DIN 934 M16 – M36 YesWLS Fastener Manufacturing Co. cc MS/HT M8 – M64 YesHex Long OS Nuts Bolt Fast MS M8 – M20 YesRawlplug South Africa MS SEE WEBSITE: www.rawlplug.co.za M8 – M16 YesTel-Screw Products MS/HT TSP M8 – M48 YesWLS Fastener Manufacturing Co. cc MS M8 – M36 YesShear Nuts or Bolt Fast MS M8 – M20 YesAnti-vandal Nuts Impala Bolt & Nut MS YesNew Aloe Fastening Systems MS M8 – M24 YesRawlplug South Africa MS SEE WEBSITE: www.rawlplug.co.za M8 – M16 Yes YesTel-Screw Products MS/HT M8 – M48 Yes YesWLS Fastener Manufacturing Co. cc MS M8 – M24 YesFlanged Nuts Bolt Fast MS M8 – M10 YesNew Aloe Fastening Systems MS/HT M8 – M100 YesTel-Screw Products HT/MS M8 – M36 YesWLS Fastener Manufacturing Co. cc MS M8 – M16 YesWASHERSThru Hardened Bolt Fast Gr: 8 M8 – M48 YesWashers New Aloe Fastening Systems Gr: 8 M8 – M48 YesTel-Screw Products DIN 6916 M10 – M64 YesWLS Fastener Manufacturing Co. cc M8 – M36 YesFlat Washers Bolt Fast MS M8 – M64 YesImpala Bolt & Nut DIN 120/125 M8 – M30 YesNew Aloe Fastening Systems MS M8 – M64Tel-Screw Products MS DIN 120/125 M8 – M76 YesWLS Fastener Manufacturing Co. cc MS M8 – M76 YesHOT DIPGALVANIZEDEX STOCK4 Hot Dip Galvanizing Today Volume 7 Issue 1 2010

FastenersTYPE OFFASTENERCOMPANY STEEL GRADE SPECIFICATION SPECIFICATIONAVAILABLESIZESHOT DIPGALVANIZEDTO ORDERWASHERS continuedSquare Flat Bolt Fast MS M12 YesWashers New Aloe Fastening Systems MS M8 – M30 Yes YesTel-Screw Products Specially manufactured to order M8 – M76 Yes YesWLS Fastener Manufacturing Co. cc MS M8 – M30 YesSquare Curved Tel-Screw Products Specially manufactured to order M6 – M76 Yes YesWashersSpring Washers Bolt Fast M8 – M52 YesImpala Bolt & Nut DIN 127 M8 – M30 YesNew Aloe Fastening Systems M8 – M52 YesTel-Screw Products DIN 127 M8 – M64 YesWLS Fastener Manufacturing Co. cc M8 – M36 YesBOLTS AND SCREWSHex Head Screws Bolt Fast MS/Gr: 8 & 10 M8 – M42 YesCBC Fasteners MS DIN 558 ISO 4018 M18 – M30 Yes YesCBC Fasteners Gr: 8.8/10.9 DIN 933 ISO 4017 M8 – M30 Yes YesImpala Bolt & Nut MS DIN 658 M8 – M24 YesImpala Bolt & Nut MS/Gr: 8.8 DIN 933 M8 – M30 Yes YesNew Aloe Fastening Systems MS/Gr: 8 & 10 M8 – M30 YesRawlplug South Africa MS DIN 933 SEE WEBSITE: www.rawlplug.co.za M8 – M12 YesTel-Screw Products MS/Gr: 8.8 M8 – M39 Yes YesWLS Fastener Manufacturing Co. cc MS/HT M8 – M36 YesHex Head Bolts Bolt Fast MS M6 – M8 Yesand OS Nuts CBC Fasteners MS DIN 601 SABS 135 M8 – M30 Yes YesImpala Bolt & Nut MS M8 – M30 Yes YesTel-Screw Products MS/HT DIN 601 Lay – 520 M8 – M39 Yes YesWLS Fastener Manufacturing Co. cc MS M8 – M36 YesHOT DIPGALVANIZEDEX STOCKcontinued on page 6...Volume 6 Issue 4 2009 Hot Dip Galvanizing Today 5

FastenersTYPE OFFASTENERCOMPANY STEEL GRADE SPECIFICATION SPECIFICATIONBOLTS AND SCREWS continuedAVAILABLESIZESHOT DIPGALVANIZEDTO ORDERHex Head Bolts Bolt Fast MS/Gr: 8 & 10 M8 – M52 Yesand OS Nuts CBC Fasteners Gr: 8.8/10.9 DIN 931 ISO 4014 M8 – M30 Yes Yes(High tensile)Impala Bolt & Nut Gr: 8.8 DIN 931 M8 – M30 Yes YesWLS Fastener Manufacturing Co. cc HT M8 – M36 YesLarge Dia Bolts Bolt Fast Gr: 8 M30 – M76 Yes& OS Nuts New Aloe Fastening Systems Gr: 8 M30 – M42 YesTel-Screw Products Gr: MS/8.8 M36 – M76 YesWLS Fastener Manufacturing Co. cc MS/HT M39 – M76 YesHOT DIPGALVANIZEDEX STOCKCup Head Square Bolt Fast MS M8 – M30 YesNeck Bolts & OS CBC Fasteners MS SABS 1143 M8 – M20 Yes SelectedNutsImpala Bolt & Nut MS DIN 603 M8 – M16 Yes Certain sizesNew Aloe Fastening Systems MS M8 – M16 YesRawlplug South Africa MS DIN 603 SEE WEBSITE: www.rawlplug.co.za M8 – M12 YesTel-Screw Products MS SABS1143/DIN 603 M8 – M30 Yes YesWLS Fastener Manufacturing Co. cc MS M8 – M20 YesC/Sunk Square Bolt Fast MS M10 – M24 YesNeck Bolts & OS CBC Fasteners MS SABS 1143 M10 – M20 YesNutsImpala Bolt & Nut MS DIN 605 M10 – M16 YesNew Aloe Fastening Systems MS M10 – M24 YesTel-Screw Products MS/HT SABS 1143 M8 – M30 Yes YesWLS Fastener Manufacturing Co. cc MS M10 – M20 YesC/Sunk Nib Bolts Bolt Fast MS M10 – M24 Yes& OS Nuts CBC Fasteners MS SABS 1143 M12 – M24 YesImpala Bolt & Nut MS DIN 604 M10 – M20 YesTel-Screw Products MS SABS 1143 M8 – M24 YesWLS Fastener Manufacturing Co. cc MS M12 – M24 YesFriction Grip Bolts CBC Fasteners Gr: 8.8S/10.9 EN 14399 M16 – M30 Yes& Nuts CBC Fasteners Gr: 8.8S/10.9S SABS 1282 ISO 7411 M12 – M30 YesImpala Bolt & Nut Gr. 8.8S/10.9S M12 – M30 Yes YesS.A. Bolt Manufacturers Gr: 8.8/10.9S M12 – M30 YesHex Socket Bolt Fast MS M8 – M39 YesC/Sunk New Aloe Fastening Systems Gr: 10.9/12.9 M8 – M30 YesHead ScrewsS.A. Bolt Manufacturers Gr: 10.9/12.9 M8 – M48 YesWLS Fastener Manufacturing Co. cc HT M8 – M24 YesLockbolts Impala Bolt & Nut Pins & Collars 1 /2 ” – 7 /8 ” 8.8 Pins/6.8 Collars 1/2 ” - 7 /8 ” (imperial) YesNew Aloe Fastening Systems 8.8 Pins/6.8 Collars M8 – M20 YesS.A. Bolt Manufacturers 8.8 Pins/6.8 Collars 1/2 ” - 7 /8 ” (imperial) YesPigtails – 1 & New Aloe Fastening Systems MS/HT M8 – M241 1 /2 Turn Tel-Screw Products MS/HT M8 – M76 Yes YesWLS Fastener Manufacturing Co. cc MS M8 – M24 Yes3m – Threaded Bolt Fast MS/Gr: 8 M8 – M30 YesRod CBC Fasteners MS DIN 975 Various diameters YesImpala Bolt & Nut MS/HT DIN 975 M8 – M24 YesNew Aloe Fastening Systems MS/Gr: 8 M8 – M30 YesTel-Screw Products MS/HT M8 – M76 Yes YesWLS Fastener Manufacturing Co. cc MS M8 – M36 Yes1m – Threaded Bolt Fast MS/Gr: 8 & 10 M8 – M52 YesRod CBC Fasteners MS DIN 975 Various diameters Yes YesImpala Bolt & Nut MS/HT DIN 975 M8 – M24 Yes SelectedNew Aloe Fastening Systems MS/Gr: 8 M8 – M52 YesRawlplug South Africa HT SEE WEBSITE: www.rawlplug.co.za M8 –M30 YesTel-Screw Products MS/HT M8 – M36 Yes YesWLS Fastener Manufacturing Co. cc MS M8 – M36 YesHD Bolts Bolt Fast MS/EN8 M8 – M72 Yes(Foundation Bolts) Impala Bolt & Nut M/S 350WA M8 – M72 Yes& OS NutsNew Aloe Fastening Systems MS/EN8 M12 – M36 YesRawlplug South Africa MS/HT SEE WEBSITE: www.rawlplug.co.za M8 – M36 YesTel-Screw Products MS/HT M8 – M72 Yes YesWLS Fastener Manufacturing Co. cc MS M8 – M72 Yes6 Hot Dip Galvanizing Today Volume 7 Issue 1 2010

FastenersTYPE OFFASTENERCOMPANY STEEL GRADE SPECIFICATION SPECIFICATIONCONCRETE ANCHOR BOLTSAVAILABLESIZESRawlbolts Rawlplug South Africa 5.8 International M8 – M24 YesHOT DIPGALVANIZEDTO ORDERSPT Throughbolts Rawlplug South Africa EU M8 – M20 Yes YesR-Cas Chemical Rawlplug South Africa 5.8/HT BBA M8 – M30 Yes YesSpin-in AnchorsR-Hac Chemical Rawlplug South Africa 5.8/HT BBA M8 – M30 Yes YesHammer-in AnchorsR-Kem Chemical Rawlplug South Africa 5.8/HT BBA M8 – M30 Yes YesCartridge SystemR-Ker Chemical Rawlplug South Africa 5.8/HT EU M8 – M30 Yes YesCartridge SystemR-KeX Chemical Rawlplug South Africa 5.8/HTSEE WEBSITE:www.rawlplug.co.za BBA M8 – M30 Yes YesSlow CureCartridge SystemExpress Anchors Rawlplug South Africa 5.8/HT EU M8 – M20 Yes YesRawl Kemfix Rawlplug South Africa 5.8/HT BBA M8 – M30 Yes YesChemical AnchorStuds – for use withall chemical anchoring(capsule and/orcartridge systems)Chemical Anchors Bolt Fast MS/EN8 Various Yeswith Studs New Aloe Fastening Systems MS/EN8 Various YesRawlplug South Africa 5.8/HT SEE WEBSITE: www.rawlplug.co.za BBA M8 – M30 Yes YesTel-Screw Products MS/HT M8 – M36 Yes YesWLS Fastener Manufacturing Co. cc EN8 M8 – M30 Yes YesHOT DIPGALVANIZEDEX STOCKcontinued on page 8...Volume 7 Issue 1 2010 Hot Dip Galvanizing Today 7

FastenersTYPE OFFASTENERCOMPANY STEEL GRADE SPECIFICATION SPECIFICATIONCONCRETE ANCHOR BOLTS continuedAVAILABLESIZESConcrete Bolt Fast MS M8 – M24 YesExpansion Bolts Bolt Fast - single collar wedge type anchor M8 – M30 YesHOT DIPGALVANIZEDTO ORDERBolt Fast - nail plug hammer in anchors M8 YesBolt Fast - mortar cartridge system 300, 345 & 380mm YesBolt Fast - double collar anchors M8 – M30 YesNew Aloe Fastening Systems 5.8/EN8 M10 – M30 YesMISCELLANEOUSType 17 Self New Aloe Fastening Systems 1022 #8 – #14 YesTapping Screws * – also applicableNew Aloe Fastening Systems 1022 #10 & #14 YesGutter or New Aloe Fastening Systems 1006 M8 x 12 to 75mm YesVeranda BoltsSelf Drilling Bolt Fast MS YesScrewsSDS can be successfully hot dip galvanized but due to a slight threadRawlplug South Africa MS Yessoftening a smaller diameter pilot hole must first be drilled. *WLS Fastener Manufacturing Co. cc MS YesCast-In Lifting Rawlplug South Africa 5.8HT BBA M10 – M24 YesSocketsSEE WEBSITE:www.rawlplug.co.zaInsulation Fixings Rawlplug South Africa BBA Various YesSPECIAL FASTENERSCountersunk Bolt Fast MS M8 – M24 YesMachine Screws Tel-Screw Products MS/HT DIN 963 & 965 M8 – M36 Yes YesWLS Fastener Manufacturing Co. cc MS/HT M8 – M36 YesRound U-Bolts Bolt Fast MS M8 – M72 YesNew Aloe Fastening Systems MS M8 – M30 YesTel-Screw Products MS/HT M8 – M76 Yes YesTel-Screw Products HT M8 – M76 YesSquare U-Bolts Bolt Fast MS M8 – M76 YesNew Aloe Fastening Systems MS/HT Various YesTel-Screw Products MS/HT M8 – M76 YesWLS Fastener Manufacturing Co. cc MS/HT M8 – M36 YesTV U- Bolts Bolt Fast MS M8 – M76 YesTel-Screw Products MS/HT M8 – M76 Yes YesHook Bolts Bolt Fast MS M8 – M76 YesNew Aloe Fastening Systems MS M8 – M10 YesRawlplug South Africa MS SEE WEBSITE: www.rawlplug.co.za M8 – M12 YesTel-Screw Products MS/HT M8 – M76 Yes YesWLS Fastener Manufacturing Co. cc MS/HT M8 – M76 YesChannel Bolts Bolt Fast MS M8 – M76 YesNew Aloe Fastening Systems MS M8 – M12 YesTel-Screw Products MS/HT M8 – M76 YesWLS Fastener Manufacturing Co. cc MS/HT M8 – M76 YesJ-Bolts Bolt Fast MS M8 – M76 YesNew Aloe Fastening Systems MS M8 – M12 YesRawlplug South Africa MS SEE WEBSITE: www.rawlplug.co.za M8 – M12 YesTel-Screw Products MS/HT M8 – M76 YesWLS Fastener Manufacturing Co. cc MS/HT M8 – M76 YesEye-Bolts New Aloe Fastening Systems MS M8 – M36 YesRawlplug South Africa MS SEE WEBSITE: www.rawlplug.co.za M8 – M16 YesTel-Screw Products MS/HT M8 – M76 Yes YesWLS Fastener Manufacturing Co. cc MS M8 – M76 YesStraining New Aloe Fastening Systems MS/HT M8 – M30 YesEye-Bolts Tel-Screw Products MS/HT M8 – M76 Yes YesWLS Fastener Manufacturing Co. cc MS M8 – M24 YesLinked Eye Bolts Bolt Fast MS/HT M8 – M76 YesLinked Eye Nuts Bolt Fast MS/HT M8 – M76 YesRawlplug South Africa SEE WEBSITE: www.rawlplug.co.za M8 – M16 YesHOT DIPGALVANIZEDEX STOCK8 Hot Dip Galvanizing Today Volume 7 Issue 1 2010

FastenersTYPE OFFASTENERCOMPANY STEEL GRADE SPECIFICATION SPECIFICATIONSPECIAL FASTENERS continuedAVAILABLESIZESLinked Eye Rods Bolt Fast MS/HT M8 – M76 YesTel-Screw Products MS/HT M8 – M76 YesForged Eyebolts Rawlplug South Africa SEE WEBSITE: www.rawlplug.co.za M8 – M16 YesTel-Screw Products MS/HT M8 – M30 YesWelded Eyebolts Rawlplug South Africa MS SEE WEBSITE: www.rawlplug.co.za M8 – M16 YesScaffold Rings Bolt Fast MS M8 – M16 YesRawlplug South Africa MS SEE WEBSITE: www.rawlplug.co.za M8 – M16 YesThreaded Studs Bolt Fast MS/EN8 M8 – M76 YesNew Aloe Fastening Systems MS/EN8 M8 – M30 YesRawlplug South Africa MS/HT SEE WEBSITE: www.rawlplug.co.za M8 – M30 YesTel-Screw Products MS/HT M8 – M76 YesHOT DIPGALVANIZEDTO ORDERWLS Fastener Manufacturing Co. cc MS/HT M8 – M76 Yes YesTie Rods Bolt Fast MS/EN8 M8 – M76 YesNew Aloe Fastening Systems MS/EN8 M8 – M36 YesTel-Screw Products MS/HT M8 – M76 YesWLS Fastener Manufacturing Co. cc MS/HT M8 – M76 YesOther specials Bolt Fast Any special manufacturing YesImpala Bolt & Nut All specials relating to fasteners M8 – M72 YesRawlplug South Africa Special application chemical and/or mechanical anchor bolts as required YesTel-Screw Products Specials manufactured to order M8 – M76 YesWLS Fastener Manufacturing Co. cc MS/HT M8 – M76 YesDomed Head or New Aloe Fastening Systems MS/HT M8 – M16 YesCap Nuts Tel-Screw Products MS/HT DIN 1587 M8 – M76 YesWLS Fastener Manufacturing Co. cc MS/HT M8 – M36 YesHOT DIPGALVANIZEDEX STOCKcontinued on page 10...Volume 6 Issue 3 2009 Hot Dip Galvanizing Today 9

FastenersHOT DIP HOT DIPTYPE OFAVAILABLECOMPANY STEEL GRADE SPECIFICATION SPECIFICATIONGALVANIZED GALVANIZEDFASTENERSIZESTO ORDER EX STOCKSPECIAL FASTENERS continuedHex Coach Screws Bolt Fast MS M6 – M20 YesNew Aloe Fastening Systems MSHCS can be successfully hot dip galvanized but due to aslight thread softening a smaller diameter pilot holeM6 – M12 YesRawlplug South Africa MS – DIN 7976 must first be drilled.M5 – M12 YesTel-Screw Products MS – DIN 7976 M6 – M12 Yes YesOS – Over Sized / MS – Mild Steel / HT – High TensileTHE ABOVE FASTENER AVAILABILITY MATRIX IS NOT NECESSARILY COMPREHENSIVE AND TOTALLY REPRESENTATIVE OF THE FASTENER SUPPLY INDUSTRY BUT INCLUDES PARTICIPATINGMANUFACTURERS AND STOCKISTS.THE ASSOCIATION ASSUMES THAT ALL PARTICIPATING COMPANIES IN THE MATRIX, DO IN FACT STOCK OR ORDER HOT DIP GALVANIZED FASTENERS WHEN REQUESTED TO DO SO. THEASSOCIATION THEREFORE, EXCLUDES ITSELF FROM THE RESPONSIBILITY OF ENSURING THAT ALL FASTENERS OFFERED WILL IN FACT BE HOT DIP GALVANIZED, BY THESE COMPANIES.SHOULD ANYONE USING THIS MATRIX FIND INACCURACIES OR ERRORS OR HAVE ADDITIONAL SUGGESTIONS, KINDLY CONTACT THE EDITOR.PARTICIPATING FASTENER SUPPLIERS CONTACT DETAILSCOMPANY TELEPHONE EMAIL WEBSITEBolt Fast 021 505 1000 ShaunD@boltfast.co.za www.boltfast.co.zaCBC Fasteners 011 767 0000 tech@cbc.co.za www.cbc.co.zaImpala Bolt & Nut 011 824 3925 adiamond@impalasa.co.za www.impalabolt.co.zaNew Aloe Fastening Systems 011 835 2171 newaloef@iburst.co.za –Rawlplug 011 894 7147 rmuller@infodoor.co.za www.rawlplug.co.zaSA Bolt Manufacturers 011 814 2240 info@sabolt.co.za www.sabolt.co.zaTel-Screw Products (Pty) Ltd 011 898 3200 info@telscrew.co.za www.telscrew.co.zaWLS Fasteners 011 882 1150 wlsandrew@telkomsa.net www.kalm.dePROUD OF OUR PRODUCTWe understand theimportance of applicationand environment and willhelp you select the rightfasteners for the job.Our range of finishedproducts are soldthroughout South Africaand neighbouring states.BigSmallenoughenoughtotocareperformTEL-SCREW PRODUCTS (PTY) LTDManufacturers of Special Bolts and Nutsto Customer SpecificationsSpecialising in U Eye J-Foundation and Straining Bolts/StudsAll types of Screw Cutting and Thread RollingCold Heading from M6 x 12 to M16 x 125Hot Forging from M8 to M36 x 1000Knurling, Special Nuts, Forging, Machining from Ø6mm to Ø250mmElectric Line Products, Tool Room Facilities1373 CBT (011) 868 3408P.O. Box 38787 Booysens 2016 JohannesburgTel.: (011) 835-2171/2/3Fax: (011) 835-1571Email: aloe@icon.co.zaMobile: 082 414 5067Manufacturers of quality fasteners forroofing and cladding since 1993NewAloeFastening SystemsP.O. Box 714 Benoni 150025 Lorna Road, Muswelldale, Boksburg North 1460Tel.: +27 (011) 917-9710/4/5 Fax: +27 (011) 892-5132/1338Cell No.: 082 937 4609E-Mail: info@telscrew.co.za Website: www.telscrew.co.zaI S O 9 0 0 1SALES HOTLINE: (011) 898-3200Small enough to care – Big enough to perform10 Hot Dip Galvanizing Today Volume 7 Issue 1 2010

FastenersSANS 1273 – settinga new standard forroofing fastenersAfter many years under revision, amendments to the SANS 1273 standard“Fasteners for roof and wall coverings in the form of sheeting” have been finalised andthe standard was published late in 2009.The main changes to the revised standard relate to the corrosion resistancerequirements of roofing fasteners and the introduction of self drilling screwsand bonded roofing washers which were not incorporated in the old standard.The amended standard specifies the corrosion resistance and mechanicalproperties of the following fastener types:◆◆◆◆◆◆◆Hook bolts; Channel bolts; “U” bolts and “J” boltsSlotted mushroom head roofing bolts (also known as gutter bolts orveranda bolts)Slotted mushroom head roofing screws with rolled threadMushroom head drive screws with rolled threadCross recessed pan head self tapping roofing screwIndented hexagon head self tapping roofing screwSelf drilling screws for steel or timberCorrosion resistance and protective coatingsIrrespective of what fastener type is used, the appropriate protective coatingon the fastener must be determined by identifying the corrosivecharacteristics of the environment in which the fasteners will be used,according to the ISO 9223 classification (see table below).Corrosion resistance classAtmosphere of intended use1 General use in internal application2 General use in other than external applicationsbut where significant levels of condensation occur.3 External use in mild, moderate industrial ormarine environments4 External use in severe marine and industrialenvironmentsAt all times the corrosion resistance of the roofing fastener must equal orexceed the corrosion resistance of the roof sheeting. This will ensure that theroofing fasteners will not become “the weakest link” in the roofing system (asthey have so often been in the past).Once the correct corrosion resistance class has been identified the Standardspecifies the following plating / coating requirements:continued on page 12...Volume 7 Issue 1 2010 Hot Dip Galvanizing Today 11

FastenersAll Class 2 fasteners:Coating Type Minimum local metallic Passivationcoating thicknessElectroplated zinc 12μm Type CMechanically platedzinc 17μm Type CMechanically platedzinc/tin 12μm Type CAll Class 3 fasteners:Coating TypeMinimum local metallic Passivationcoating thicknessExamples of Class 2 electroplated screws.Electroplated zinc 30μm Type AHot dip galvanized 30μm Type AMechanically platedzinc 40μm Type AMechanically platedzinc/tin 25μm Type AAll Class 4 fasteners:Coating Type Minimum local metallic Passivationcoating thicknessHot dip galvanized 50μm Type A: Examples of Class 3 mechanically plated screws.Mechanically platedzinc/tin 45μm Type AIn addition to the plating / coating types and thicknesseslisted above, fasteners can be protected with a sheradized zinccoating EXCEPT for self tapping roofing screws and selfdrilling roofing screws. These cannot be sheradized as thecooling process which forms part of the sheradizing processhas a detrimental effect on the drilling and tappingperformance of the screws.Where the fastener can be hot dip galvanized, this can beapplied according to SANS 121 (ISO 1461).The big advantage of the classification of the environment andassociated plating / coating specifications is that the expectedlife span of the fasteners can be calculated.Example:An electroplated self drilling screw (Class 2) with 12µm zinc isused in a rural environment with low corrosivity (zinc lossmaximum 0.7µm per year as per ISO9223). The expected lifespan of the fastener is 12µm ÷ 0.7µm = 17.14 years.If the same fastener is used in a Class 3 moderateindustrial environment (zinc loss maximum 2.1µm zincper year as per ISO9223) the expected life span of thefastener will only be 12µm ÷ 2.1µm = 5.7 years. Thiswould clearly be an unacceptable situation and a Class 3Examples of Class 4 mechanically plated screws.fastener which would offer between 14 to 19 yearscorrosion protection should be used.The short comings of the old SABS 1273 standard made itvirtually impossible for architects and specifiers to specifyroofing fasteners according to a South African standard. Selfdrilling screws are by far the most commonly fasteners usedto fix roof sheeting and cladding on commercial, industrialand other large projects.As these screws were not specified in the old SABS 1273standard, the quality and especially the corrosion protectionof the self drilling screws used in South Africa was of a verypoor quality. It is hoped that the revised standard will go along way in ensuring that the correct type of fasteners and thecorrect corrosion protection will be specified and that thestandard will be embraced by the roofing industry.12 Hot Dip Galvanizing Today Volume 7 Issue 1 2010

Continuous Wire GalvanizingThe introduction of Galfan coated wireat Cape Gate, VanderbijlparkCape Gate added Galfan coated wireto its product range in 2007. They havethe capacity to produce twenty wiresat a time, and the diameters rangebetween 1.80mm and 4.00mm, withcoating weights of anything from145gm 2 to 275gm 2 depending on thecustomer’s requirements. Some of theproducts that Galfan coated wire canbe used to manufacture are Gabions,Welded Mesh and Chain Link. It canalso be used for any application wherebetter corrosion properties thanordinary galvanized wire is required.The origin of GalfanThe name Galfan originated in July1981 at a business meeting held atthe Ziegler S.A. factory in Mouzon,France. At the time J.L.Pagniez wasthe head of the “French Coated SteelInformation Centre,” and he used thetwo French words “GalvanisationFantastique,” to describe the product.These two words were laterabbreviated to the first three lettersof each word, which when combinedform the name Galfan.Galfan is a registered trade mark anda licensed product. It is producedaccording to stringent regulationsand annual royalties are payable tothe Galfan Technology Centre at theUniversity of Pittsburgh in the UnitedStates. If the criteria laid down bythis institution are not met then theproduct is not licensed and cannotbe sold under the Galfan trademark.Composition and qualities ofGalfanThe molten Galfan mixture consists ofabout 95% Zinc and 5% Aluminium.About 0.05% of rare earth mischmetalsconsisting of a combination ofLanthanum and Cerium are added tothe molten alloy, to improve the fluidityand wetting properties. Galfan coatedwire has superior corrosion resistanceto galvanized wire because of thepassive corrosion preventativeproperties of aluminium, combined withthe active and passive properties ofcontinued on page 14...CAPE GATE(PTY) LTDTel: 016 980 2121 Web: www.capegate.co.za Fax: 016 988 3421Cape Gate is a fully integrated producer ofsteel, wire and wire products with our ownsource of raw materials.All our products meet recognisedinternational standards and are sold worldwide in a secured and well establishedgrowing customer base.We serve....● Mining● Agriculture● Industry● Commerce● Civil engineering and construction● Domestic and foreignmarketsVolume 7 Issue 1 2010 Hot Dip Galvanizing Today 13

Continuous Wire Galvanizingzinc, though its cosmetic appearancetends to dull and grey quicker than zinccoated wire. Galfan coated wire is moreductile than normal galvanized wire andtherefore can be redrawn easier andplaced under more strenuous twistingand bending.The production processThe conventional method ofmanufacturing ordinary galvanized wireis done by pulling wires through acontinuous line using motorised takeups.The wire is pulled from thepayoffs, through an in line annealingprocess, then an in line acid cleaningand fluxing tank, and finally an in linezinc bath containing molten zinc. Awiping system is mounted at the exit ofthe zinc bath to control the coatingthickness on the wires.Looking back at the zinc bath from the Galfan bath..A similar method is used tomanufacture Galfan, though doubledipping is employed, because normalgalvanizing fluxes, such as zincammonium chloride, are notcompatible to molten Galfan. Toovercome this problem, the first dip isdone as in an ordinary wire galvanizingprocess, with a normal galvanizing flux.The wires are pad wiped to form alightly galvanized coating, thus forminga zinc-iron alloy layer, with a very thinlayer of free zinc on the surface.In the second dip, the lightly galvanizedwires are pulled through the Galfantank. The free zinc melts away from thesurface of the wires and the alloy layerchanges to an aluminium-zinc-iron layerthus bonding the Galfan to the surfaceof the wires. The excess Galfan isremoved from the wires by nitrogen jetwiping, in accordance with thecustomer’s requirements.View of Galfan bath and zinc bath from the side.The concentration of zinc, aluminiumand mischmetals in the Galfan tankmust be carefully monitored by regularanalysis, to determine if the productmeets the license specifications laiddown by the Galfan Technology Centre.By I.R.ZoellnerGalfan take-ups.14 Hot Dip Galvanizing Today Volume 7 Issue 1 2010

Continuous Wire GalvanizingSANS 675:2009Zinc coatedfencing wire, hasbeen revisedWe have outlined the differences, particularly those that arerelated to coating thickness and hence coating life, between the1999 and 2009 editions. Also included from the 2009 version isAnnex A “Notes to purchasers”.ScopeThis standard specifies the characteristics of drawn steel wire,zinc-coated by the hot dip process, to be used for line fencingor barbed fencing wire for general purposes. (The scope for thetwo editions remains the same).Tensile strengthMass of coating per unit area.SANS 675:1993 (Old)1 2 3Nominal diameter of Minimum mass Approximatezinc coated wire (mm) per unit area of equivalent averagezinc coating (g/m 2 ) coating thickness (µm)1.20 – 1.50 215 301.51 – 1.80 230 321.81 – 2.20 245 342.21 – 2.50 260 362.51 – 3.50 275 383.51 – 5.00 290 40Table 3: SANS 675:2009 (New)1 2 3Diameter Mass of coating Approximated (see annex A) g/m 2 equivalent averagemm coating thickness µmSANS 675:1993 (Old)SANS 675:2009 (New)Class #1 2 1 2Grade of steel Tensile strength Grade of steel Tensile strengthMpa Mpa MpaMild steel (MS) 350 – 575 Mild steel (MS) 350 – 575High tensile (HT) 1 050 min High tensile (HT) 950 minVery high tensileVery high tensile(VHT) 1 400 min (VHT) 1 250 minSANS 675:2009 Annex AA.1 The following requirements shall be specified in tenderinvitations and in each order or contract:a) The grade of the line wire(s) (see 4.1) and, in the case ofbarbed wire, of the wire used for barbs;b) Whether information about the steel manufacturingprocess is required;c) The nominal diameter(s) of the zinc coated wire (see 4.6)d) The type of wire (line or barbed wire) and in the case ofbarbed wire, the pattern (see 4.9);e) The length of the barbs if other than as specified (see4.9.3.4);f) The spacing between the barb units if other than asspecified (see 4.9.3.5);g) The mass of the wire on a reel or in a coil (see 5.2.1 and5.2.2);h) Mass of coating (see table 3).A.2 The following requirement shall be agreed upon betweenthe manufacturer and the purchaser: whether the steelmanufacturing process is to be left to the discretion of themanufacturer (see 4.2).Editor’s Comment: Figures in parenthesis refer to specification.A D A D0.15 ≤ d < 0.20 - 10 - 1.420.20 ≤ d < 0.25 30 15 4.28 2.140.25 ≤ d < 0.32 45 15 6.42 2.140.32 ≤ d < 0.40 60 15 8.57 2.140.40 ≤ d < 0.50 85 15 12.14 2.140.50 ≤ d < 0.60 100 20 14.29 2.860.60 ≤ d < 0.70 115 20 16.42 2.860.70 ≤ d < 0.80 130 20 18.57 2.860.80 ≤ d < 0.90 145 20 20.71 2.860.90 ≤ d < 1.00 155 25 22.14 3.571.00 ≤ d < 1.20 165 25 23.57 3.571.20 ≤ d < 1.40 180 25 25.71 3.571.40 ≤ d < 1.65 195 30 27.86 4.291.65 ≤ d < 1.85 205 30 29.29 4.291.85 ≤ d < 2.15 215 40 30.71 5.712.15 ≤ d < 2.50 230 45 32.86 6.432.50 ≤ d < 2.80 245 45 32.86 6.432.80 ≤ d < 3.20 255 50 36.43 7.143.20 ≤ d < 3.80 265 60 37.86 8.573.80 ≤ d < 4.40 275 60 39.29 8.574.40 ≤ d < 5.20 280 70 40.00 10.005.20 ≤ d < 8.20 290 80 41.43 11.438.20 ≤ d

2010 Soccer World Cup StadiaReviewing the corrosion protection provided byhot dip galvanizing of the stadia for the 2010Soccer World CupDuring the construction of the four main stadia, Cape Town, Port Elizabeth, Moses Mabhida and Soccer City - Johannesburg, we visited the stadiums for anumber of reasons. While there were some issues relating to coating quality (many of which were as a result of pre-conceived misconceptions), it wasenlightening to see how the designers and fabricators have used the modular concept in many of the handrail sections, to good effect. Components have beenfabricated, taking into account the size of the local galvanizing baths, minimising potential repair on site, ease of installation by handling and fixing, etc. Manyof the connection and holding down fasteners were also hot dip galvanized. We did however, observe in a number of instances, the undesirable use of zincspray paint for small reparation work and a number of zinc electroplated fasteners.MOSES MABHIDA STADIUMcontinued on page 18...Volume 7 Issue 1 2010 Hot Dip Galvanizing Today 17

2010 Soccer World Cup StadiaCAPE TOWN STADIUM18 Hot Dip Galvanizing Today Volume 7 Issue 1 2010

2010 Soccer World Cup StadiaPORT ELIZABETH STADIUMcontinued on page 20...Volume 7 Issue 1 2010 Hot Dip Galvanizing Today 19

2010 Soccer World Cup StadiaSOCCER CITY20 Hot Dip Galvanizing Today Volume 7 Issue 1 2010

2010 Soccer World Cup StadiaInnovative use of Mentis grating atSoccer CityTypically used in horizontal industrial and mining flooringapplications, Gripweld grating is being used as part of the‘Pit of Fire’ at Soccer City Stadium, south of Johannesburg.What makes this application so unusual is that the gratingwill be placed within a framework, produced by SpiralEngineering, in a vertical orientation. Some 1 100 runningmetres of B-100 Gripweld grating has been supplied byAndrew Mentis to Spiral Engineering.The design of the stadium is based on the calabash orAfrican pot which is constructed on a raised podium,referred to as the ‘pit of fire’, to lend the impression of thepot being fired. The ‘fiery pit’ demarcates the security andturnstiles line, separating the outer areas and the secureinner areas.“As a result of our reputation of producing architecturallypleasing, functional objects, we were selected byconstruction contractor Grinaker-LTA to design andmanufacture a hot dip galvanized framework that wouldhave both aesthetic appeal and uncompromising strength,”Les Steel-Smith, director at Spiral Engineering, says.Gripweld product was made that much easier by workingwith a reputable supplier,” Steel-Smith adds.The grating was selected over traditional fencing materialbecause of its integral strength and inflexibility. Steel-Smith points out that in order to eliminate unauthorisedremoval of panels, Spiral Engineering has used 5 000tamper-proof bolts and sheer nuts to secure the Gripweldpanels into the framework.“Probably our biggest obstacle is that each panel was adifferent size so we needed to first produce a mock-up ofour requirements, then get Andrew Mentis to produce exactsizing for the 260 double gates and 180 single gates,” Steel-Smith says.The contract was awarded at the end of 2008, with supplyof the panels having commenced in February and thecomplete project delivered by Spiral Engineering at the endof 2009.“In essence, the framework with incorporated grating, formsan architectural column, complete with a roof and entailsclipping the panels into rectangular tubular frameworkengineered and manufactured by ourselves and hot dipgalvanized locally,” Steel-Smith explains.“The Andrew Mentis B-100 Gripweld was specified by thecontractor. We have built up a very close workingrelationship with Andrew Mentis over the years so thesuccessful incorporation of our conceptualisation and thePROPOSED FEATURES FOR 2010May/June (No 43):• Tubes, pipes and scaffolding• Masts and poles• Water storage• Heat exchangers and cooling fansAugust/September (No 44):• Awards• Cable ladders and traysNovember/December (No 45):• The world of hot dip galvanizing around us• Sustainability of the industryNOTE: FEATURES MAY BE SUBJECT TO CHANGEVolume 7 Issue 1 2010 Hot Dip Galvanizing Today 21

Each accepted nomination must comply with the following:■■■Each winning project should have the potential to be used as a case study in thefutureEvery accepted submission should add to market developmentAwards are specifically aimed at market developmentThe submission process for 2010 is as follows:1. Call for Nominations (closing date is 31 March 2010).Please complete the nomination form and submit, together with photos and anoverview of the project, to the Association via e-mail or by hand.2. Screen Possible Projects for Consideration3. The Nominator / Project Team Owner will be responsible for the completion of thesubmission; however Association staff will be on hand to assist.4. The submission deadline is 28 May 2010. However, you may submit earlier.5. The submission will be made available on the website for peer review and comment.6. Assessment of Final Entries. The various categories will be agreed on.The Conditions of Entry are as follows:■ All nominations to be submitted to the HDGASA by 31 March 2010.■ All submissions to be submitted to the HDGASA by 28 May 2010.■ The Judge’s decision is final and no correspondence will be entered into.■ By submission of an entry, the nominator assumes responsibility for the accuracy ofall information and provides the HDGASA with assurance that permission has beenobtained and that the information and photos may be used in the magazine, on theAssociation’s website and for promotional purposes.■ Submissions to be completed according to template (available on website or onrequest).■ Only new submissions will be accepted, other than previous projects now qualifyingas a possible Vintage submission.■ The project or product must be complete before 28 May 2010 (deadline date forsubmissions). Please note that you may nominate it for consideration if it is notcomplete by 31 March 2010, but the project must be completed by 28 May 2010.Material to be submitted:■ A motivation as to why your project should be chosen as a winner is essential. Doesit have the WOW factor? Will it have an impact on the market by aiding developmentof the hot dip galvanizing industry? Is it a new application or difficult to galvanize?■ Technical information is extremely important. Motivation, numbers and facts willassist with the adjudication.■ The professional standard of the submission forms an integral part of the judgingcriteria.■ Submissions should include a minimum of 5 full colour photographs. If digitalphotographs are to be supplied, please ensure that they are taken at 300dpi forreproduction purposes.■ Kindly ensure that electronic copies of the digital photographs are supplied withentry.Please contact the Association for further details on (011) 456-7960 or hdgasa@icon.co.za

Education and TrainingThe new features for the Elcometer 456Coating Thickness GaugeIntroductionElcometer Limited has an updatedversion of perhaps the mostadvanced hand-held coatingthickness gauge available for generalcoating applications including themeasurement of hot dip galvanizing,the Elcometer 456 Coating ThicknessGauge.◆◆◆Improved Data ManagementSoftware: ElcoMaster Softwarewith reading upload, reportgenerator and data archivingcapability.Calibration Review: Checksettings without data storage.User Definable welcome screen:To personalise your gauge.Now with Bluetooth wirelesscommunications, the Elcometer 456Standard and Top versions have fullmenu-driven operation and graphicsdisplay, in 25 languages, with thecapability to measure on ferrousmetal substrates using a wide rangeof probe options. The gauge also hasprobe options for coatings on nonferrousmetals and the FNF probeoption allows dual operation withautomatic substrate determinationand display.The Elcometer 456 in the Basic,Standard and Top options also havemany new features:◆◆Choice of separate or integralprobe: integral probes offersingle hand operation; separateprobes offer flexibility of accessand thickness ranges.Simplified Menu Structure:Simple and extended menus.ElcoMaster SoftwareThe Elcometer 456 Standard and Topversions have memory for readings,which can be taken on site and thenuploaded to a PC running theElcoMaster Software. The softwaresupports Bluetooth communicationfor up to 7 different 456gauges at the same time and willalso support RS 232 communicationfor all gauges with this data outputformat.The 456 Standard version hasmemory formatted for a single batchwith up to 250 readings. The Topversion has memory capacity for upto a total of 40 000 readings in up to999 live batches. These batches canbe closed and re-opened to addfurther readings where the totalmemory consumption allows.ElcoMaster features include:Elcometer 456 Coating Thickness GaugesShowing the Measurement of a CoatedSurface, Bluetooth ® Operating with a PDA.◆◆◆◆◆Copy and paste reports into otherdocuments.Combination of reports in orderto easily compare differentbatches of data.E-mail reports directly fromElcoMaster.Assignment of batchidentification tags.Renaming of batches to clear theinspection batch.◆Calibration Lock: Preventsaccidental resetting.◆Creation of professional reportsin seconds.◆Wide range of standard reportsinclude:◆On-screen Help: Definitions ofscreen icons.◆Report export to spreadsheets, textfiles or save as PDF or JPEG files.• Individual measurementscontinued on page 24...Volume 7 Issue 1 2010 Hot Dip Galvanizing Today 23

Education and Training• Statistics• Histograms• Individual line or bar charts• Log normal• Pie charts◆ Fully customise reports using theElcoMaster report designertool.◆ Include company graphics andlogos on every report.◆ Combine batches to comparereadings or link batches togetherfrom different gauges into onecomprehensive inspection file.◆ Find feature to quickly locate aspecific file or batch.In addition a digital photograph canbe assigned to an individual batch ofdata, allowing the inspection area tobe shown in the reports on theassociated batches.ConclusionsMeasurement of coating thickness ismade simple and convenient by theuse of the Elcometer 456 CoatingThickness Gauge for inspectingcoatings in many differentapplications.The 456 family of gauges have ferrouscapability for coating on magneticmetals, such as steel, and a nonferrouscapability for non-conductivecoatings on non-ferrous metals, suchas stainless steel and aluminium.NOWWITH CPDPOINTSGalvanizersInspectors CourseHot dip galvanizing is one of the most widely used methods of protecting steelfrom corrosion. As a final step in the process, the hot dip galvanized coating isinspected for compliance with the appropriate specifications.This Galvanizers Inspectors Course has been designed to provide delegates with sufficient knowledge to test,inspect and interpret test results.Following the course and successful result in a three-part exam, the delegate will be issued with a certificate, andif required, registered as an approved HDGASA inspector. Registration will be confirmed on an annual basis.Successful inspectors will become Individual members of the Association for the year.The course is usually run from the Hot Dip Galvanizers Association in St Andrews, Bedfordview but from2009 it will be available in Cape Town. Bookings are limited to 10 people on a first-come-first-serve basis.COURSE CONTENT◆ Introduction to corrosion ◆ Understanding zinc coatings◆ Inspection before hot dip galvanizing ◆ Inspection after hot dip galvanizing◆ Quality assurance in coating applications.COURSE DURATIONThis is a 2-Day Course comprising lectures on the first day, a Plant Tour in the morning of the second day, and thequalifying examination in the afternoon.DATE AND TIMECourses commence at 08h00 sharp and end at 16h30. Lunch and refreshments will be provided. Comprehensivecourse notes can be collected from our offices two weeks before the course.Johannesburg:February 16 - 17; March 17 - 18; April 20 - 21; May 18 - 19; June 22 - 23; August 17 - 18; October 5 - 6 andNovember 23 - 24.Cape Town:May 11 - 12; September 7 - 8.COURSE COST AND PAYMENT TERMSR2 800.00 per person inclusive of VAT. Should you have 2 or more delegates from the same company, course costswill be R2 600.00 per person inclusive of VAT. Please note that payment is due on the first day of training. Chequesto be made payable to “Hot Dip Galvanizers Association SA”. Members qualify for a discount.SHOULD YOU BE INTERESTED, KINDLY CONTACT SASKIA SALVATORI ATTHE ASSOCIATION.NOTE: All professional Engineers, Technologists, Technicians and Certificated Engineers are required toachieve a certain number of points for Continuous Professional Development (CPD). By attending theAssociation's two day Coating Inspection Course, you will obtain 2 points (accredited by ECSA).ElcoMaster Software providespowerful tools for data analysis, datamanagement and reporting.For more information on theElcometer 456 Coating ThicknessGauges and the ElcoMasterSoftware contact the salesdepartment or visit our website at:www.elcometer.com.24 Hot Dip Galvanizing Today Volume 7 Issue 1 2010

Case HistoryNo. 19/2010Case HistoryNewlands Rugby Stadium – Railway StandThe applicationThe decision to buy the ground thestadium stands on was made by theWestern Province Rugby and FootballUnion in 1888. The first official matchat Newlands took place on 31 May1890 when Stellenbosch defeatedVillagers there in front of a crowd ofabout 2 400 people. The followingyear the stadium hosted its firstrugby test when the British Lionstoured South Africa.It wasn't until 1919 that the firstpermanent concrete stands wereerected on the grounds. Later, in1927, the new grandstand waserected and the field layout waschanged to run from North-South.Yet more changes came in 1931 whenthe South stand was also enlarged tomake it bigger.In the 1950s parts of a newgrandstand as well as South standwere completed, facilities such aslifts and a Presidential room wereadded, a fourth bay was added to thegrandstand, and an extension wasadded to the lower gallery.The 1970s saw the stadium changeonce again as the headquarters of SARugby moved to Newlands, andseveral stands including the EasternRailway Stand were built (1979) orrenovated, while the 1980s sawprivate suites and function roomserected on top of the North stands aswell as demolition of the old Southstand and inauguration of the newDanie Craven stand (also with privatesuites and function rooms). The1980s also saw 10 253 seats added tothe stadium.Between 1990 and 1995 the stadiumwas under constant renovation,adding technology, increasingcapacity, and upgrading facilities, aspart of a 3-phase redevelopment planin anticipation of the 1995 RugbyWorld Cup, when Newlands hostedthe opening match of thetournament.After the World Cup, developmentcontinued with severalredevelopment and expansionprojects to make the stadium moremodern and increase capacity.The stadium's name was changedseveral times by various sponsors,first from Newlands to Norwich ParkNewlands in 1996, then to FedsurePark Newlands in 2000 due to amerger between Fedsure andNorwich, and finally back to simplyNewlands by Investec when theybecame the main sponsor in 2002. Inlate 2005, Vodacom became thestadium's main sponsor, but followedInvestec's precedent and kept thestadium name as Newlands.The environmental conditionsNewlands Rugby stadium is situatedat the foot of Table Mountain about6km from Table Bay, 15km from FalseBay and over the mountain about10km from Camps Bay. Conditionsare most probably mild coastal. Inaccordance with ISO 9223-Corrosionof Metals and Alloys – Corrosivity ofAtmospheres – Classification, theslow rate of corrosion achievedsuggests that the micro-climaticenvironment on the East side of theRailway Stand, inside the stadiumfalls within the Corrosion CategoryC3. (Corrosion rate of about2µm/year).Hot dip galvanizing is specifiedprimarily for corrosion protection.For this reason the two requirementsto satisfy this, are coating thicknessand continuity.continued on page 26...General view of the Newlands Rugby Stadium (left) and the stadium seats (right).Hot Dip Galvanizers Association Southern AfricaUnit U4 (Upper Level), Quality House, St. Christopher Road, St. Andrews, BedfordviewP.O. Box 2212, Edenvale, 1610 • Website: www.hdgasa.org.za • E-Mail: hdgasa@icon.co.za

Case HistoryCoating thickness readings on the round bar of the seat (152µm) (left), on the side support (117µm) (middle) and on the seat support (114µm) (right).Coating thickness readings on the handrails (above left - 96.2µm and right - 89µm).Removal of contaminants prior to takingcoating thickness readings on seat side bracket.The seat brackets were hot dipgalvanized by the general processwhich was then specified by theprevious national standard, SABS763. Similarly, SANS 121 (ISO 1461)requires that for steel thicknessgreater than and equal to 1,5mm andless than 3mm, the local coatingthickness shall be 45µm and themean be 55µm.Coating thickness readings of seat side bracket (above left - 92.1µm and right - 97.6µm).The coating thickness readings takenon the seat bracket, seat supportbracket and handrail, in accordancewith the photos, still generouslyexceed this requirement.Conclusion andrecommendationThe Railway Stand at Newland RugbyStadium is already 31 years old andthe hot dip galvanized steel seatbrackets and handrails has proved tobe the correct material of choicenotwithstanding effects of a commoncorrosion problem, known asdifferential aeration (or neckingcorrosion) that can be seen onsome of the handrail/concreteinterfaces.Coating thickness readings on seat side support (above left - 149µm and right - 143µm).View of cast in non-galvanized bottom railshowing corrosion products.Corrosion products removed and residualcoating thickness (13.1µm) taken on bottom rail.Hot Dip Galvanizers Association Southern AfricaUnit U4 (Upper Level), Quality House, St. Christopher Road, St. Andrews, BedfordviewP.O. Box 2212, Edenvale, 1610 • Website: www.hdgasa.org.za • E-Mail: hdgasa@icon.co.za

Bob’s BanterLike bacteria, the business community needs a common immune systemThe widespread use of antibiotics over the last fifty yearshas resulted in many bacteria being resistant to one ormore types of antibiotics. Speculation is rife that in a fewyears we may not have any more effective antibiotics.The spread of immunity to antibiotics is enhanced bybacteria of different species being able to swap usefulgenes with each other in a process known as conjugation.Thus as one strain develops a resistance to a particulardrug others then develop it as well. Bacteria recognisethe importance of having a common immune systemwhich works co-operatively to resist harmful intrusions.The ability to share ‘life and survival skills’ by conjugationhas also been the main reason for the longevity andabundance of bacteria. For the first half of our geologicaltime our ancestors were bacteria and most creatures on ourplanet still are bacteria. Their instinct for survival enablesthem to inhabit virtually every corner of the earth, includinginside the human body. Fully ten percent of our own drybody weight consists of bacteria, some of which we cannotlive without. It is a sobering thought that the number of E.coli in the human gut far exceeds the total number ofpeople that now live or who have ever lived.continued on page 28...Specialists inhot dip galvanizingwith quick turnaround timesHOT DIP GALVANIZINGTO APPROVED QUALITYSTANDARDS20 Dekenah StreetAlrode 1449P.O. Box 124581Alrode 1451Tel.: (011) 908-3411(011) 908-3418(011) 908-3420Fax: (011) 908-3329Volume 7 Issue 1 2010 Hot Dip Galvanizing Today 27

Bob’s BanterAs bacteria do, all human societiesand cultures emphasise theessential value of helping others.Most will agree that co-operation isin general advantageous, eventhough it may curb someindividuals’ freedom and personalobjectives. The benefits achieved byco-operation are generally believedto exceed those from individualselfishness. Co-operation canincrease the fitness of the cooperators,when the co-operatorstogether can collect more resourcesthan the sum of the resourcescollected by each of themindividually. The difference is thatbacteria unequivocally accept thisphilosophy and do not wastevaluable time debating it orapplying it.Unlike bacteria, businesses arenot in a position to swap theirgenes to increase their resistanceto pending disasters. What theycan do, however, is to share usefulknowledge with other companies.Many observers believe thatworldwide we are in the midst of asweeping skills and knowledgecrisis that threatens to bring to anend any form of economicexpansion. A recent survey of highgrowth companies in Americashowed that a lack of highlyskilled employees was cited as thenumber one barrier to growth by70% of the respondents. In SouthAfrica, particularly, the shortage ofskilled employees and the lack ofresources to provide skills trainingcould become the major reasonfor a stagnating or decliningeconomy. Empowerment withoutproviding for skills and knowledgeis surely meaningless.Co-operation between competingcompanies has usually beenviewed with a great deal ofsuspicion by both business andconsumers alike. Losingcompetitive advantages and thepossibility of cartels andmonopolies are seen as the majorrisks of such co-operation.Fortunately, many progressivecompanies and regulatory bodiesare looking past these apparentobstacles and beginning to seethe many benefits that cooperationcan bring. Partnershipsand alliances are gaining inpopularity as a means of providingsynergy that a small and emergingeconomy like ours needs for joband wealth creation.Unfortunately, many partnershipsand alliances exist at the'boardroom' level only. Transferringequity, joint financial ventures andoutsourcing are indeed valuableforms of co-operation. What is alsoneeded, however, is to allow theserelationships to move down tomuch 'lower' levels where relevantand practical skills and knowledgecan be shared between people fromdifferent companies andbackgrounds.The key to co-operation, both in theimmune system of bacteria and inorganisations, is the co-operativemanagement of knowledge.Appropriate knowledge has tobecome embedded in all theorganisms so that strategies to resistcommon negative influences areavailable on a broad front. Instead oftraining their own employees,companies should perhaps beinvesting in wide knowledge'networks' that enable individualsfrom similar companies to shareexpertise, exchange knowledge andlearn on demand. In this way'communities of learning' woulddevelop which, by learning how tocontinually adjust to new andchanging ideas, would benefitbusiness and the country as a whole.The Association wishes to thank BobAndrew who is a consulting value engineerand honourary member of the Associationfor his article. He can be contacted onanneve@iafrica.com orboband@mweb.co.za.The meritsof using hotdip galvanizedsteelreinforcementin concretestructuresProfessor Stephen Yeomans was invitedto South Africa during February to givepresentations countrywide on themerits of using hot dip galvanized steelreinforcement in concrete structures.Professor Yeomans was Head of theSchool of Civil Engineering of theUniversity of New South Wales at theAustralian Defence Force Academy inCanberra over the period 1993 - 2003.He recently retired from his position asAssociate Dean (Education) and ispresently a Senior Visiting Fellow in theSchool of Engineering and InformationTechnology at the University of NewSouth Wales at the Air Force DefenceAcademy. Prof. Yeomans' principalresearch interests are the corrosion ofreinforcement in concrete and inparticular the use of galvanizedreinforcement for corrosion protection.Since 1987 he has worked closely withthe International Lead Zinc ResearchOrganisation (ILZRO) and in 2004edited a compilation volume on thecurrent knowledge available ongalvanized steel reinforcement. Thisbook has become the definitiveresource on hot dip galvanized steelreinforcement. Copies can be orderedthrough the Association.The week of seminars started inJohannesburg with a morningpresentation to invited industryleaders at Robor Galvanizers onMonday 22 February. Over 25delegates attended. This was followed28 Hot Dip Galvanizing Today Volume 7 Issue 1 2010

Hot dip galvanized rebarby a presentation to the Joint Structural Division of theSouth African Institute of Consulting Engineers in theafternoon. Again some 25+ attendees were present.On Tuesday presentations were given at the University ofJohannesburg to 22 students studying final year metallurgyand in the afternoon 16 chemical and metallurgy studentsof the University of the Witwatersrand.On Wednesday a seminar was hosted by PhoenixGalvanizers in Durban with 19 consulting engineers andspecifiers, attending.On Thursday morning a Workshop was organised by theAssociation in conjunction with IZASA at the BreakwaterLodge in Cape Town. This workshop targeted practicingcontinued on page 30...Volume 7 Issue 1 2010 Hot Dip Galvanizing Today 29

Hot dip galvanized rebarThe IZA started its high profile campaign to develop thegalvanized reinforcement steel market in 2005. This hasresulted in the development of a resource sitewww.galvanizedrebar.com in addition to the production of thebook by Prof Yeomans. Papers have been given worldwide atrelevant conferences and industry working groups establishedto identify the challenges to be overcome in furtherdevelopment of the market. Clearly, the IZA in its mission tofurther develop markets for zinc needs to focus on sizeablemarkets. Estimates of the global market for reinforcement inconcrete exceeds 100m tonnes per annum. It is clear that evena small market penetration would result in a significantlyincreased consumption of zinc.From left: Prof. Stephen Yeomans, Keith Mackie and Prof. Mark Alexander.engineers and specifiers. A full program comprised twopresentations by Prof Yeomans with additional presentationsby Prof Mark Alexander (from the Civil EngineeringDepartment of UCT who is a well known authority in concrete,concrete degradation and concrete rehabilitation) and KeithMackie (Consulting Coastal and Harbour Engineer).Prof Yeomans completed his week with a presentation to 20post-graduate students in the Department of Civil Engineeringat UCT.By the end of the week some 170 people had been able tolisten to and question Prof Yeomans on the benefits of hotdip galvanized steel reinforcement and challenge thehypotheses and assumptions in his presentations. It is hopedthat this will result in an ongoing debate over the use oflonger life structures for infrastructure development where taxRands should be spent wisely and effectively.South Africa already has some well known examples of theuse of hot dip galvanizing for reinforcement of concrete. Theseexist in Cape Town (Groote Schuur Hospital, Seapoint seawallamongst others), Durban (Gateway Shopping Centre andothers), Port Elizabeth, Johannesburg and other cities aroundSouth Africa. The visit by Prof Yeomans certainly stimulatedthe audience in terms of widening awareness but in addition,it will result in the development of a local case histories filefor future reference and as an added incentive to aid futuremarket development.A group of students listen attentively to Prof. Stephen Yeomans.On a final note, the New York State Thruway Authority hasnow adopted hot dip galvanized rebar for all of its currentbridge decks. Within the US it is estimated that there are over600 000 bridges requiring some form of rehabilitation. Clearly,recognition has occurred that hot dip galvanizing does offeradditional benefits to concrete works. Perhaps this shouldhave been used for the coastal bridges in KwaZulu-Natal. It isbetter than the use of the words – Beware of falling concrete!Editor’s CommentAs stated by Keith Mackie at the seminar, “hot dip galvanizedreinforcement for concrete only works when you don’t need it”. To thisend and warranted by the general interest in the hot dip galvanizedreinforcement for concrete, we will be publishing a series of papers insubsequent issues of the magazine on this subject.The Association would like to acknowledge theadvertisers and thank them for their supportArmco Superlite Galvanizing..................................................Back coverBAMR ........................................................................................ page 23Bolt Fast .................................................................................... page 7Bulldog Projects cc .................................................................. page 37Cape Gate (Pty) Ltd ................................................................ page 13CBC Fasteners .......................................................................... page 9Chemplus .................................................................................. page 21Galvanising Techniques (Pty) Ltd............................................ page 41Galvrite Galvanising (Pty) Ltd ................................................ page 33Galvspin Galvanizers cc ........................................................ page 31Impala Bolt & Nut SA (Pty) Ltd .............................................. page 3New Aloe Fastening System .................................................. page 10Orlik Metal Chemicals ............................................................ page 29Pro-Viro ...................................................................................... page 27Rawlplug .................................................................................. page 11Robor Galvanizers .................................................................. page 15S.A. Bolt Manufacturers (Pty) Ltd............................................ page 5Strutfast Cable Management Systems .................................. page 35Supergalv (Pty) Ltd .................................................................. page 27Surface Treatment Technologies (Pty) Ltd .............................. page 13Tel-screw Products (Pty) Ltd...................................................... page 10Trident Steel....................................................................Inside front coverVerni .......................................................................................... page 39WLS Fastener Manufacturing Company cc .......................... page 730 Hot Dip Galvanizing Today Volume 7 Issue 1 2010

Hot dip galvanized rebarProfessor Stephen R Yeomans presenteda series of presentations and seminars inSouth Africa in February 2010The presentations/seminars providedan overview of the corrosion of steelreinforcement in concrete constructionand strategies that can be adopted toavoid this insidious problem, especiallyso in building and general RCconstruction. Corrosion ofreinforcement is the most likely causeof the lack of durability of concrete andrepresents a significant expense in themaintenance and repair of concretestructures of all types. In buildings inparticular, the early stages of cracking,rust staining and spalling of concreterepresents a significant challenge tobuilding owners in the long-termmaintenance of the structure. If suchdeterioration is allowed to progress,reinforcement corrosion may also affectthe structural integrity of the concreteelements of the building itself.Hot dip galvanizing is a well-known andwidely-utilised method for the protectionof steel reinforcement embedded inconcrete in a range of building andconstruction activities. The history of theuse of galvanizing steel in concreteextends over a period of more than 70years. Recent experience indicates anincreasing use of galvanized steel in awide variety of concrete structuresexposed to differing environmentalconditions including severe topicalmarine and industrial environments.Presentations and seminars reviewedthe characteristics and use of hot dipgalvanized reinforcement withparticular emphasis on buildings andsimilar forms of construction. Itcovered the characteristics andprocessing of galvanized reinforcementas well as its corrosion performance,mechanical behaviour andconsiderations in design, fabricationand construction. A wide range ofworld-wide applications of galvanizedreinforcement were presented. A keysource of reference information on thistopic is Galvanized Steel Reinforcement inConcrete, SR Yeomans (Editor),Elsevier,2004. A supporting document for theseminar entitled Galvanized SteelReinforcement in Concrete: An Overview isavailable from the HDGASA.Volume 7 Issue 1 2010 Hot Dip Galvanizing Today 31

W amoshaCapricorn Park – “Are the two coatingsthe same?”Capricorn ParkSouth easterly windsPhotos 1:The South Easterly winds off the coast in combination with highwave action with chlorides, relatively high humidity, distance from the sea,low lying land mass, etc. make the conditions along this coastlineextremely corrosive.Photos 2: A guard rail adjacent to the sea that has lost its coating overtime and is now corroding.“Wamosha” which in Zulu means inappropriateuse, misuse or messing about, is the name forthis column. The column will feature articleswhere we find hot dip galvanizing misused orwhere other zinc coatings that are ofteninappropriately specified when general hot dipgalvanizing is preferred, have beeninappropriately used.The Hot Dip Galvanizers Associationwas requested to inspect and commenton the performance of continuous andgeneral hot dip galvanized roofingmembers on an industrial building(No. 1) in Capricorn Park (photo 3),exposed to the atmosphere for two anda half years. The components wereinspected on Tuesday 26 January 2010and I report as follows:Capricorn Park off False Bay on thecoast side is situated about 1km fromthe sea, with the M5 entrance beingabout 2 - 2.5km from the sea.In our experience wind drivenchlorides can be found up to 3km ofthe sea along this coast line from andincluding Glencairn through to justwest of the Strand, whereas areas suchas Simonstown and Gordons Bay areconsiderably less corrosive due mainlyto the exclusion of the directonslaught of the South Easterlychloride carrying winds.Conditions within Capricorn Parkfrom the M5 gate (photo 4 and 5)through to the coastal gate off FalseBay are corrosive.The conditions at the coastal gate offFalse Bay are extremely corrosive, photo6 shows the entrance, photo 7 shows abadly painted (now failed) anglewelded to a failed duplex coated gateand photo 8 a failed powder coated wiremesh fence.This security intercom sign (photos 9 -11) was most probably installed at thetime Capricorn Park was established(December 2000) see label on back ofsign. While the pre-galvanized bracketand unistrut and zinc electroplatedfasteners are corroding, the hot dipgalvanized post shows someinteresting observations.Photos 12 - 14 show, after scraping thesurface to remove chloridePhoto 3.Photo 4. Photo 5.32 Hot Dip Galvanizing Today Volume 7 Issue 1 2010

W amoshaPhoto 6. Photo 7. Photo 8.Photo 9. Photo 10. Photo 11: Installed December 2000.contaminants, coating thicknessreadings of 57.6; 43.4 and 50.8µmrespectively, on the landside of the post.Photos 15 - 17 show, after scraping thesurface to remove chloridecontaminants, coating thickness readingsof 32.6; 8.4 and 8.6µm respectively, onthe coastal side of the post.While removal of the contaminantsmay not be 100% effective, theresultant coating thickness readingsdo indicate that there is aconsiderable coating thicknessreduction on the coastal side versusthe landside over the 10 odd years.continued on page 34...Volume 7 Issue 1 2010 Hot Dip Galvanizing Today 33

W amoshaPhoto 12. Photo 13. Photo 14.Photo 15. Photo 16. Photo 17.Tube hot dip galvanizing is generallydone to SANS 32 (EN10240) whichrequires a minimum coatingthickness of 55µm and because theprocess generally includes nonreactivesteel tubing and an exit airring.As the tube exits the zinc bath,via the air-ring, it is mechanicallywiped on the outer surface and thisensures that coating thicknesses fargreater than 55µm are unlikely.The specific building (No. 1) in thispark (photo 19) is situated alongsideCapricorn Drive and is reported to be2 1 /2 years old, while another building(No. 2) is closer to the coast and is 4 1 /2years old (photo 20).M5 GateBuilding No. 1Building No. 2Coastal GateNote: The location and position(relative to the coast line) of the twobuildings shown on the plan (photo18) are not necessarily 100% accuratebut have been shown merely toillustrate the corrosivity of the areawith respect to the coast line anduse of hot dip galvanized steel.Building No. 2Photo 21 shows the raker support armsfor the roof on Capricorn Road side.Photo 22 shows the hot dip galvanizedrafters and purlins. The only corrosionis on the painted barge plate (circled).Photo 23 shows the residual coatingthickness (177µm) on the rakersupport arm wall plate.Photo 24 shows the appearance of thetubular raker support arm on seawardside (note the chloride deposit) whilephoto 25 shows the appearance landwardside (note less chloride deposit). Photo26 (179µm) and photo 27 (149µm) showthe landward side coating thickness.Photos 28 and 29 (119 and 121µm,respectively) show the seaward sidecoating thickness. Note the significantresidual coating thickness differencebetween the two faces after 4 1 /2 years.Building No. 1As expected the hot dip galvanizedsteel components on the South Eastand South West face of the buildingappear to be the worst affected, withconsiderable performance differencesbetween the hot dip galvanized roofrafters and bracing (to SANS 121) (seephotos 36 - 40 and 47 - 50) and thecontinuously hot dip galvanizedpurlins (to SANS 3575 or 4998) (seephotos 30 - 35 and 41 - 46).South east corner and eavesPurlinsPhoto 30 is general, photo 31 shows theconcerns on the purlins and photos 32Approximateposition of coastlinePhoto 18. Photo 19. Photo 20.34 Hot Dip Galvanizing Today Volume 7 Issue 1 2010

W amoshaPhoto 21. Photo 22. Photo 23.Photo 24. Photo 25. Photo 26.- 35 show where the chlorides havebeen scraped off and residualcoating thicknesses (5.4 and 9.5µmrespectively) have been taken.RaftersThe close up appearance of the rafter(photo 36); coating thickness readingsof 161 and 165µm on the rafter (photos37 and 38) and 179 and 175µm (photos39 and 40), respectively on the roofbracings.continued on page 36...Volume 7 Issue 1 2010 Hot Dip Galvanizing Today 35

W amoshaPhoto 27. Photo 28. Photo 29.South west corner and eavesPurlinsPhoto 41 is a general view of the southwest end of the building, photo 42 showsthe corrosion concerns on the purlins.Surfaces scraped and residual coatingthickness measured on the rafters andpurlins.The purlins have been manufacturedusing a continuously hot dip galvanizedsheet to SANS 3575/4998. Two places onthe inside of the purlin were scraped asclean as possible and residual coatingthickness readings taken, measuring 18.3and 24.6µm respectively (photos 43 - 46).The horizontal and areas adjacent tothis on the purlins have due to thecorrosivity of the atmosphere and timeof wetness, shown a markeddegradation and subsequent red rust.RaftersThe rafters have been hot dipgalvanized to SANS 121. Two areas ofthe exposed web of the I-Beam werescraped as clean as possible andresidual coating thickness readingstaken, measuring 241 and 237µmrespectively (photos 47 - 50).Difference between continuouslyhot dip galvanized sheeting toSANS 3575 (commercial grade)or SANS 4998 (structural grade)and general hot dip galvanizingto SANS 121Continuously hot dip galvanized sheetingThis is manufactured by ArcelorMittalin Vanderbijlpark or Durfuco in theWestern Cape. Continuous sheetingtravelling at about 140m/min runsthrough a reducing atmosphere atabout 950°C, the sheet travels into ahot dip galvanizing bath under amandrel and as the sheet exits thebath, it runs through a series of air orgas knives where the excess coating,according to the grade of coatingrequired, is mechanically removed.Various coating grades are availablefrom Z100 to Z700, with the mostavailable grade being Z275. The 275represents the mass of zinc ingrams/sqm. To convert the coatingmass to coating thickness 275 must bedivided by 7 (Specific Gravity of zinc)and by 2 (includes both faces), ie.275/2x7 = 19,6µm. The fine print in thespecification allows not less than 40%of the individual value (235 gm/sqm)to be found on one surface, ie.13.4µm.General hot dip galvanized steelThis process is available in most largecentres and in Cape Town there are 6hot dip galvanizers, 5 of which aremembers of the HDGASA, with varyingbath sizes.Pre-cleaned components aredipped into a bath of molten zinc atabout 450°C. A metallurgical reactionbetween the steel and zinc results in acoating comprising a series ofPhoto 30. Photo 31. Photo 32.Photo 33. Photo 34. Photo 35.36 Hot Dip Galvanizing Today Volume 7 Issue 1 2010

W amoshaPhoto 36. Photo 37. Photo 38.iron/zinc alloys which are generallyovercoated with a layer of pure zinc.A number of things influence thecoating thickness and appearance,with the chemical composition of thesteel as in silicon and phosphorusplaying the major role. Steel thicknessand surface roughness also have amajor influence.Photo 39. Photo 40.SANS 121, requires that for steel 6mmthick and above, the minimum localcoating thickness must be 70µm withthe minimum mean being 85µm.As can be seen from the photos, dueto reactive steels, this minimumcoating thickness is generallyexceeded by upwards of 50%.For further differences on the twotypes of hot dip galvanized coatings,refer to Magazine No. 37 or back issuecontinued on page 38...Volume 6 Issue 3 2009 Hot Dip Galvanizing Today 37

W amoshaRaftersPurlinsPhoto 41. Photo 42. Photo 43.Photo 44. Photo 45. Photo 46.Photo 47. Photo 48. Photo 49.magazines on www.hdgasa.org.za.Conclusion and recommendation:Due to the prevailing off sea chloridecarrying winds (South Easterly), highwave action, humidity, low lying landmass and lack of rainfall from the seaside, the False Bay coastline from andincluding Glencairn to just west of theStrand up to about 2 to 3km from thesea is considered to be extremelycorrosive.The specifying and use of a materialsignificantly inferior (for corrosionresistance purposes), is unacceptableand although our organisation, has forthe past 13 years tried to educate usersand specifiers in all the major centresas to the differences, there are stillmany who innocently mis- specify,accept the incorrect materials and whenthey fail prematurely are significantlyembarrassed by the situation.As discussed previously, tocomprehensively remove the tenaciouszinc chloride layer on the galvanizedpurlins, abrade the red rust areas (manyof which are directly below the sheetingand in inaccessible areas –shape of thepurlin), followed up by patch priming ofthe latter surfaces, with subsequentlayers of paint, within a short period ofcleaning, will in my opinion beextremely difficult and expensive tosuccessfully achieve.Most of the fasteners, which have alsofailed are only zinc-electroplated. Theycan often be confused by uninformedpersons with hot dip galvanizedequivalents.The difference essentially between thetwo methods of coating is in thecoating thickness and appearance,where the zinc electroplated fastenerswould have a coating thickness ofabout 5 to 15µm and be shinywhereas, by the hot dip galvanizedmethod will rarely be less than 55 to65µm and matt grey in colour. As lifeis proportional to thickness, it standsPhoto 50.to reason that a thicker coating willlast that much longer.My recommendation would be that thepurlins be removed and replaced withhot dip galvanized purlins to SANS 121.As stated this area off the False Baycoastline is extremely corrosive and ifour opinion was sought at the outset ofthe project, we would have specified aduplex coating (hot dip galvanizing plusan appropriately thick paint coatingsystem) for all external components toachieve a durable service free life.Terry Smith38 Hot Dip Galvanizing Today Volume 7 Issue 1 2010

Executive Committee 2010HOT DIP GALVANIZERS ASSOCIATION EXECUTIVE COMMITTEE 2010Front row, left to right – Kim Guest (Metsep); Terry Smith (HDGASA); Bob Wilmot (HDGASA); Nelis Pienaar (Lianru Galvanisers);Nick van der Mescht (Africa Cellular Towers); Werner Petrick (Macsteel Tube & Pipe); Saskia Salvatori (HDGASA);.Back row, left to right – Hendrik Stenkamp (HDGASA); Tat Greyvenstein (Supergalv); Tom Loughran (Armco Galvanizers);Don Voysey (Bay Galvanizers); Nico Schoeman (Robor Galvanizers); Mike Book (Bulldog Projects); Iain Dodds (Cape Galvanising);Owen Tennant (Exxaro Base Metals – Zincor Ltd.); Michael West (Cape Gate); and Anni Ramkisson (Phoenix Galvanizing).concrete & steel tankcorrosion resistant liningsVerni undertake the complete restoration ofexisting linings by stripping, repairingconcrete and re-lining with a suitable system.On new projects, Verni will assist from designstage, offering advice on a suitable liningsystem to withstand the corrosive conditionsand limit the mechanical damage caused bythe galvanizing process.We offer a specialist Fibre Reinforced Laminated Resin system or an AcidResistant Brick Lining system. Other linings include epoxy/ polyurethaneresin screeds and coatings for concrete bunded areas.Tel: +27 (0)11 552 8393 • Fax: +27 (0)11 552 8391Website: www.verni.co.za • Email: vernon@verni.co.za45 Malcolm Moodie Crescent, Jet Parkacid proofing, epoxy coatings/flooring, tank linings, concrete repairs/waterproofing & speciality construction chemicalsVolume 6 Issue 3 2009 Hot Dip Galvanizing Today 39

Member’s NewsRobor restructuring enhances offeringRobor, the largest manufacturer ofsteel tube and pipe in southernAfrica, has announced a restructuringof its operations in order to expandits service offering and deliver acomprehensive, simplified approachto projects.Spearheaded by a new R80 millionfacility and the purchase of state-ofthe-artlaser cutting and highdefinition plasma cutting equipment,the initiative sees all value addedservices grouped under one divisionwith one management structure forimproved efficiency.According to Andrew Winter,Managing Director, Robor SteelServices, the value added serviceoffering, used with much success inits Pipe Systems business unit for thesupply of conveyance systems, isbeing vertically integrated into theentire Elandsfontein operation. “Thismove enables Robor to offercustomers a more comprehensiveservice from one supplier, essentiallybacking our products from start tofinish. We are taking advantage of ourestablished systems and logistics toroll out these services, in effectbecoming part of our customers’supply chain,” says Winter.The Microstep HD Plasma Cutter is idea for providing tube for structural applications and featuresa three dimensional head.project while waiting for othercomponents from other suppliers.”Winter notes that further benefitsinclude better yield and fewer stocklosses. “While a customer can cut orbend our tube themselves, mistakesare often made and more items needto be ordered. This obviouslyincreases their costs and causesdelays. We take that risk away fromthe customer by delivering preciselywhat they order, in the state in whichthey need it and, most importantly,on time,” says Winter.projects on a just-in-time (JIT) basis.This reduces a customer’s stockholding and assists in making theproject more efficient.“We have established ourselves inthe market as a reliable companythat offers consistently good qualityproducts. The addition of theseservices means that we are meetingcustomer demands for acomprehensive supplier and will bedelivering them with the same highstandards,” Winter concludes.In addition to the conventionalservices, such as cutting, ring rolling,bending, hot dip galvanizing,painting and drilling, Robor is able totake a customer’s requirements ordrawings and convert them into asolution that is transported to siteready to assemble.“We are supplying components forprojects, ready to be installed onceon site. The benefit for our customersis cost-effectiveness and improvedefficiency. As the only supplier, wecan ensure better lead times,simplified logistics, lessadministration and better coordination.There are no delays on aRobor has established solidrelationships with sub-contractorsthat are able to offer complementaryequipment and skills should they berequired. “If we don’t have thosespecific resources we use our trustedsub-contractors while still managingthe process to ensure that it isseamless.”The value added service facility isalso available for fabricators anddistributors to use.The company’s resources, establishedsystems and logistics capabilitiesallow Robor to supply to a number ofThe Trumpf TruLaser Tube 7000 laser cuttingmachine is the first of its kind in South Africa.40 Hot Dip Galvanizing Today Volume 7 Issue 1 2010

Member’s NewsArmco Galvanizers hot dip galvanizes steel forthe “ring of fire” at Soccer City, JohannesburgArmco Galvanizers hot dip galvanizedsome 280 ton of steel for Omni Structwhich was used in the “ring of fire” atSoccer City.Due to minor imperfections in thecoating (normally acceptable in termsof the specification SANS 121 (ISO1461), most of the verticalcomponents were cleaned using anindustrial orbital sanding disc toincrease the aesthetical acceptabilityand smoothness of the coating.The final coating was acceptable butshortly would convert to a uniformdull matt grey colour as the final zinccarbonate patina appeared.Galvadip chosen ashot dip galvanizerfor FIFA WorldCup Soccerstadium turnstilesA total of 35 470kg of turnstiles has been hot dip galvanizedby Pretoria-based Galvadip, for Turnstar Systems.Turnstar, a specialist supplier of turnstiles for varioussporting stadia around Africa including the 2003 ICCCricket World Cup in 2003 and the 2008 Africa Cup ofNations in Nigeria, is the sole supplier of turnstiles for allthe 2010 soccer stadia.Galvadip has galvanized approximately 70% (105turnstiles) at Soccer City, all 77 turnstiles and 10 gates atNelspruit’s Mbombela Stadium, 14 turnstiles for thePrincess Magogo Stadium in KZN and 16 turnstiles for thePhilippi stadium in Cape Town (for photo of turnstiles seefront cover).For hot dip galvanizing withservice excellence• 12 400 long x 1 400 wide x 2 600deep kettle• Shot blasting• Technical assistance• Collection and delivery service• Open Saturdays• SABS ISO 1461 accredited52 Burman Road, Deal Party, Port ElizabethTel.: 041-486-1432 Fax: 041-486-1439Volume 7 Issue 1 2010 Hot Dip Galvanizing Today 41

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