Awards Event - hdgasa

Awards Event◆starting from 1 200m 2 – and itsneighbouring estate, WaterfallCountry Village, consisting of1 000 stands of approximately650m 2 each.These two estates form part ofWaterfall City – the greatestmulti-purpose development everto enter the South Africanproperty market, which includesfacilities such as private schools,an international hotel andconference venue, fishing damsand lakes and an exclusivecountry clubhouse.◆architectural appeal of thebuildings.This submission encompasses allthe main “common area” buildingson the estate, due to the fact thatthe central theme using an integralsystem of building materials isfeatured throughout.◆Hot dip galvanizing has beenused to form part of the façadeand ambiance of the architecturaldesign throughout the estate.The use of hot dip galvanizing incombination with wood is ofparticular aesthetic appeal.continued on page 6...◆There is a strong focus on ‘greendesign’ within the development,the aim being to create a healthycommunity centred onenvironmentally consciousprinciples. Concepts such aswaste recycling and guidelines tosustainable living are mandatorywithin the estate and will beseamlessly integrated into thelifestyle.◆The successful use of hot dipgalvanizing in conjunction withall the other building materials isits ability to blend and harmonisewith the indigenous landscape.This theme has been successfullyretained on the major structuresthroughout the estate.◆Hot dip galvanized steel providesthe corrosion protection for thestructural components; at thesame time it forms part of theVolume 8 Issue 3 2011 Hot Dip Galvanizing Today 5

Awards Event◆Hot dip galvanized steel exposedto the atmospheric conditionswill provide many years ofmaintenance free service life.owners with flexibility anddiversity of choice, while ensuringoverall aesthetic harmony andhigh standards within the estate.and create spaces that are openand free. Steel is a modernmaterial that can be used to createdramatic effects. It may be hot dip◆◆Many people view the surfacefinish of hot dip galvanized steelas “rough and unsophisticated”,but what is clearly evident inthese structures is a blending inand complementary to all theconstruction materials.The architectural guidelines havebeen developed in consultationwith leading firms of consultants,architects, urban designers andlandscape professionals. Thegoal was to provide investors and◆The developer aims to encouragethe use of materials in their naturalstate, thereby creating a unifyingelement to all the homes, asdiverse as they hope they will be.The materials that are expressed intheir natural form on the estate arestone, brick, plaster, wood, steel,glass and green materials.According to their guidelines, “steelallows spaces to become light andairy, especially when used inconjunction with glass. It makes itpossible to span large openings◆◆galvanized or painted grey.”Designs embrace both classic andcontemporary interpretations ofHighveld vernacular such asfarmhouses, barns, manorhouses, sheds and the use ofmaterials such as wood, stone,steel and concrete in their naturaland honest state.Existing trees on and around theproperty were protected andpreserved.6 Hot Dip Galvanizing Today Volume 8 Issue 3 2011

Awards EventDuplex Coating Systems Category WinnerAmbotovy Nickel MineDescriptionThe use of a duplex coating systemusing powder coating on cable laddersand support products in a Nickel Minein Madagascar.LocationMadagascarProject partnersDeveloper / ownerSNC Lavalin / SherritSpecifierSNC LavalinMain contractorB&WHot dip galvanizerArmco GalvanizersPowder coaterO-line Coatings (Pty) LtdTons of steelApproximately 1 000 tonnesProject inception dateSeptember 2009Project valueApproximately R45 million (O-linecommodities only)Information◆ The need for products, especiallyin the electrical and mechanicalindustry to not only be hot dipgalvanized, but also coated with apowder coated surface, promptedO-line, through its powder coatingfacility to become innovative andmarket leaders in this field.◆During the past few years, variousduplex coated projects weresuccessfully completed, some of◆which are older than 10 years.Unfortunately, through no fault ofO-line, but rather due to acombination of misinformation,lack of knowledge and badexperience, duplex coatedproducts (with powder coating asthe paint system) fell out of favourwith local consultants, specifiersand contractors, who opted forstainless steel rather than duplexcoated products.continued on page 8...Volume 8 Issue 3 2011 Hot Dip Galvanizing Today 7

Awards EventNo zinc rich spray was allowed tobe used to repair areas. In orderto eliminate the necessity forexcessive cleaning, specialisedjigging was developed in order toaccommodate the galvanizingprocess.◆No passivation after galvanizingwas allowed. The producttherefore had to be stored undera roof at all times in order toavoid wet storage stain. The useof Ammonium Chloride wascontrolled in order to managevisual quality.◆◆◆In early 2009, O-line successfullyventured into the area of DuoDuplex for product supplied toTransnet for the Coega ContainerTerminal and the successfulcompletion of this projectreturned to O-line the confidencein a duplex system.O-line proved that if the duplexprocess in terms of cleaning, pretreatmentand oven temperatureare strictly controlled, the resultantcoating is a major enhancement tothe galvanizing process, bothaesthetically and from a corrosionprotection point of view.With this knowledge in hand andbased on a combination of priceand delivery, SNC Lavalin, aCanadian based mining developer,awarded the Ambotovy Mine◆◆◆contract for the supply of electricalsupport systems to O-line.The construction of this mine iscurrently the biggest miningconstruction in the world andcompeting against internationalcompanies, O-line was awardedthis contract.The client specified that all cableladder and support products(except bracketry) had to beduplex coated. In order toaccommodate such a largeproject, O-line relocated theirpowder coating plant into bigger,more suitable premises.There were various projectchallenges as this was the firsttime in South Africa that thesecable ladders were manufactured.◆◆◆◆In excess of 1 000 tonnes ofproduct was hot dip galvanized,then pure polyester powdercoated before being loaded into180 containers. To date allproducts were received in a goodcondition on site.Eight contractors were employedfor every container loaded.Twenty five manufacturingpersonnel were employed untilthe completion of every receivedorder.Approximately 40 tonnes of purepolyester powder was used.Closer quality control in terms ofthe galvanizing process has led tothe elimination of degassingprocess of products as a prerequisiteto powder coating.8 Hot Dip Galvanizing Today Volume 8 Issue 3 2011

Awards EventInfrastructural Development CategoryWinnerLula Pipe Cable Lock TMDescriptionLula Pipe is a socketed hot dipgalvanized steel pipe system that hasbeen designed to be compatible andinterchangeable with standard sizes ofPVC pipe in common use in the waterreticulation industry. The CableLock makes use of a socket andspigot system, where the socket,complete with an integral seal isformed on one end of the pipe and theother end forms the spigot.Project partnersOwnerEPNS EngineeringProject managerExxaro and Simmer & JackHot dip galvanizerMacsteel Tube & PipeProject inception dateApplication Patent 2006 & 2009Information◆ Lula Pipe is a socketed hot dipgalvanized steel pipe system thathas been designed to becompatible and interchangeable◆◆◆with standard sizes of PVC pipecommonly used in the waterreticulation industry.The Lula Pipe has made for aneasy and effective way to install asteel pipe system that is proudlySouth African and innovativelydesigned to deal with SouthAfrica’s water supply challenges.Traditional systems of joining hotdip galvanized steel pipes such asflanged or screwed and socketedsystems are difficult and slow toinstall. The Lula Pipe hasspeeded the introduction of thealternative plastic systems whichare not as skill dependent toinstall. By making a systemcompatible with the PVC systemhas meant that system aspectssuch as sockets and seals arealready accepted and don’t haveto be proven in service foracceptance.Development of the Lula PipeSystem to provide an improvedlocking system led to the CableLock .◆◆The Cable Lock piping systemmakes use of a socket and spigotsystem, where the socket,complete with an integral seal isformed on one end of the pipeand the other end forms thespigot.The innovation with the CableLock system is that in additionto the integral seal there is also alocking element which iscontinued on page 12...10 Hot Dip Galvanizing Today Volume 8 Issue 3 2011

Awards EventMining and Industrial Category WinnerMedupi Chimneys, North & South – Internalflue support steelworkDescriptionThe hot dip galvanizing and zincthermal spray of the flues contained inthe two concrete chimneys at MedupiPower Station.LocationMedupi Power Station, LephaleleProject partnersDeveloper / ownerEskomProject managerKarrena / Concor JVMain contractorKarrena / Concor JVHot dip galvanizerRobor (Pty) Ltd – GalvanizersSteelwork fabricatorAveng Grinaker LTA Mechanical &Electrical DSE FabricationShot blastingBulldog ProjectsTons of steel78 tonnes zinc thermal sprayed128 tonnes hot dip galvanizedTotal steelwork206 tonneslevels of support steelwork, at 55m,90m, 180m and the main supportgirders at 205m level. As the 205mlevel girders support most of theload from the flues, these had to bethe largest and weighapproximately 13 tonnes each.◆ These three fish belly girders (17mlong, 3m deep at the centre with50mm thick flanges and 20mm thickwebs) could not be hot dipgalvanized due to their size. Even adouble dip approach was ruled outdue to the length of the girders.◆Having to handle such large girders,it was decided to complete themetal spray operations at the AvengGrinaker-LTA DSE Fabricationworkshops in Vanderbijlpark.Cranes were readily available forhandling large girders, with BulldogProjects running the blastingfacilities on the DSE Fabricationproperty.continued on page 12...Project completion dateNovember 2010Project valueR7 millionInformation◆ Medupi Power Station has twoconcrete chimneys, 213m high, witheach chimney / windshieldcontaining three flues, whichextend all the way up the chimneyand protrude 7m above the top ofthe concrete.◆ These flues are supported by 5◆◆All the other girders were hot dipgalvanized according to the client’sspecification.Robor Galvanizers proposed analternative to hot dip galvanizing –zinc thermal spray. This is the bestalternative when dealing with suchlarge girders due to the fact that thezinc applied during zinc metalspraying is of the same chemicalcomposition as the zinc used in thehot dip galvanizing process. Theonly difference is that adhesion tothe steel surface is mechanical,whereas hot dip galvanizing forms ametallurgical bond.Volume 8 Issue 3 2011 Hot Dip Galvanizing Today 13

Awards Event◆◆Safety, environment and qualityissues all had to be addressedwhen working on the DSE site.Robor covered all of theserequirements with their methodstatement, which was accepted bythe DSE Fabrication managementand by the client.Robor’s equipment, consumablesand personnel were transported toVanderbijlpark.◆◆The metal spraying process entailedthe shot blasting of the girders,which had to be done individuallyand one side at a time. This wasnecessary to avoid flash rusting ofthe newly blasted areas. Sprayingwas then carried out in an allocatedarea. This process was repeated forthe other side of the girder.Robor’s operators were issued withcalibrated thickness gauges so◆checks could be made on an ongoingbasis in order to identifyareas that required additionallayers of metal spray, with frequentchecks made by the managementteam in order to ensure the correctthickness was maintained.Final inspection was based on therequirements of the SANS 121 / ISO1461 standard.14 Hot Dip Galvanizing Today Volume 8 Issue 3 2011

Awards EventCommunity Development Category WinnerZwelitsha Pedestrian BridgeDescriptionThe duplex coating of a pedestrianbridge in the Eastern CapeLocationZwelitsha, Eastern CapeProject partnersDeveloper / ownerBuffalo City MunicipalitySpecifier / engineerVela VKE Consulting EngineerProject managerVela VKE Consulting EngineerMain contractorRobert Brothers JVSteel fabricatorIndustrial Service GroupHot dip galvanizerRobor (Pty) Ltd – Galvanizers (mainstructure) and Morhot (Pty) Ltd(handrailing)Tons of steel17.5 tonsProject dateAugust 2010Project valueR2.46 millionInformation◆ The Zwelitsha Pedestrian Bridgecrosses the Buffalo River in a ruralarea of the Eastern Cape. Thebridge was commissioned by theBuffalo City Municipality inresponse to tragic drowningincidents.◆◆The bridge now provides a safe rivercrossing to some 500 pedestriansper day, linking the ruralcommunities with essentialservices, including schools andclinics.The design brief was for aninexpensive and functional bridgethat would cross the Buffalo River◆◆◆above the 1:50 year flood level. Itwas also requested that theconstruction method be keptsimple. This was to encouragesmaller local contractors to tenderfor the construction work, ultimatelyuplifting the local communitythrough job creation and skilldevelopment.This project shows that through wellplanned and innovative design, anattractive rural steel bridge can bedeveloped at an affordable cost.Due to the remote bridge site andthe high costs associated withpossible future maintenance,effective corrosion protection was afactor that played an integral role inthe design process.All steel components of this striking58m long and 1.5m wide ruralfootbridge were hot dip galvanizedand painted with a duplex coatingsystem prior to being boltedtogether on site.The standard stock of ruralpedestrian bridges is U-frame steeltruss bridges as they are consideredthe most economical option.Typically these structures arefabricated in sections that can beeasily galvanized, transported,handled and bolted together. Their◆construction on remote sites istherefore possible without the useof heavy plant equipment. TheZwelitsha Pedestrian Bridge tookthis concept and adapted it for anattractive cable stayed bridge.The design had two main goals: thefirst was to create a cable stayedstructure that could be built for aprice comparable to that of a simpletruss bridge; the second was todetail a durable, low maintenancestructure that could be easilyerected in a remote area.continued on page 16...Volume 8 Issue 3 2011 Hot Dip Galvanizing Today 15

Awards Event◆◆◆◆The bridge design responds to thenatural surrounds of the BuffaloRiver. Low towers with a limitedamount of stays give the bridge anappropriate scale. The steel towersare integral with the concrete piers.Their stiffness is relied upon to limitthe deflection in the deck due toasymmetric pedestrian loading. Theresulting high moments in thetowers are transferred to theconcrete pier bases that aredowelled into the river’s rock bed.The foundation dowels are hot dipgalvanized Y32 reinforcing bars thatare grouted into a corrugated plasticencasement for additional corrosionprotection.The deck section floatsindependently of the towers and itslongitudinal restraint is provided bythe stays. This was the onlyalternative that maintainedadequate tension forces in the staysduring the thermal expansion andcontraction of the deck.A key element in the detailing of thebridge was to restrict the length ofthe individual elements. Thismeant the sections were easy tohandle on-site. It also meant theycould be hot dip galvanized. Thisallowed the specification of aduplex coating system that willensure the bridge requires minimalfuture maintenance.An important benefit of bolting thebridge together was that no on-sitewelding was required. This meantthat the hot dip galvanizing was notcompromised during the erectionprocess. All bolts specified werealso hot dip galvanized.◆◆◆The erection process was quick andsimple. Trestle towers supportedthe main beam during theinstallation of the stays. Theconcrete deck was then poured ontothe hot dip galvanized permanentsteel formwork. The stays were thenstressed by the system’s deadweight as the trestle towers wereremoved. The vertical alignment ofthe deck achieved by this simpleconstruction method was verysatisfactory.The benefits of hot dip galvanizingsteel structures exposed to theelements are well known. However,this project is significant from agalvanizing point of view as thedecision to hot dip galvanize theentire bridge influencedconstruction sequence and in turn,the structural form of the bridge.The decision to make use ofsegmented bolted construction waslargely influenced by the fact thatthe segments could be of a practicallength that would facilitate effectivegalvanizing.The successful implementation ofthis project rested on theprofessional relationships betweenthe contractor, steel fabricator andthe design engineer. An exampleof this close working relationshipis the instance when constructivedialogue resulted in appropriatevent and drain holes beingspecified for the tower base plate.The pockets created by the towerbase plate could have caused air to◆◆become trapped during thedipping process.This project shows that an attractivestructure can be developed at anaffordable price withoutcompromising on effective corrosionprotection. The total cost ofgalvanizing the entire bridge,including the handrailing, wasapproximately R100 000. This costis similar to the cost of the paintsystem applied to the bridge and isapproximately 12% of the totalsteelwork cost.The specifying of a duplex coatingsystem has enabled the successfuldelivery of a robust and durableasset. The maintenance freeperiod for the paint work isexpected to be in the region of 20to 25 years.◆All the bridge elements arecommonly used standard sections.A simple handrail, fabricated intoindependent panels, was boltedinto place with sufficient toleranceto easily align it. The vertical poststo the handrail are 16mm solidsquare sections and were favouredas they have sufficient stiffness toresist distortion induced by the heatof the galvanizing process.Furthermore, for similar reasons,the minimum thickness of flat platespecified was 10mm.16 Hot Dip Galvanizing Today Volume 8 Issue 3 2011

Awards EventContainer Terminal Cape TownDUPLEX COATING SYSTEMS CATEGORY ENTRYDescriptionThe application of a duplex coating system to the refrigerationcontainer terminal at Portnet.Project partnersOwnerTransnet National Ports AuthorityProject manager Transnet Special ProjectsMain contractor WBHOSteel Fabricator: Scott SteelHot dip galvanizer andpaint applicator: Cape GalvanisingTons of steel1 200 tonnes of steel(10 tons per unit x 120 units)Information◆ As visitors drive into Cape Town, they will pass the Cape Towndocks where they will see row upon row of neatly paintedyellow and grey structures for the refrigeration containerterminal at Portnet. The structures are being used to houserefrigerated containers which are stacked three high, to whichthey are connected to the local electricity supply provided forat the site.◆◆◆◆◆◆◆◆Each unit weighs 10 tons, stores 9 refrigerated containers andhas separate walkways so that each container can be accessedindividually and are positioned directly adjacent to the harbourand in some areas as close as 20 metres to the sea.As the galvanized frames spent some time in the zinc due totheir size, the zinc coating could be classified as heavy with amean coating thickness of 175 microns, which together withthe paint will provide a total dft of 300 microns.However, our classification for this area would be mild tosevere marine as Cape Town docks is not subjected toexcessive salt spray and is in the main belt of the North Westwind which blows only in winter and provides a wash downeffect of contaminants.This corrosion protection system will have an indefinite lifetimeif correctly maintained and if the final paint coat is replaced atreasonable intervals.The only items that are not painted (but are hot dipgalvanized) are the 200 ton of grating panels that are fittedinto the walkways.At the same time as the new refrigeration Container Terminalwas being planned, Transnet staff also took the decision torenovate and disassemble approximately 100 lighting masts inthe entire dock area. In order to achieve this they put out atender, which included the dismantling, removal of paint byblasting, stripping, re-welding, the base sections, re-galvanizingand then painting the entire mast and ultimately replacing allthe electric cables and light fittings on the masts.All of this work, including transport, was undertaken by CapeGalvanising, with the exception of replacing the electricalfittings. The original hot dip galvanizing was still in goodcondition after some 20 years, but as all the welds had to bechecked it was considered necessary to strip and re-galvanize.This project involved educating the client, design authority andthe erectors as to the characteristics of duplex coating systemsand the service life advantages that can be obtained.20 Hot Dip Galvanizing Today Volume 8 Issue 3 2011

Awards EventMarine Floating Barriers Niger Delta, Nigeria (2009) & Simonstown, Cape Town (2010)MINING AND INDUSTRIAL CATEGORY ENTRYDescriptionA marine floating barrier, with all carbon steel components being hot dipgalvanized, designed to prevent boat borne access to strategic sites.Project partnersDeveloper / owner Cochrane SteelHot dip galvanizer Lianru GalvanisersInformation◆ Designed to prevent boat borne access to strategic sites, the marinefloating barrier is constructed of multiple floating buoys (standard1150mm dia) that are coupled together allowing for free 360◆◆◆◆◆◆◆◆◆◆degree rotation. The buoys are linked to form a barrier of anylength to suit a specific application.Buoys are supplied with a smooth surface or are alternatively fittedwith an array of spikes, the size and shape of which are tailored tosuit the threat.All carbon steel components have been hot dip galvanized toprovide for corrosion control in a range of operation sites andenvironmental conditions.The Marine Floating Barriers are filled with marine closed cell foamwhich renders them virtually unsinkable even when perforated orpunctured by bullet holes.Intruders have no opportunity to gain hand or foothold due todeadly spikes and revolving buoys.The ± 30 ton breaking strain barrier will restrict access of mostinsurgent types of water craft.All materials utilized have extended life span in corrosive fresh andsea water conditions. Stainless steel, hot dip galvanizing andduplex coating systems (for high visibility) are offered in terms ofcorrosion control designs.During the development stages of the product, extensive tests wereundertaken to establish the performance criteria from a defence andsecurity standpoint. This knowledge has become an essentialcomponent in marketing the product.To date this product has been successfully used in the Niger Deltaand in Simonstown Naval Dock Yard.Service life with a duplex system in a marine environment can beprojected as 18 years to first maintenance and more than 30 yearsfor hot dip galvanized products on inland water ways.The system is movable and can be relocated to suit changingsecurity conditions. It can also be extended in order to cover largersecurity zones.Volume 8 Issue 3 2011 Hot Dip Galvanizing Today 25

Awards EventGalvaglow – Environmentally friendly plantMINING AND INDUSTRIAL CATEGORY ENTRYDescriptionAn environmentally friendly hot dip galvanizing plant in SouthAfrica.Project partnersDeveloper / owner GalvaglowProject manager: Johan du PlessisMain contractor: VJL TechnologiesCompletion date: November 2010Project value: R13 millionInformation◆◆◆The plant boasts a 4m x 2.5m x 1.5m galvanizing kettlemanufactured by WPilling.The furnace was manufactured by Gimeco in Italy and is theonly new technology high velocity gas fired furnace operatingin a galvanizing plant in South Africa.The pre-treatment plant consists of ten polypropylene tanksmanufactured locally using the finest materials available. Thetanks have pumps installed to circulate the acid which allowsGalvaglow to pickle faster and therefore run their acid to alower count before replacing it.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: 041-486-1439◆◆◆◆◆◆◆◆◆The fume extraction system operates in an entirely enclosedpre-treatment plant built with polyethylene sheeting. The 9polypropylene tanks are fitted with a lip extraction plenumalong the sides of the tank. The pre-treatment plant also hasone larger vertical plenum with multiple slots on the furtherside of the plant which joins into the horizontal plenums alongthe tanks.This form of extraction which is known as the “push pullextraction system” is the most proven and effective localizedextraction principle. The plenum size and slot size is critical toensure the system works efficiently.The net effect of the system is that it allows the plant to operatewithout releasing harmful gasses into the environment.The Wet Scrubber System is connected to the extraction unit inthe pre-treatment plant; this is designed to absorb toxicparticles from the air streams using water to scrub the air.A final demister stage removes the liquid from the air stream.In essence, this system cleans the hazard and toxic fumesbefore releasing it back into the atmosphere.Galvaglow’s very efficient, high velocity gas fired furnacereduces the strain put on Eskom’s electricity supply.Excess exhaust gases from the furnace are redirected using hotwater pipes to heat the degreaser and flux tanks, savingfurther energy.Civil works are already complete to install their own effluenttreatment plant.Galvaglow uses a Chrome 6 Free Flux Solution which is anenvironmentally friendly chemical as it does not emit harmfulgases into the air.26 Hot Dip Galvanizing Today Volume 8 Issue 3 2011

Awards EventAnti-Vandalism CoversMINING AND INDUSTRIAL CATEGORY ENTRYDescriptionThe hot dip galvanizing of anti-vandalism apparatus cupboards in theDurban area for Metrorail Signalling Department.Project partnersDeveloper /owner ERB TechnologiesArchitectAfri Welding SolutionsSpecifierMetro Rail Signalling DurbanProject manager ERB TechnologiesMain contractor ERB TechnologiesSpecialists 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) 908-3329Hot dip galvanizerTons of steelArmco Galvanizers212 tonsInception date January 2009Project valueR20 millionInformation◆ Afriweld is a small local engineering firm that has grownrapidly from a small signage company to a firm that services aspecialized industry; that of vandal-proof enclosures mainly forrailway applications.◆ Vandalism has become a country wide problem, whichincreases annually and this has resulted in many signalcupboards being vandalised or destroyed, for sale as scrap.This in turn leaves the electronics for the signal controls opento the environment and an easy target for theft. Vandalisedsignal cupboards could lead to train accidents resulting inserious injuries or even death.◆ Afriweld, in conjunction with ERB Technologies, has designedand produced vandal-proof enclosures which have alreadyproved their worth as not a single signal cupboard has beendamaged since being replaced with these new vandal-proofcupboards.◆ In addition to being vandal-proof, this newly designedcupboard has a double layer wall which helps keep thecontrols cooler, resulting in a longer life span of the electricalcomponents.◆ Various vandal-proof designs have been tried and tested, butone of the features which makes this cupboard so effective isthe unique design of the lock and key. The door is almostimpossible to open without the special key.◆ Once the old cover has been removed, a new easy to carrymodular foundation is installed under the existing controls. Thecupboard and foundation come in several easy to handlecomponents, thus making it easy to carry to remote places.◆ As there is no need to disconnect the electrical components,this eliminates long down time of the signal controls, whichcould lead to delays in the train schedules.◆ These vandal proof cupboards are hot dip galvanized. Withan average coating thickness of over 50 microns, the lifeexpectancy is at least 50 years and exceeds any normalpainted specification. As galvanizing is a neutral colour itblends into the surrounding environment easily.◆ Once the initial proto-type had been built, Afriweld contactedthe galvanizers for advice on drainage and ventilation holes.They also investigated possible distortion during thegalvanizing process. The relevant changes were made and aneasy to galvanize enclosure was produced.Volume 8 Issue 3 2011 Hot Dip Galvanizing Today 27

Awards EventSustainable Affordable Buildings ParysMINING AND INDUSTRIAL CATEGORY ENTRYDescriptionAffordable housing, manufactured in kit form.Project partnersArchitectUrban Edge SV PS Architects &Plan ServicesProject manager SASSIMain contractor SASSIHot dip galvanizer Armco GalvanizersTons of steel4 tons per low cost dwellingCompletion date November 2010Project value >R250 000Information◆ SASSI is an organisation engineered to offer a sustainable,affordable and innovative approach to constructionmethodologies. Their methodology entails steel structures thatare pre-cut in their factory to a set design and used for eithercommercial or residential projects.◆ Utilities such as plumbing and electrical can be packaged withthe home and are easy to apply. Their completed structures areachieved swiftly and because of the bolt on system, ease oferection and assembly is ensured. As a result, high level skills arenot required.◆ This housing project is an easy to erect concept which allows theowner - builder to participate in a venture which is recognised byfinancial institutions.◆ Buildings are all based of hot dip galvanized steel platforms andsuperstructure. Longevity is guaranteed to exceed 50 years inmost urban and rural environments.◆ Demountable structures are available in either 35m 2 or 40m 2units. The elements are packed and ready to be transported andassembled. Foundations are cast as part of the assemblyprocess.◆ For the demountable structures, only the holding down bolts arecast in concrete bases. For permanent structures, the holdingdown bolts and nuts are cast into concrete. The steel elementsare bolted on and the roof is fitted as part of the assemblyprocess.◆ All structures are erected above the ground in order to reduce therisk of flooding. Walling-Demountable-Channels are secured toSassi elements to receive externally corrugated sheets andinternally plaster boards are used.◆ As the basic steel structure is sent in a kit form, the local marketsupplies the cement and bricks for the walls and foundation,thereby creating a further partnership between the fabricator andlocal industry.◆ SASSI is currently awaiting approval for the first 1 000 houses inthe Free State.28 Hot Dip Galvanizing Today Volume 8 Issue 3 2011

Cable Ladders and TraysMore than just bent metalTwo views of edge mounted cable ladders for a recent major project.With their recent move to larger and better appointed Strutfast’s focus is the manufacture and supply of cablepremises in Maraisburg, conveniently situated just off the management products to construction and industryN1 in Johannesburg, Strutfast has shown confidence in throughout the African continent. The company'sthe market they set out to serve when the company was competitive edge in the market is achieved by theestablished in 2001. continued on page 30...Volume 8 Issue 3 2011 Hot Dip Galvanizing Today 29

Cable Ladders and TraysA view of external and internal storage facilities at Strutfast.continual addition of new manufacturing expertise and newproduct development in all areas.Its success has been achieved by a hands-on managementapproach and employing people with the necessaryknowledge and skills, people who are genuinelypassionate about service and quality. Strutfast believes inempowering its staff to give the customer the bestadvantage.Besides its people skills and commitment to Broad BasedBlack Economic Empowerment (BBBEE) and constantlystriving to grow skills development in the country, quality isalso essential to Strutfast. Its Management System for theDesign, Manufacture, Stocking and Supply of CableManagement Systems is certified by Bureau Veritas to be inaccordance with the requirements of ISO 9001:2008. Thecompany is in the process of extending its ManagementSystems Requirements to attain compliance with the ISO14001:2004 "Environmental", and the OHSAS 18001:2007"Occupational Health and Safety" Standards.Cable management systems for the mining andpetrochemicals industries form the majority of its work.Strutfast has completed numerous exciting projects in thepast. Supply of support solutions for cable reticulation atMedupi Power Station in Lephalale is one of their largestcurrent long term projects. Strutfast’s centralised stock isbased in Gauteng, however the company distributesthroughout South Africa and the African Continent.Strutfast provides a network of services to ensure totalsupport. The company provides system design, marketingand project management support for its customers as wellas being the stockist of manufactured products.An additional view of edge mounted cable ladders for a recent major project.30 Hot Dip Galvanizing Today Volume 8 Issue 3 2011

Cable Ladders and TraysGeneral and continuous hot dip galvanizedunistrut sign support channelsThe top four photos show the location, cross sectional shape and typical coatingthickness of a 1.6mm thick continuous hot dip galvanized strut. The lower three photosshow the location and typical coating thickness of a 2.5mm thick general hot dipgalvanized strut. As life of the coating is proportional to its thickness, it makes sense touse the thicker coating offered when the signage support is exposed to more aggressiveenvironments.The Association would like to thank Strutfast for this table.Volume 8 Issue 3 2011 Hot Dip Galvanizing Today 31

Artistic WorksArtistic works of artthat require durabilitywhile maintaining theirdesirabilityWhat internationally known artists andsculptors such as Willie Bester (photos 10 to15) and Andries Botha both SouthAfricans (photos 3 and 9), Ralph Helmick(photo 6), Roxy Paine (photos 1 and 7) andBettye Hamblen Turner of the USA (photos4, 5 and 8) and Andy Scott of Scotland(photo 2), have in common is their desire touse steel as their selected material ofchoice. But because of steel’s tendency toreturn to its natural state (rust) it has tobe suitably protected.While providing the flexibility required,steel has one major drawback in that itrusts if not properly coated. For long termdurability and very little or no mainte-nance after exposure to the elements theseartists chose to either hot dip galvanize orzinc metal spray their works of art.A traditional choice of material such asbronze is always a consideration due toits natural durability but by includingother less exotic and more flexiblematerials such as steel the artist is ableto expand on his or her choice.Many of these artistic structures, besidesbeing eye-catching, innovative and uniquemust be maintenance free for as long aspossible because most of them areexposed to the natural elements ofcontinued on page 34...Photo 1.Photo 2.Photo 3.Photo 4.Photo 5.Photo 6. Photo 7.32 Hot Dip Galvanizing Today Volume 8 Issue 3 2011

Zinc Metal Spraying?Suppliers of Arc Spray andFlame Spray Equipmentand ConsumablesWEARTECH (Pty) LtdTHERMAL SPRAY DIVISION187 Galjoen Street, WadevilleP.O. Box 14125, Wadeville 1422Gauteng, South AfricaTelephone: (011) 824-6010/2/3/4/5Fax: (011) 824-6090KZN - Telephone: (031) 466-4461CAPE TOWN - Telephone: - (021) 447-4728E-mail: sales@weartech.co.zaWebsite: www.weartech.co.za

Artistic Workscollectors’ gardens, public parks, andother outdoor public spaces.Both zinc metal spraying (for morefragile and thin structures) and hot dipgalvanizing (for more robust structures)are utilised to perform this function.Some of the works of art are over coatedusing some form of paint or lacquerspray and then afterwards finely etchedusing a mechanical wire wheel toproduce the desired artistic effect.It is important however, that theseartists have a sound working understandingof the design requirementsnecessary in order that their sculpturesare comprehensively coated whilemaintaining their shape. Alsoimportant is the addition of adequatevent holes that when dipped intomolten zinc, prevent the formation ofsuper-heated steam, the inevitableexplosion and sub-sequent loss of anexpensive work of art.Furthermore, the sourcing by the artist ofa galvanizer who is willing to undertakethis type of work is extremely importantto achieve the necessary results.As Bettye Hamblen Turner says, “Planning,co-ordination and luck, lucknever hurts, even when everything iscarefully planned. The AmericanGalvanizers Association has a websitethat offers tutorials,http://www.galvaniziet.org/. I studied thetutorials when I made the horses. IPhoto 8. Photo 9.Photo 10.Photo 11.Photo 12. Photo 13. Photo 14. Photo 15.34 Hot Dip Galvanizing Today Volume 8 Issue 3 2011

Artistic Worksspoke with the plant manager at USGalvanizing in Arlington, Texas severaltimes during the sculpturing processon the horses. By the time I made thebull, I had a better idea of how tobrace the floating pieces to avoiddistortion. As most galvanizers spendtheir time doing structural, gates,burglar bars and uninteresting widgets,hot dip galvanizing a sculpture is apleasant change of pace for them”We salute these artists in their choiceof long term metal protection.The Association wishes to thank Willie Besterfor his time and material as well as DesereStrydom for her love of hot dip galvanizing andencourage readers to visit her blogspot for moreinformation on these artists and much more:http://commentfromthecouch.blogspot.comVolume 8 Issue 3 2011 Hot Dip Galvanizing Today 35

Bob’s Bantersaid: “A man’s private thoughts cannever be a lie; what he thinks, is tohim the truth, always.” We are moreeasily able to forget facts than ourthoughts. From here can we notdeduce that written facts will bemore easily forgotten than our ownspecial thoughts, and they are allspecial for we as individuals areunique? So perhaps Socrates and hiscolleagues may have been right.One of the problems psychologistshave in the measurement of memoryis that each time we remember wetransform our memories; the humanmemory is not like that of acomputer, called up from store,consulted and replaced unmodified.It’s almost as if the memory isrecreated each time we have toremember. Our thoughts are alsotransformed by our environment,which again is very unlike thememory of a computer. Spare athought for one Shereskevskii (hewas mostly called Mr.S becausenobody could remember his name)who had a major problem; he couldnot forget. Psychologists who studiedhim found that he translated allinputs into his brain in the form ofintricate pictures and stories. All pastmemories kept intruding on freshones.But let’s get back to our corporateobsession with written documents.What we are writing to each other allday are mostly facts and data whichmay be very important but which aredifficult to remember. Perhaps weshould rather communicate thoughtsand meanings. Ricardo Semmler atSemco (Maverick) has obtainedamazing results by asking all staff towrite only ‘headline’ memos. The fullmeaning, not the facts and data, isthus communicated. An engineer inhis organisation who invents anddevelops a new machine does nothave to write an endless report tocommunicate and justify his idea: hesimply sends the boss a memostating’ “New Cost Effective GismoInvented-It Works!”. Those who wantto see how it was developed can askhim. There is also little doubt that weshould use the spoken word more. AsSocrates implied: when we speak toeach other we communicate ourthoughts and our meanings of things.In this way we enrich not only ourown minds but also those that listento us. Quoting Mark Twain again:“Life does not consist of facts andhappenings. It consists of the stormof thoughts that is forever blowingthough one’s heads.”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.Volume 8 Issue 3 2011 Hot Dip Galvanizing Today 37

Education3CPD POINTS3-day Galvanizers Inspectors CourseHot dip galvanizing is one of the most widely used methods of protecting steel from corrosion. Duringfabrication and after hot dip galvanizing the coating is inspected for compliance with the relevant specifications.Following up on comments received from the many participants attending our regular two day inspector courses over the last nine years, wedecided to expand and update our 2-Day course into a more comprehensive 3-Day course.Included are revisions of the course material and the introduction of more practical activities in the form of a full morning at a hot dip galvanizing plant followed by an afternoonof Duplex coatings. The galvanizing plant visit examines materials prior to galvanizing and hands on inspections of finished product. The afternoon is a visit to a paint applicatorsyard and Duplex coatings systems. Included are demonstrations on chemical cleaning and/or sweep blasting, examination of resulting profiles and followed by the applicationof paint onto galvanizing. The course will provide delegates with sufficient knowledge to advise on fabrication for successful hot dip galvanizing and also test, inspect and interprettest results after hot dip galvanizing.COURSE DURATION AND CONTENTSDay 1 (08h00 to 16h00)Lecture 1 Introduction to the Environment, Steel & CorrosionLecture 2 Understanding Zinc Coatings (How does Zn protect)ISO 9223 & 12944Lecture 3 Designs, Fabrication and Inspection before hot dip galvanizing SANS(ISO) 14713:1999Lecture 4 General Hot Dip Galvanizing ProcessesSANS 121 (ISO 1461:2009) Batch type galvanizingSANS 32 (EN 10240: 1997) Automatic T & PSANS 10094:2007 HDG of Friction Grip FastenersDay 2 (07h00 to 16h00)DATE AND TIMECourses commence at 08h00 sharp and end at 16h30 (or as otherwise instructed).Lunch and refreshments will be provided. Comprehensive course notes can becollected from our offices two weeks before the course (this is highly recommended).Johannesburg:15 to 17 February; 15 to 17 March; 19 to 21 April; 17 to 19 May; 21 to 23 June;16 to 18 August; 4 to 6 October; 22 to 24 November.Cape Town:8 to 10 March; 7 to 9 June; 6 to 8 September.Special courses can be arranged for a minimum of 6 delegates at appropriate venuesin South Africa.COURSE COST AND PAYMENT TERMSLecture 5Day 3Lecture 6Lecture 7Hot Dip Galvanizing Plant Visit and InspectionDuplex Coatings and HDG Reinforcement in ConcreteDuplex Coatings Plant Visit and Applications(08h00 to Completion of Exam)Inspections after Hot Dip GalvanizingQuality Assurances in Coating ApplicationsApplication of specificationsControl documentation for a QA SystemExamination on Course EffectivenessR4 200.00 per person exclusive of VAT. Should you have two or more delegates fromthe same company, course costs will be R4 000.00 per person exclusive of VAT. Pleasenote that payment is due on the first day of training. Cheques are to be made out to“Hot Dip Galvanizers Association SA”. Members qualify for a discount.CONTINUOUS PROFESSIONAL DEVELOPMENT (CPD)By attending the Association’s 3 day course Galvanizing Inspectors Course, you willobtain 3 points (accredited by ECSA).Course schedule may be altered and interesting activities added for thebenefit of delegates.Following the course and successful result in a three part exam, thedelegate will be issued with a certificate and if required, registered as anapproved HDGSA Galvanizing Inspector. Registration will be confirmed onan annual basis. Successful galvanizing inspectors will become AffiliateGalvanizing Inspector Members of the HDGASA for the year.VENUE AND NUMBER OF DELEGATESThe courses are usually run in Johannesburg from the Hot DipGalvanizers Association in St Andrews, Bedfordview and also from asuitable venue in Cape Town. Bookings are limited to 10 people percourse on a first come first serve basis.SHOULD YOU BE INTERESTED, KINDLY CONTACTSASKIA SALVATORI OR MARJORIE MONTGOMERIE AT THE ASSOCIATION38 Hot Dip Galvanizing Today Volume 8 Issue 3 2011

New ProductsElcometer sets new standards forcoating inspection data managementIntroductionMany clients now request evidence of the coating inspectionprocesses carried out when a coating is applied. It is oftensaid that while inspection processes earn money, thereporting of such inspections costs money, as this is time thatthe inspector is not inspecting. A method for automating andspeeding up the coating inspection process is essential.◆◆A 2.4” colour display, clear menu structure and largebuttons making the new Elcometer 456 incredibly easy touse.Measurement capability to ±1% on smooth, rough, thinand curved surfaces the new Elcometer 456 gives yourepeatable and reproducible results and is backed by a 2year gauge warranty.Elcometer have recently introduced a new range of coatingthickness gauges with a new and much improved datamanagement software, ElcoMaster 2.0, which offers users asingle software solution, not only for coating thicknessmeasurements, but also for other gauges used in theinspection and monitoring of coating processes – such assurface profile and climate monitoring equipment - providinga solution for the creation of professional inspection reportsin minutes, for all coating inspection parameters, therebygiving a competitive advantage in today’s industrialenvironment.The new Elcometer 456 coating thickness gaugeFast, reliable and accurate, the new Elcometer 456 sets newstandards in coating thickness measurements. Available in arange of models for measuring dry film thickness on ferrous &non-ferrous metal substrates, the new Elcometer 456 is evenmore powerful, rugged and easier to use than ever before.Key features include:◆ Incredibly fast measuring speed of more than 70 readingsper minute – the new Elcometer 456 is more than 40%faster than other gauges.The new Elcometer 456 gauges are available in four Modelswith each level providing the user with increasingfunctionality, from the entry level Elcometer 456 Model E tothe top of the range Elcometer 456T with memory, alphanumericbatch identification and Bluetooth® wirelesscommunication.Integral and separate probe versions are also available -allowing users to select the most appropriate coatingthickness gauge for their application. Integral probe versionsare ideal for single handed operation and the wide footprintof the Bigfoot probe provides good stability on the coatingsurface during measurement for consistent, repeatable andaccurate results. Separate probe versions provide a very widerange of thickness scale and probe-format options, whichgreatly enhances the measurement flexibility. Straight, RightAngle, Miniature and Telescopic probes are available as wellas a range of special probes for under water, hightemperature, soft coatings and anodising. Armoured probes,which have metal reinforced heavy duty, are also available.Separate probe models can be converted to an integralversion using the Elcometer Plug-In Integralprobe (PINIP).◆◆Memory capacity of up to 75 000 readings in alphanumericbatches, interchangeable probes and output toElcoMaster 2.0 software the new Elcometer 456 isincredibly powerful.Impact resistant and sealed against dust and waterequivalent to IP64, the new Elcometer 456 is incrediblyrugged and is the ideal gauge for all environments.Data managementsoftwareOnce all the inspectionreadings have been taken,and stored within thegauge’s memory, Elcometer’scontinued on page 40...Volume 8 Issue 3 2011 Hot Dip Galvanizing Today 39

New ProductsData Management Software.Data Management Software.new ElcoMaster 2.0 Data Management Software providesusers with a simple, yet powerful tool for managing,analysing and generating reports.Elcometer began developing software over 30 years ago and,with the release of ElcoMaster 2.0, has created an easy to usesolution for the need to minimise the time generatinginspection reports. Some of the key features of the ElcoMaster2.0 software include:◆◆Download readings from any type of Elcometer inspectiongauge and combine different measurement parameters(climate, profile, coating thickness, etc.) on a single reportImport and attach photographs, together with inspectionnotes, to your reportsThe Association would like to acknowledge theadvertisers and thank them for their supportArmco Superlite Galvanizing..............................Outside Back CoverAveng Trident Steel (Pty) Ltd ..................................Inside Front CoverBAMR .................................................................................... page 39Bulldog Projects (Pty) Ltd ...................................................... page 14Central Support Systems cc ................................................ page 30Chemplus................................................................................ page 22Chemserve Systems (Pty) Ltd................................................ page 35Galvanizing Techniques (Pty) Ltd ........................................ page 26Hi-Tech Elements (Pty) Ltd .................................................... page 20Macsteel Tube & Pipe .......................................................... page 11HDGASA................................................................................ page 9Phoenix Galvanizing ............................................................ page 21Pro-Galv cc ............................................................................ page 5Robor Galvanizers ................................................................ page 17◆◆◆◆◆◆Export readings, images and notes, together with gaugeand calibration information, into Excel or otherspreadsheet formatsPrint, email or generate a .pdf report file directly fromElcoMaster 2.0Design your own reports, scan or directly import from apdf file a predefined report template and simply drag &drop readings or statistics onto the appropriate area ofthe reportE-mail a partially completed report to another sitelocation for completion at final assembly - ideal forcombining multiple site inspectionsUsing the ‘webupgrade’ feature ElcoMaster 2.0, allowsusers to ensure that their gauges and software are alwaysup to dateConnect to the Elcometer Internet Cloud and downloadpredesigned report formatsSigma Coatings .................................................................... page 42Speccoats .............................................................................. page 41Strutfast Cable Management Systems ................................ page 29Supergalv (Pty) Ltd ................................................................ page 27Surface Treatment Technologies (Pty) Ltd .......................... page 25Transvaal Galvanisers (Pty) Ltd ............................................ page 3VJL Technologies (Pty) Ltd .................................................... page 37Weartech (Pty) Ltd ................................................................ page 33ElcoMaster 2.0 has been designed to be completely userfriendly. Internal wizards guide the user through all thevarious steps from connecting and downloading readingsfrom a gauge to generating reports and archiving the data forISO records.Other data collection gauge optionsElcoMaster 2.0 combines data from different electronicgauges in to a project folder so, for a particular coating40 Hot Dip Galvanizing Today Volume 8 Issue 3 2011

New Productsproject or client, data on material thickness, surface profile,climatic conditions, appearance (Gloss) and coatinghardness can be combined with the coating thickness datato provide a single comprehensive report.Gauges, connecting via Bluetooth, USB or RS232, can eitherdownload the measurement readings from the batchmemory, or can connect to ElcoMaster 2.0’s live gaugereading application, allowing real time charting and datastorage – directly into the computer.For those inspection tasks that do not have a gauge torecord the value (relying on pictorial comparisons forexample), or have mechanical or non-memory testequipment (adhesion, surface cleanliness or wind speedgauges for example), data can be manually entered –making ElcoMaster 2.0 the data management solution.ConclusionsThe management of data collected when coating inspectiontasks are carried out can be vital when the Client requiresdetailed reports on the quality control procedures. A newcontinued on page 42...Zinc Deficiency in Cane SugarThe two essential micronutrients needed by cane areiron and zinc. Though needed in ppm levels, they are asessential as the macronutrients for the normal growthand yield of all crops. When the contents of iron andzinc in the 3 - 6 leaves from the top of the sugarcanefall below 10ppm, the crops will suffer deficiency.Deficiency of iron and zinc is aggravated by highalkaline pH, calcareousness and low organic matterstatus of the soil. In case of zinc deficiency, veins andareas adjacent to the veins become chlorotic while theintervenial spaces remain green. Under severedeficiencies of iron and zinc, the crop will becomechlorotic and presents a sickly yellowish-white canopy.To rectify the deficiencies of iron and zinc, the cropmust be sprayed with spray fluid prepared by dissolving1kg ferrous sulphate, 0.5kg zinc sulphate and 2kg ureain 100 liters of water at the rate of 500 liters per hectareof spray fluid immediately after observing thecharacteristic chlorotic symptoms and the sprayingmust be repeated once or twice fortnightly.The Association wishes to thank IZASA for this contribution.Volume 8 Issue 3 2011 Hot Dip Galvanizing Today 41

New Products and Duplex Coating Systemspowerful, fast and easy to use software solution is nowavailable, ElcoMaster 2.0.ElcoMaster 2.0 software has been developed not only tomake use of many of the features available in the newElcometer 456 Coating Thickness Gauge, but also allowsusers to link other digital inspection gauges to handleinspection data such as material thickness, surface profile,climatic conditions, appearance and coating hardness,whilst also allowing manual data entry of other inspections.The new Elcometer 456 Coating Thickness Gauge is fast,versatile, rugged and has benefited from over 60 years ofElcometer experience.For more information on the Elcometer 456 Digital CoatingThickness Gauge range including the ElcoMaster 2.0 DataManagement Software contact Elcometer atsales@elcometer.com or visit our website www.elcometer456.com.For information on the other Elcometerproducts mentioned in this article,contact Elcometer at sales@elcometer.comor visit our website www.elcometer.comAbout ElcometerElcometer is a leadingmanufacturer of highquality inspectionequipment, withspecialised divisionsdedicated to coatingsinspection, concreteinspection and metaldetection.For information on our fullrange of products visit ourwebsite atwww.elcometer.comSIGMA COATINGS DUPLEX SYSTEMSADVERTORIALSigmaCover 280 (previously called SigmaCover Primer) is a well-knownprimer for over coating hot dip galvanized steel and other ferrous and nonferrousmetals. The unique green/gold colour makes it instantly recognisable.SigmaCover 280 has been used as part of duplex systems on hot dipgalvanizing for many years. Its success lies in the fact that notwithstandingthe appropriate preparation of the substrate the adhesion to hot dipgalvanized steel is exceptional as it is very forgiving and user friendly.Sigmacover 435 is used as an intermediate high build coat when structuresare in severe marine environments and an additional moisture barrier isrequired. The finish coat is usually Sigmadur 550 because duplex systemsare long-lasting and the top coat needs to be able to withstand the elementsfor an extended period of time.Sigma Coatings duplex system offer the following coatings: SigmaCover 280:75 – 100µm; SigmaCover 435: 100 – 125µm; SigmaDur 550: 40 – 60µm.The intermediate and top coats of the Duplex systems may change forspecific project related reasons; however the SigmaCover 280 is almostalways used as the primer.Sigma Coatings has worked closely with Cape Galvanising and Terry Smith ofthe Hot Dip Galvanizers Association Southern Africa over the last few yearsto specify suitable duplex systems in a marine environment.The best example we have to date on the efficacy of duplex systems in amarine environment is the walk-way grating at Exxaro Brand-se-Baai Mine(previously Namakwa Sands). The grating is in an environment where thereis a fine mist of sea water from the plant operation, permeating the air Theatmosphere is similar to a salt spray bath while the plant is in operation.When the plant is not in operation the grating remains moist.Most of the grating was covered in red ferrous corrosion, showing that mostof galvanizing had been sacrificed after five years in operation. Replacementand refurbishment of grating started around 2001. All the grating that hadnot lost more than critical mass was blasted and painted with a zinc-richepoxy and all the grating that had lost more than critical mass was replacedwith hot dip galvanized grating. SigmaCover 280 was applied to thegalvanized grating and both the new and old grating was then coatedglassflake reinforced epoxy to withstand the abrasion on the top edge thatcarries the traffic. None of the replaced or refurbished grating has to dateshown any signs of further corrosion.The photo of a section of palisade fence exposed to salt spray testing clearlyshows the corrosion of the galvanizing and benefits of duplex coatings insevere marine and coastal conditions.Contact:Sean Haywood: Cape Town 021 528 3680 • Frans Viljoen: Port Elizabeth 041 372 1860Alvin Varaden: Durban 031 569 6234 • Fred van Deventer: Gauteng 011 389 480042 Hot Dip Galvanizing Today Volume 8 Issue 3 2011

GeneralThe realprotection atJozini PrivateBush Lodge ishidden!In the interest of a longer lasting andmaintenance free structure, which wouldnot easily be accessible in future,Cousins Steel International decided toconstruct the sub-frame using hot dipgalvanized steel and then clad withtimber on both the inside and outside.General hot dip galvanized (and notcontinuous hot dip galvanized) purlinswere also used as cross members onwhich ceiling timber was anchored.GALVATECH2011BRINGS STEEL AND ZINCINDUSTRY TOGETHEROver 500 steel company engineers and researchers joined with academicand government officials at Galvatech 2011, the 8th edition of the worldspremier zinc and zinc alloy coated sheet conference during June 21-24 inGenoa, Italy. Nearly 200 papers and posters were presented in 72 technicalsessions, plus an opening session for all participants.Highlighting the opening session were speeches by Kazuaki Takada ofToyota Motor Europe on expected challenges for galvanized automotivesteel applications, Don Smale of International Lead Zinc Study Group on thecertain adequacy of zinc supply for further galvanizing demand, DebanshuBhattacharya of ArcelorMittal with a global perspective of advanced galvanizedsteel development, and Klaus Peters of ThyssenKrupp who describedEuropean challenges and opportunities. The session concluded with a presentationby Qifu Zhang of the China Central Iron and Steel ResearchInstitute on Chinese industry developments.For the first time, sessions were dedicated to recent advances in Zn-Al-Mgcoating development and also hot press forming steels for ultra-highstrength automotive applications. Special sessions on laboratory simulationand quality control were also included. In addition to Toyota, leaders fromFiat and General Motors presented future automotive challenges for galvanizedsteel sheet to participants. Challenges from the appliance and constructionindustry were given by Whirlpool and the University of Naples.Sessions giving details of many of the new galvanizing lines constructed inthe last 4 years, especially in Europe, were included together with many sessionson operating technology and product characterization.PROPOSED FEATURESFOR 2011November / December (No 49):• The world of hot dip galvanizingaround us• Greening of the hot dip galvanizingindustryNOTE: FEATURES MAY BE SUBJECTTO CHANGEGalvatech 2011 was co-chaired by Josef Faderl (voestalpine), Frank Goodwin(Intl Zinc Assn.), Thomas Koll (Saltzgitter) and Giancarlo Quaranta (ILVA).According to Dr. Goodwin, Galvatech 2011 carried on the story of successoriginating in Tokyo in 1989. In many cases the session speakers includedthe worlds leaders on each topic, making this a compelling conference toattend. I was very pleased that speakers came from 24 countries, with manymore countries represented among attendees. The exposition, which soldout a few weeks after it was announced, included 20 leading suppliers ofgalvanizing equipment.At the conference dinner at the Genoa Aquarium, the largest in Europe, itwas announced that Galvatech 2013 will be held in China, followed byGalvatech 2015 in Canada.International Zinc AssociationVolume 8 Issue 3 2011 Hot Dip Galvanizing Today 43

On the CouchRob WhiteOn the couch caught up with RobWhite of the IZASA on the eve of hisfirst holiday in four years!Please tell us briefly about yourbackground? I was born in a smallmarket town in Yorkshire. My firstdegree at Manchester was followed byfive years working in the WaterIndustry, before returning to varsity. Iwas fortunate to be a Shell Bursar atthe time of the troubles in Iran, so myresearch work was diverted from theoil industry to the Royal Navy inPortsmouth. That was my first realtaste of corrosion close up and aftercompleting my M. Sc. on diving lifesupport systems and nuclear subs, Iwas offered a position, in SA, to startup a research group at the thenNational Institute for Metallurgy tosupport the mining industry. Thisgroup developed numerous corrosionprotection schemes for industry andwas my first real taste of thegalvanizing industry.How did you get into this industry? Theearly 1980s were heady days andmining development was expanding atan unbelievable pace. The HDGASAwas very active in the mining industrywith Walter Barnett pushing hard forthe use of galvanized steelwork forunderground shafts. Work at Kinrossmine, dating back to the 1970s, stillstands out as a milestone in theadoption of galvanized steelwork indeep level mining world-wide. Ibecame more involved with theCorrosion Institute. Those days theExecutive Director was Dennis Twiggwho had been the Head of theMetallurgy Section at the SABS before.I went overseas for a bit and on myreturn I worked in the stainless steelindustry for some years. I then got toknow the galvanizing industry very wellas we had constant battles between3CR12 and galvanizing.About the IZASA? Anglo and the thenKumba Resources had been membersof the International Lead ZincResearch Organisation and theinternational Zinc Association for anumber of years. The feeling was thatlocal market development activities inthe zinc industry should be stepped upand Ernst Venter (who headed theBase Metals Division at Kumba) feltthat we should establish a local bodyto leverage the international worklocally. From this IZA Southern Africa(IZASA) was born.Your role at the Zinc Association? I wasasked by the IZA if I would be willingto provide general galvanizing industrysupport globally at about the time thatIZASA was formed and this hascontinued.What synergies are there between the IZASAand the hot dip galvanizing industry?Galvanizing is still the main market forzinc in SA with the general galvanizingindustry consuming over a quarter of allthe zinc produced locally. We haveprovided support through hosting twoconferences with the HDGASA and havefunded seminars using Prof StephenYoemans of Australia, to support thedevelopment of galvanized steelreinforcement (rebar) applicationslocally. I personally keep in touch withthe key industry players.The IZASA has associated itself with AZcoating technology, now available in SouthAfrica, through SAFAL steel. Yourcomments comparing AZ coatingtechnology to that of the traditionalcontinuously hot dip galvanized roofsheeting, traditionally available? I am onrecord as having said that it was apity that South Africa did not have aAZ coater in the country so it’spleasing to see SAFAL (who areIZASA members) finally inproduction. AZ coatings are superiorin most circumstances to normalgalvanized coatings and savings canbe made in terms of coating weightsfor each exposure environment. Withthe recently adopted new standardsin building it is essential thatspecifiers have confidence inspecifying correct systems. With thisin mind IZASA is project managing alimited corrosion exposure programto test full systems in the moreaggressive environments of thecountry. This program will includefasteners as well to try and protectconsumers from using substandard,roofing and cladding products beingcurrently imported.Please tell us about your hobbies andpassions? I enjoy canoeing, and cyclingand I do have a piano and try to playwhen time permits. I have found thatthe zinc industry is quite a musicalfraternity and we would have enoughplayers to found a good band!When Rob White goes home... I try topark off by either reading or listeningto music.©Desere Strydom for Hot Dip GalvanizingToday 201144 Hot Dip Galvanizing Today Volume 8 Issue 3 2011

HOT DIP GALVANIZING MEMBERSGALVANIZER LOCATION TEL. NO SPIN NO. OF BATH SIZESLINES (L x W x D) (m)GAUTENGArcelorMittal South Africa Vanderbijlpark 016 889-9111 3 Sheet galvanizerArmco Galvanizers Isando 011 974-8511 1 13.2m x 1.5m x 2.2mArmco Galvanizers – Dunswart Dunswart 011 914-3512 ● 3 5.2m x 1.2m x 2.0m3.0m x 1.0m x 1.5m2.0m x 1.0m x 1.5mArmco Galvanizers – Randfontein Randfontein 011 693-5825 1 6.5m x 1.3m x 2.0mBabcock Ntuthuko Powerlines (Pty) Ltd Nigel 011 739-8200 1 12.0m x 1.4m x 1.8mCape Gate (Pty) Ltd Vanderbijlpark 016 980-2270 # Wire galvanizerDB Thermal SA (Pty) Ltd Nigel 011 814-6460 In-line 16.0m x 1.0m x 1.0mGalvadip (Pty) Ltd Waltloo 012 803-5168 2 7.2m x 1.7m x 2.2m7.0m x 1.5m x 2.5mGalvaglow Factoria 011 955-5200 1 4.0m x 1.5m x 2.5mGalvspin Galvanizers cc Boksburg North 011 918-6177 ● 2 2.0m x 1.2m x 1.5m1.5m x 1.0m x 1.5mGEA Air Cooled Systems Germiston 011 861-1571 In-line 11.5m x 1.0m x 1.0mLianru Galvanisers cc Nigel 011 814-8658 2 7.2m x 1.3m x 1.6m4.5m x 1.3m x 1.6mMacsteel Tube & Pipe Boksburg 011 897-2194 In-line 13.5m x 1.6m x 2.4mPro-Tech Galvanizers (Pty) Ltd Nigel 011 814-4292 ● 2 3.2m x 1.1m x 1.5m3.0m x 1.1m x 1.2mRobor Galvanizers (Pty) Ltd Germiston 011 876-2900 3 14.0m x 1.35m x 2.5m10.0m x 2.0m x 4.0mTube Dia 42mm to 114mmmax tube length 6.7mRobor Tube Elandsfontein 011 971-1600 1 Tube & pipe galvanizerSupergalv Alrode 011 908-3411 1 6.0m x 1.2m x 1.8mTransvaal Galvanisers Nigel 011 814-1113 3 9.0m x 1.0m x 1.0mIn-line & general 8.0m x 1.2m x 1.5m6.0m x 1.3m x 1.3mNORTH WESTAndrag Agrico Lichtenburg 018 632-7260 # In-line galvanizerFREE STATEHarrismith Galvanizing & Steel Profile Harrismith 058 623-2765 2 4.5m x 1.3m x 2.5m(NB: Big line is not in operation)(12.0m x 1.2m x 2.5m)WESTERN CAPEAdvanced Galvanising (Pty) Ltd Bellville 021 951-6242 1 8.0m x 1.5m x 3.0mCape Galvanising (Pty) Ltd Parowvalley 021 931-7224 1 14.0m x 1.6m x 2.6mGalvatech (Pty) Ltd Bellville 021 951-1211 1 7.5m x 1.5m x 2.6mHelderberg Galvanizing Strand 021 845-4500 1 5.5m x 0.8m x 2.4mPro-Galv cc Stikland 021 945-1803 1 7.2m x 1.3m x 2.6mSouth Cape Galvanizing (Pty) Ltd George Industria 044 884-0882 2 3.7m x 0.94m x 2.3m(NB: Big line is not in operation)(5.5m x 1.0m x 2.6m)EASTERN CAPEGalvanising Techniques cc Port Elizabeth 041 486-1432 1 12.0m x 1.3m x 2.3mGalvaspin (Pty) Ltd Port Elizabeth 041 451-1947 ● 1 3.0m x 1.2m x 1.8mMorhot (Pty) Ltd East London 043 763-1143 1 6.0m x 1.2m x 2.5mKWAZULU/NATALA&A Galvanisers Pietermaritzburg 033 387-5783 ● 1 3.3m x 0.9m x 1.9mBay Galvanisers Richards Bay 035 751-1942 1 5.0m x 1.2m x 2.5mPhoenix Galvanizing (Pty) Ltd Phoenix 031 500-1607 ● 2 14.0m x 1.4m x 2.5m3.0m x 1.2m x 1.2mPinetown Galvanizing Pinetown 031 700-5599 1 9.0m x 1.2m x 3.0mVoigt & Willecke (Pty) Ltd Durban 031 902-2248 1 14.0m x 1.3m x 2.5m# Sheet, wire, pipe and other in-line galvanizing members dedicate their plants to the galvanizing of their own products.Note:- Where more than one galvanizing line is available, the number of lines and the significant bath dimensions are listed, ie. widest, longest and deepest.- For specific contact names (e.g. sales or production personnel) and mobile telephone numbers, contact company receptionist.- The bath sizes are inside dimensions and not maximum component size (length, width and depth). Kindly take note of the expansion of the componentwhen dipped into molten zinc, or discuss with relevant galvanizer.

HOT DIP GALVANIZING MEMBERS