Stephen’s Cornermigrated a considerable distance (300-500 microns) beyond the surface of thecoating and into the adjacent concretematrix with no visible effect on theconcrete mass.Studies such as these clearly indicatethat galvanized bar, when properly usedas the exclusive reinforcing material, canprovide enhanced corrosion protectioncompared to black steel in equivalentconcrete and exposure conditions. Whatis clear is that in good quality concretethat is well compacted, cured and ofadequate cover, galvanized bar survivesfor extended periods of time and offers acost-effective method of corrosionprotection. In poor quality concretehowever, particularly those with high w/cDeepwater ocean outfalls, Australia.Coal storage bunker, Australia.The Association would like toacknowledge the advertisersand thank them for their supportArmco Superlite Galvanizing ..............Outside Back CoverAvlock International.................................... page 5Bolt & Engineering Distributors (Group) ........ page 7Bolt Fast .................................................... page 10Bulldog Projects cc...................................... page 43CBC <strong>Fasteners</strong> ............................................ page 15Chemplus .................................................. page 29Galvanizing Techniques (Pty) Ltd.................. page 29Galvatech (Pty) Ltd .................................... page 35Galvrite Galvanising (Pty) Ltd ...................... page 25Galvspin Galvanizers cc .............................. page 21HDGCS ...................................................... page 37Hi-Tech Elements (Pty) Ltd .......................... page 27Impala Bolt & Nut SA (Pty) Ltd.................... page 3National Socket Screws .............................. page 16Pro-Galv cc ................................................ page 27Rawl Fixings .............................................. page 6Robor Galvanizers ...................................... page 33SA Bolt Manufacturers (Pty) Ltd .................. page 13Speccoats ............................................Inside Back CoverStrutfast Cable Management Systems .......... page 39Supergalv (Pty) Ltd .................................... page 19Surface Treatment Technologies (Pty) Ltd...... page 19Tel-screw Products ...................................... page 16Trident Steel (Pty) Ltd ................................ page 23Weartech (Pty) Ltd ..............................Inside Front CoverWLS Fastener Manufacturing Company ........ page 9Outfall pipes, Singapore.Waste treatment facility, Bermuda.Figure 2: Galvanized reinforcement concrete in general construction.ratio and low cover to the reinforcement,galvanizing will delay the onset ofchloride induced corrosion of thereinforcement, but this may be of limitedbenefit.Economics of galvanizedreinforcementWhen the costs and consequences ofcorrosion damage to a reinforcedconcrete building are analysed, the extracost of galvanizing is seen as a smallinvestment in corrosion protection.While the initial cost of galvanizing mayadd up to 50% to the cost of thereinforcement, depending on the countryof origin and the availability and accessto galvanizing plants within the country,the cost of using galvanizedreinforcement as a percentage of totalbuilding cost is always significantly lessthan this. The overall cost depends, ofcourse, on the nature and location ofconstruction and the extent to whichgalvanized bar is used throughout thestructure. For example, it is rarelynecessary for the structural core orinternal elements of large reinforcedconcrete structures such as high risebuilding, or the deeply embeddedcomponents of large abutments andfoundations, to be galvanized.General cost analysis for buildingconstruction reveals that the galvanizingof reinforcement increases the overallcost of reinforced concrete as-placed byabout 6-10%. The actual value will varydepending on many factors includingthe type of bar and the galvanizingprice, the amount of steel used percubic meter of concrete poured, and theunit cost of the concrete mass. Theconcrete price is made up of severalmain components including the supplyof the concrete, the formwork and steelsupply and fixing costs. On average, thecost of the steel would not be morethan about 25% of the total cost of theconcrete as placed. Considering alsothat it is rarely necessary to galvanize allsteel in the structure, and that the costof the structural frame and skin of abuilding normally represents only about38 Hot Dip Galvanizing Today Volume 8 Issue 1 2011
Stephen’s Corner25-30% of total building costs, theadditional cost of galvanizing reduces tobetween 1.5-3.0% of total building cost.However, by galvanizing only certainvulnerable or critical elements, e.g.surface panels, the additional cost ofgalvanizing reduces further still, perhapsto as little as 0.5-1.0%.These percentages, of course, relate onlyto total construction costs and whentaken against total project costs or finalselling prices the added cost ofgalvanizing becomes very small indeed,often less that 0.2%. This represents avery small fraction of the cost of repairsshould unprotected reinforcementcorrode. Similar costing analysis hasbeen reported on a number of occasions.Applications of galvanizedreinforcementin a variety of reinforced concretestructures and elements. The rationalefor this is based on the philosophy thatthe coating provides a safeguardagainst early or unexpected corrosionof the reinforcement. Should suchdamage occur costly repair andremediation of the structure may benecessitated in order to realise the fulldesign life of the structure. Thisrepresents an ever-increasing economicburden and the redirection of scarceresources.Particular circumstances where thegalvanizing of reinforcement is likely tobe a cost-effective and soundengineering decision include:◆ light-weight precast claddingelements and architectural buildingfeatures;◆ surface exposed beams andcolumns and exposed slabs;◆ prefabricated building units such askitchen and bathroom modules andtilt-up construction;◆ immersed or buried elementssubject to ground water effects andtidal fluctuations;◆ coastal and marine structures;◆ transport infrastructure includingbridge decks, roads and crashbarriers; and◆ high risk structures in aggressiveenvironments.Many examples exist around the worldwhere galvanized reinforcement hasbeen successfully used in a variety oftypes of reinforced concrete buildings,structures and general construction.Some prominent, world-wide examplesare shown in Figures 2-5.Finally, it is noteworthy that in theState of the Art Report on CoatingProtection for Reinforcement (ComiteEuro-International du Beton, 1992) theGalvanized steel bar and other fittingsincluding bolts, ties, anchors, dowelbars and piping, have been widely used continued on page 40...Volume 8 Issue 1 2011 Hot Dip Galvanizing Today 39