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Zingametall

Zingametall. www.zinga.eu. Content Zingametall History and location Current activities ZINGA Main characteristics Advantages Summary Reports/ certificates Reference information. Zingametall. History and locations. Created in the late 70’s Started with ZINGA (Zinganisation)

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Zingametall

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  1. Zingametall www.zinga.eu

  2. Content • Zingametall • History and location • Currentactivities • ZINGA • Maincharacteristics • Advantages • Summary • Reports/certificates • Referenceinformation

  3. Zingametall • History and locations • Created in the late 70’s • Started with ZINGA (Zinganisation) • to fill the void between hot-dip and paints • development in cooperation with: • University of Ghent (http://www.ugent.be/en) • Umicore (http://www.umicore.com/en/) • Move to Eke, Belgium Small country, but with lots of opportunities (strong in chemicals) • Applications started in Europe and later all over the world • Test reports and certificates followed • ISO 9001:2008 • New website (a lot of information and updates) (www.zinga.eu)

  4. Zingametall • Current activities • ZINGA as main system (film galvanisation) • ideal combination advantages • galvanisation (hot-dip, metallisation) • → offer cathodic protection • paints • → passive protection • reports/references • Expansion of distributionship • presence in Europe, Middle-East, • Asia, Africa, Australia, North-America • and more recently South-America • Expansion of range of products • primers • sealers • topcoats

  5. ZINGA (film galvanisation) • Main Characteristic • Active, cathodic, galvanic protection thanks to its high zinc content • active, cathodic, galvanic protection due to its high zinc content • ~ other galvanisation techniques (hot-dip, metallisation) • passive barrier protection due to the zinc salt on top of the surface • and due to the binder in ZINGA (encapsulation of zinc particles) ~ paint

  6. ZINGA (film galvanisation) • Advantages • Easy application on site and in workshop • (Zinganisation) • by brush, roller, painting gloves, • spray-application • can be applied on site, even • by non-professionals • Application in a wide range of weather conditions • damp surface (no droplets) • high or low temperatures • Application under ambient temperatures • no deformation • no energy loss Egypt, El Salaam Bridge Australia; high tension pylons

  7. ZINGA (film galvanisation) • Advantages • Quick drying time • new layer of ZINGA: after 1 hour • topcoats can be applied after 4 to 24 hours • Does not peel off and is not brittle • will be compressed or squashed • will not crack thanks to its flexibility • Local damages can be repairedeasily (e.g. after transport or heavy mechanical impact) Australia, culverts

  8. ZINGA (film galvanisation) • Advantages • Galvanized structures can be recharged with ZINGA • ZINGA • Metallised or hot-dipped • Each new layer of ZINGA blends perfectly • with the previous one. • Additional layers all blend to one single, homogeneous ZINGA layer Gold particles on top of ZINGA Gold particles in between the two layers of epoxy paint Gold particles blend in the two layers of ZINGA

  9. ZINGA (film galvanisation) • Advantages • Based on protectedzinc by a special resin • allows the formation of the galvanic couple • also gives an additional protection • 96% zinc in the dry layer of ZINGA • Very high amount of metallic zinc (97%) • Very high purity of the zinc granules (99,995%) • Especially shaped zinc granules • provide bigger contact surface through which • they can attach to one another ZINGA

  10. ZINGA (film galvanisation) • Advantages • Can be topcoated by a large number of compatible paints duplex systems will more than double the lifetime • Topcoats from the same supplier • (see our systems) • fire retardant properties • (will not spread flames) Belarus, subway

  11. ZINGA (film galvanisation) • Advantages • Composed of non-toxic elements and can be used in contact with potable water (WRAS; BS 6920) • unlimited pot and shelf life UK, Braithwaite tanks for potable water

  12. ZINGA (film galvanisation) • Summary

  13. ZINGA (film galvanisation) • Report/certificates Report and certificates from all over the world. Some of them are: • British Board of Agrément major approval body in the UK • BNF Fulmer Research Institute same galvanic protection as hot-dip at a depletion rate of 1/3 (when immersed ~ Pier legs in Killybegs, Ireland) “In the opinion of the British Board of Agrément, Zinga is fit for its intended use provided it is installed, used and maintained as set out in this Certificate.” BBA certificate • “Zinga offers galvanic protection to steel comparable to that offered • by galvanised steel. • Under the continuous immersion conditions studied, the Zinga coated • mild steel specimens corroded at a lower rate than galvanised zinc coated • specimens. • The electrochemical work has confirmed that Zinga is a corrosion resistant • zinc coating which protects mild steel effectively under simulated marine conditions.” Graph from BNF Fulmer

  14. ZINGA (film galvanisation) • Report/certificates • Det Norske Veritas practical ballast tank test • SGS Yarsley Technical Services (BS 476 part 6 and part 7) no fire propagation • Jadavpur University and National Metallurgical Laboratory (India) ZINGA was best in a comparison to other means of corrosion protection of rebars: Fusion Bonded Epoxy Coating Hot-dip Alloys Tests done: “180 days testing in condensation chamber 180 days testing in wave tank Evaluation of results after testing, including blister detection (when applicable), undercutting from scribe, adhesion and coating flexibility” Conclusion “The results from the performed testing show that Zinga coating has a beneficial corrosion protective performance, probably due to its qualities with regard to cathodic protection related to the high zinc content.” DNV “In accordance with the Flame Spread Classification given in the Standard and reproduced above, the results show that the material has a Class 1 surface.” This is the best result possible.

  15. ZINGA (film galvanisation) • Report/certificates Report and certificates from all over the world Some of them are: • NORSOK • Water Regulations Advisory Scheme + comparable certificates from other countries (e.g. Iran) contact with potable water Tests done: 4200 hours immersion in seawater 4200 hours cyclic test pull-off (7MPa) no cathodicdisbondment Conclusion: “The system Zinga, dry film thickness 60/60 IJm, meets the evaluated requirements of Norsok M·SOI Rev. 5 system 7” Conclusion: “ZINGA has passed full tests of effect on water quality” WRAS certificate

  16. ZINGA (film galvanisation) • Report/certificates Report and certificates from all over the world Some of them are: • Amirkabir University (Iran) tests on Zinganised rebars • KTA TATOR (US) Slip coëfficiënt (0,52) (Hot-dip ±0,19) “It is observed that the coating of rebars with ZINGA protects the steel core against corrosion by cathodic protection as sacrificial anode.” Amirkabir University (most of these reports can be downloaded from our website: www.zinga.eu)

  17. ZINGA (film galvanisation) • Report/certificates Report and certificates from all over the world Some of them are: • 4 year Field test at Kennedy Space Centre (USA): • Pacific Rim Corrosion Research Program (PRCRP) ended in 2005 • The picture has been taken after 4 years. You see no red rust, only the • white rust in the scribe where ZINGA has cathodically protected the • bare metal. • The above report resulted in the approval • by the US Army and US Navy • Zinga conforms to the requirements of CID A-A59745. • Additionally, it has successfully undergone additional testing. (most of these reports can be downloaded from our website: www.zinga.eu)

  18. ZINGA (film galvanisation) • Report/certificates Report and certificates from all over the world Some of them are: • NATO Approval • In 1989 Zingametall received a Manufacturer’s card and a NATO Stock Number for ZINGA • A NATO Stock Number is recognised as a stock number of the armies of the member states. • Every product that is accepted by the NATO can be used by all the armies of the • NATO member states without the necessity or obligation to test the product again. (most of these reports can be downloaded from our website: www.zinga.eu)

  19. ZINGA (film galvanisation) • Report/certificates Report and certificates from all over the world Some of them are: • APAS Recognition • After a thorough research of test reports, applications in Australia • and a visit to the factory in Belgium, Zingametall BVBA was • acknowledged as a recognized manufacturer by the APAS. • “APAS (Australian Paint Approval Scheme) is the largest • and most widely recognized paint scheme in the world” • (http://www.apas.gov.au/index.asp). (most of these reports can be downloaded from our website: www.zinga.eu)

  20. ZINGA (film galvanisation) • Report/certificates Report and certificates from all over the world Some of them are: • ISO 12944 on ZINGA 2 x 60µm DFT • Atmospherically • C5I-Medium (equals to C5M-Medium and C4-High) relates to real life situations as follows: • C5I: industrial zones with high humidity and aggressive environment • (continuous condensation and high pollution) • C5M: Coastal zones and marine zones with high salinity • (continuous condensation and high pollution) • Medium: life expectation between 5 and 15 years • C4: industrial or coastal (with moderate salinity) zones • (chemical factories, swimming pools, shipyards) • High: life expectation >15 years Since 1988, several pulp and paper factories in Canada used ZINGA in 2 layers of 60µm DFT to treat their structures. In 2005 (17 years after application), no touch-ups were necessary. (most of these reports can be downloaded from our website: www.zinga.eu)

  21. ZINGA (film galvanisation) • Report/certificates Report and certificates from all over the world Some of them are: • ISO 12944 on ZINGA 2 x 60µm DFT • Immersion: • Im2-Medium and Im3-Medium relate to real life situations as follows: • Im2: sea or brackish water • (harbors with locks, jetties, offshore structures; make sure there is no stray current) • Im3: soil • (underground storage, iron poles) • Medium: life expectation between 5 and 15 years (most of these reports can be downloaded from our website: www.zinga.eu)

  22. ZINGA (film galvanisation) • Report/certificates Report and certificates from all over the world Some of them are: • ISO 12944 on ZINGA 2 x 90µm DFT • Atmospherically • C5I-High (equals to C5M-High) relates to real life situations as follows: • C5I: industrial zones with high humidity and aggressive environment • (continuous condensation and high pollution) • C5M: Coastal zones and marine zones with high salinity • (continuous condensation and high pollution) • High: life expectation >15 years The phosphate Mine in Togo (Office Togolais des Phosphates) was treated in 1994 with 2 layers of ZINGA. In 2006 (12 years after application), no trace of rust was found. (most of these reports can be downloaded from our website: www.zinga.eu)

  23. ZINGA (film galvanisation) • Report/certificates Report and certificates from all over the world Some of them are: • ISO 12944 on ZINGA 2 x 90µm DFT • Immersion: • Im2-Medium and Im3-Medium relate to real life situations as follows: • Im2: sea or brackish water • (harbors with locks, jetties, offshore structures; make sure there is no stray current) • Im3: soil • (underground storage, iron poles) • Medium: life expectation between 5 and 15 years (most of these reports can be downloaded from our website: www.zinga.eu)

  24. Reference information We have many interesting reference documents on applications in different fields. This is a small selection of them: (you can find more on our website: www.zinga.eu) • Bridges • QR Railways Burdekin river bridge (Australia) • Since 2001 • Maintenance program (Queensland Rail) • ZINGA 2 x 60µm DFT • Kalvoya bridge (Norway) • In 1985 • 30µm DFT ZINGA depletion after 25 years • Only minor repairs were required

  25. Reference information • Bridges • MDOT Mississippi bridge (US) • In 2002 • 2500m² • ZINGA 2 x 75µm DFT • An inspection in 2007 showed no sign of rust. • Hangzhou Bay Cross-sea Bridge; • 37 km (China) • In 2005 • On rebars in bridge • ZINGA 1 x 60µm DFT

  26. Reference information • Bridges • BC Ferry Terminal (Canada) • Between 1988 and 1992 • ZINGA 2 x 60µm DFT (by brush) • An independent inspection in 2002 and • another in 2005 showed no need for repair • IRPC Petrochemical complex • (Thailand) • In 2009 • On jetty (gas pipeline and supporting • structure) • Close to sea • On 15.000m² and growing • ZINGA 1 x 40µm DFT + • Alufer N 1 x 80µm DFT

  27. Reference information • Bridges • El Salaam Bridge (Egypt) • Bridge to carry a gas pipeline (from GASCO) • In 2007 • ZINGA 2 x 60µm DFT

  28. Reference information • Storage tanks • Dangote (Ghana) • In 2009 • In repair of a previous system that failed after • only 3 years • On every metal part of the plant • At 100m of the ocean • ZINGA 2 x 60µm DFT • NATO Pump Stations (Belgium) • Application in 1986 • ZINGA 2 x 60µm DFT • On numerous pump stations all over Belgium • 17 years after application an official inspection • showed the pump stations in excellent state

  29. Reference information • Storage tanks • Quartes (Belgium) • In 1980 • On previously hot-dipped storage tanks • 4 silos, 20 m in height, 4 m in diameter • 4000 m² • ZINGA 2 x 60µm DFT • 30 years after application only minor repairs • were required • Braithwaite Potable Water Tanks (UK) • Application in 2007 • On the inside of 9 storage tanks for potable water • ZINGA 2 x 60µm DFT

  30. Reference information • Storage tanks • Pulp and Paper (Canada) • Since 1988 • On previously hot-dipped storage tanks • for several pulp factories • ZINGA 2 x 60µm DFT • 14 years an independent inspection • showed no need for repair • Shell storage tanks (Morocco) • Since 2006 • 4 huge storage tanks for hydrocarbon products • ZINGA 1 x 60µm DFT + Alufer N 1 x 80µm DFT • + topcoat • Very close to the ocean

  31. Reference information • Storage tanks • Univar storage tanks (Norway) • In 2008 • Outside of 48 storage tanks for chemicals • ZINGA 1 x 60µm DFT + Alufer WR 1 x 60µm DFT • (after CO2 cleaning) • Red Bull storage tanks (Thailand) • In 2008 • Inside of 6 storage tanks (700m² inside alone) • for wheat to produce whisky • ZINGA 1 x 60µm DFT

  32. Reference information • Storage tanks • Exxon Mobil oil storage tank (UK) • In 2007 • Floating roof of a crude oil storage tank • ZINGA 2 x 60µm DFT

  33. Reference information • Electricity, pylons, poles, transformers • Nexrad radar tower (US) • 2009 • 10m high radar tower • To reload the old hot-dip • 2 x 60µm DFT ZINGA • Located on the Altus Air Force Base • CR EW183 in Frederick, Oklahoma. • EGAT (Thailand) • Since 2005 • 37 high tension pylons • Swampy areas • Above ground: ZINGA 2 x 50µm DFT • Under ground: ZINGA 1 x 40µm DFT • + PU Tarfree MIO 1 x 100µm DFT

  34. Reference information • Electricity, pylons, poles, transformers • Transgrid Networks (Australia) • In 2006 • 2 km from the coast line • On old galvanised pylons • ZINGA 2 x 60µm DFT • Don Muang Tollway (Thailand) • In 2008 • On thousands of old galvanised poles • ZINGA 1 x 60µm DFT

  35. Reference information • Electricity, pylons, poles, transformers • Trash racks (South Korea) • In 2008 & 2010 • At the Young Heung Power Plant, to filter big • floating objects out of sea water from getting • into the cooling system. • ZINGA 2 x 40µm DFT + topcoat • KEPCO Transformers (South Korea) • Since beginning 2009 • Thousands of transformers • ZINGA 1 x 60µm DFT + Zingaceram topcoats

  36. Reference information • Electricity, pylons, poles, transformers • Krasikov (Czech Republic) • In 1994 • ZINGA 1 x 50µm DFT + topcoat • An independent inspection in 2003 showed • the system in excellent condition • Slavetice (Czech Republic) • In 2000 • ZINGA 2 x 40µm DFT • To repair an Atmofix anti-corrosion protection • on sensitive points

  37. Reference information • Electricity, pylons, poles, transformers • Kiev Energo (Ukraine) • In 2003 • Repair of old hot-dipped towers (some 45m high) • ZINGA 2 x 50µm DFT • Zuyevskaya thermal power plant • (Ukraine) • In 2003 • 3500m² • ZINGA 2 x 50µm DFT • To repair the anti-corrosion protection • in the cooling tower

  38. Reference information • Other structures • Bird’s nest (China) • In 2006 • On sensitive parts • ZINGA 2 x 40µm DFT • (+ sealer + topcoat) • National grand theatre Beijing (China) • In 2005 • ZINGA on underwater structures in aquarium • ZINGA 2 x 60µm DFT

  39. Reference information • Other structures • Düsseldorf Airport (Germany) • In 1990 on a hangar • ZINGA 2 x 75µm DFT • International airport Jean-Lesage • (Canada) • In 2008 • ZINGA 2 x 40µm DFT (on welds) • Alu ZM 2 x 50µm DFT (on complete structure)

  40. Reference information • Other structures • Mumbai domestic airport (India) • In 2006 • On all steel structures in the halls • ZINGA 1 x 60µm DFT + PU topcoat • Savarnabhumi airport (Thailand) • From 2002 to 2006 • On 9200 small steel structures • ZINGA 1 x 50µm DFT

  41. Reference information • Other structures • Guangzhou New Baiyun Airport (China) • In 2002 • Touch up of new hot-dip • ZINGA 1 x 60µm DFT

  42. Questions?

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