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*Faculty of Civil Engineering, University of Belgrade, Bulevar Kralja Aleksandra 73, Belgrade, Serbia; 128
fric@imk.grf.bg.ac.rs
Nenad Fric - Usage of zinc-silicate coatings
in friction connections
required training of the workforce and cost. Even using putty) for preventing exposure to oxygen.
though implementation of protection systems of The emergence of coatings, which simultane-
friction surfaces based on coatings has a very ously provide a satisfactory friction coefficient,
long tradition in the world, it was practically im- caused the decrease in use of metallization pro-
plemented in Serbia for the first time in 2011, cess. By standardization of testing, the determi-
during reconstruction of the Gazela bridge in nation of friction in friction joints is facilitated and
Belgrade. The reason for this are difficulties in standardized. Regarding the continuous devel-
procurement of the adequate coating and tradi- opment of the anti-corrosion systems industry,
tional recommendations for implementation of which places a large number of coatings on the
metallization procedure on the friction surfaces. market, the determination of their characteristics
This procedure comprises application of a cer- for use in friction joints is considerably simplified.
tain alloy on the friction surface. The most fre- The values of friction coefficient were defined by
quently used alloy is one of aluminum and mag- SRPS standard [02] (Table 1) for various levels
nesium AlMg5. Metallization certainly results in of treatment and systems for protection of friction
high friction coefficients, but on the other hand joints from corrosion. In case of EN standards [3]
requires adequate equipment (metallizing gun), the classes of friction surfaces are defined, and
consumption of gas and metal wire, skilled work- the friction coefficients which must be attained
force, adequate protective equipment and seal- for each of them. (Table 2).
ing of the joints after fitting of bolts (most often by
Table 1. Friction coefficients for various methods of treatment of friction joints surfaces, according to SRPS
standard [02]
The method of treatment of contact (friction) surfaces !
Without a special treatment S235 S355
Cleansing by fire 0,30 0,30
Unprotected
Sandblasted 0,40 0,40
Sandblasted surfaces subsequently protected by 0,50 0,55
Protected coating of aluminum alloy 0,50 0,50
Table 2: Friction coefficients for various methods of treatment of friction joints surfaces, according to EN
standard [03]
Surface treatment Class !
Surfaces blasted with shot or grit with loose rust removed, not pitted A 0,5
Surfaces blasted with shot or grit:
1. spray-metallized with a aluminium or zinc based product; B 0,4
2. with alkali-zinc silicate paint with a thickness of 50 !m to 80 !m
Surfaces cleaned by wire-brushing or flame cleaning, rust removed C 0,3
Surfaces as rolled D 0,2
From the enclosed tables, it can be clearly seen FRICTION COEFFICIENTS FOR VARIOUS
that the contemporary regulations have a more SYSTEMS OF PROTECTION OF FRICTION
conservative approach to these issues and that JOINTS FROM CORROSION
they prescribe lower friction coefficients. Also, the
contemporary regulations recognize zinc-silicate The friction coefficients for unprotected friction
coatings as a form of anti-corrosive protection of surfaces, friction surfaces protected by classic
friction surfaces as opposed to the national reg- anti-corrosive protection, and the surfaces pro-
ulations adopted thirty years ago (1985) which tected by zinc rich ethyl-silicate coating will be
were, until recently, the only binding regulations presented through two referential researches.
in the Republic of Serbia. These values are significant for analysis of ad-
equacy of zinc-silicate coatings implementation.
In his doctoral dissertation, Vlaji! [01] experi- production cost. For this reason, it became wide-
mentally, using standardized procedures, deter- ly used in industry, especially for production of
mined friction coefficients on the friction surfaces sandpapers, abrasive materials and similar.
protected by: The author conducted an extensive experimen-
- metallization using aluminum and magne- tal research (a total of 260 specimens) and de-
sium alloy AlMg5, termined friction coefficients (table 3) with small
- metallization using pure aluminum, standard deviations, which confirms quality and
reliability of this experimental research.
- classic anti-corrosion protection (chlorine
primer manufactured by Zorka abac), The obtained values for the surfaces treated
by sandblasting and metallization are consid-
- chlorine primer coating with addition of sili-
erably higher than those defined by Eurocode
con carbide (or carborundum) SiC.
which makes experimental determination of fric-
In addition, for the purpose of comparison, in the tion coefficients for the purposes of construction
same research was determined friction coeffi- of structures increasingly important. By adding
cient on the surfaces without anti-corrosive pro- carborundum to the classical coatings, friction
tection, for two different levels of treatment: by coefficient was increased for more than 30%,
sandblasting and by polishing. which justified this procedure. It was concluded
The initial idea was to improve the characteristics that better results could be achieved by applying
of classic anti-corrosive protection and increase carborundum on only one friction surface. In this
the friction coefficient by adding silicon carbide, way, crushing of the grains in mutual contact at
which would make it applicable in friction joints. the moment when the bolts are being tightened
Silicon carbide belongs to inorganic compounds would be prevented.
with extremely high toughness and relatively low
Table 3: Friction coefficients for various methods of treatment of friction areas Vlaji [01]
Standard Number of
Steel grade Surface treatment Friction coeff. "
deviation [%] samples
sandblasting 0,616 4,30 24
sandblasting + metallization (AlMg5) 0,548 5,20 188
sandblasting + metallization (Al) 0,363 7,80 24
S235
sandblasting + hlorvenmijum + SiC 0,308 2,44 24
sandblasting + hlorvenmijum 0,235 8,82 24
polishing 0,156 6,80 12
Wylliam Husson in the research which is the in- The coating, used during research, has already
tegral part of his thesis [4], among other things, been widely used in construction of wind tur-
determined friction coefficients on the surfaces bines and it can be used as a single coating, or
treated in two ways: as a primer in a complex system of anti-corro-
- steel plates of S355 class, sand blasted to sion protection. In both cases it is applied in a
Sa2,5 level, in all according to the standard layer of 50 µm to 80 µm with the zinc content
ISO-8501-1 [5], subsequently coated with ranging between 70 and 90%.
two-component zinc rich ethyl silicate coat- Weathering steel contains elements allowing
ing TEMASIL 90, manufactured by Tikku- formation of patina in the event of exposure
rila Coatings, to weather effects. A number of samples was
- weathering steel plates with commercial formed from the plates which did not exhibit
name COR-TEN B [6] manufactured by rust, and the remaining number from the plates
Ruukki, in the first batch sand blasted and exposed to weather effects which were fitted
immediately tightened with bolts, and in the among the samples after formation of patina.
second batch sandblasted and exposed to The product COR-TEN B, according to its me-
weather effects prior to tightening. chanical properties corresponds to the steel of
the S355J0W(P) class.
The friction coefficients presented in Table 4 prescribed for the class B of friction surfaces
were determined for formed specimens. It is im- were not attained on the samples protected by
portant to point out that the friction coefficients zinc rich coating.
Table 4: Friction coeff. for various methods of treatment of friction surfaces Husson [04]
Steel grade Surface treatment Friction coeff. ! Number of samples
Cor-Ten B sandblasting 0,591 3
Cor-Ten B sandblasting + atmospherics 0,629 3
Cor-Ten B sandblasting + atmospherics 0,611 5
S355 sandblasting + Temasil 90 0,310 17
ZINC-SILICATE COATING RESIST 86 shortens the expiry time and causes conversion
MANUFACTURED BY JOTUN of liquid into a jelly. Because of these facts, im-
plementation of zinc-silicate coating, Resist 86,
Zinc-silicate coating Resist 86 (manufactured especially in summer season, calls for a careful
by Jotun, Norway) as anti-corrosive protection planning both in practical application and in con-
of friction surfaces of the Gazela bridge was ducting of experimental research.
selected assuming that the friction coefficient The manufacturer prescribes minimal, maximal
higher than 0,4 can be achieved between two and optimal coating thickness (Table 5). It is
steel plates protected by this system. This is particularly stressed that if the film thickness ex-
simultaneously the first implementation of zinc- ceeds 120 µm there is a high probability that the
silicate coatings on the friction surfaces in the film would crack.
Republic of Serbia. It was the first time (2010)
that the value of friction coefficients which can Table 5. Prescribed coating film thickness in wet and
be used on friction surfaces with this system of dry states [08]
anti-corrosion protection applied was determined Film Film thickness [µm]
for the bridge reconstruction purposes [07]. The condition Minimum Maximum Typical
procedure of determination of friction coefficient Dry 50 90 75
was conducted in all according to the provisions
Wet 75 135 115
of the SRPS U.E7.140:1985 standard [02].
TECHNICAL CHARACTERISTICS AND After the completed cleaning using sandblasting,
METHOD OF APPLICATION OF ZINC-SILI- dust is removed from the cleaned surfaces us-
CATE COATING RESIST 86 ing compressed air of manually using brushes,
which completes the preparations for application
This system of anti-corrosive protection was de- of anti-corrosive protection.
signed by the manufacturer [8] for heavy duty In the course of application of zinc-silicate coat-
corrosion protection system, both: ing, it is necessary that the substrate tempera-
- as the primer (first layer) in multi-layered sys- ture is no less than 5ºC, but also no less than
tems, or 3 ºC above the dew point. In principle, curing of
- as a single-layer coating for protection of the zinc-silicate coatings requires moisture. At
steel surfaces in medium-to-severe corro- low relative humidity of air, curing is increased
sive environments. by sprinkling of coating film with fresh water or
It is a two component, fast curing, zinc rich ethyl- by artificial increasing of the environment humid-
silicate coating. It consists of component A and ity (Figure 1a).
powdery component B (dry zinc dust) which are In order to create a desired thickness in dry state,
mixed in the ratio A : B = 8 : 2,6. Component the coating thickness in wet state (immediately
A must be well shaken before use, since sedi- after application) was measured, using wet paint
ment is bound to settle while it is still. It is very comb gauge (Figure 1b and 1c).
important to pay heed to the fact that the liquid Each of the coating application techniques, ei-
component A has a limited shelf life, which is 6 ther using compressor or manual, requires con-
months stored in dry and dark place at a temper- tinuous stirring in order to avoid settling of the
ature of 23 ºC. Exposure to higher temperatures heavy zinc particles, which is a fast developing
Journal of Applied Engineering Science 14(2016)1, 363 131
Nenad Fric - Usage of zinc-silicate coatings
in friction connections
process. At the moment of application of any the conditions prescribe by the manufacturers,
of two layers of anti-corrosion protection, the which is measured on the site and registered in
weather conditions must be in accordance with the log book.
a) b) c)
Figure 1: a) Spraying of film with fresh water in low humidity conditions; b) and c) Measuring of the coating
thickness in wet state [09]
FRICTION COEFFICIENTS IN CASE according to the standard.
OF IMPLEMENTATION OF ZINC-SILICATE The obtained results certainly justified imple-
COATING RESIST 86 mentation of Resist 86 coating in the friction
surfaces of the Gazela bridge, but they raised
The fact the zinc-silicate coating Resist 86
the question of technology and duration of con-
never before was used for friction joints, called
struction regarding the anti-corrosive protection
for an extensive experimental research aimed
of friction surfaces. Since it was a reconstruction
at determining of friction coefficient. Friction co-
of the existing bridge structure, it was conducted
efficient was determined by testing of a total of
in phases, and it was very important to provide
48 specimens, and a particular emphasis was
restoration of the prefabricated elements of the
placed on analysis of the impact of time interval
bridge (plates and bolts) into the original state
between the application of coating and tighten-
in as short time as possible after their disman-
ing of the bolts, for the attained friction coeffi-
tling. For that reason, a third part of this research
cients. The test [07] was divided in two parts.
was conducted, where the friction coefficients
The first, where the tightening of the bolts and
were determined 10 days after application of
testing of the specimens took place at the same
the coating, and tightening of the bolts to the full
moment one after another, and the second part
torque was accomplished 72 h after application
where the samples were tested after a certain
of the coating. The obtained results allowed im-
time passed since the bolts had been tightened.
provement of technology of reconstruction of the
The initial tests demonstrated that in a short time
bridge construction and considerable shortening
period after application of the coating (up to 3
of time required for works on the anti-corrosive
days) it is not possible to attain the required fric-
protection. The bolt tightening 72h after applica-
tion coefficient. The obtained friction coefficients
tion of the coating and loading of the structure 10
of 0,29 to 0,38, but also a prominent dissipation
days after that yielded the best results, i.e. the
of results, indicated the need to perform tests
best friction coefficients between 0,49 and 0,50.
after a longer time period since the moment of
application of the coating. Accordingly, the tests Following the made conclusions, the contractor
were performed 6, 8 and 10 days since the mo- developed of a system of supporting the platess
ment of application of the coating, on 4 speci- using a long grub screws (Figure 2). In this way,
mens for each time period. The attained friction it was made possible to tighten the bolts 72 h
coefficients were between 0,46 and 0,50 but after application of the coating. After tightening
there was also a standard deviation of less than of all the joints, more than ten days passed until
8 % which is within the permissible boundaries they were exposed to service loads.
Figure 2: Reconstruction of the Gazela bridge in Belgrade implementation of zinc-silicate coating Resist
86 as anti-corrosive protection of friction surfaces [09]
CONCLUSION REFERENCES
Implementation of zinc-silicate coatings repre- 1) Lj. Vlaji#: Ponaanje spojeva sa visokovred-
sents an efficient way of anti-corrosive protec- nim zavrtnjevima pri eksploatacionom i
tion of friction surfaces. The main precondition grani$nom optere#enju, Doktorska disert-
for them to substitute the metallization proce- acija, Univerzitet u Niu, 1993, 122 str.
dure is attainment of required friction coefficients 2) SRPS U.E7.140:1985: Spojevi sa vijcima
in friction joints. However, the required friction visoke klase $vrsto#e kod nose#ih $eli$nih
coefficients for the surface treatment catego- konstrukcija - Tehni$ki uslovi, 1985.
ry A and B, according to Eurocode, !"0,4 and
3) SRPS EN 1090-2:2012: Execution of steel
!"0,50 respectively, cannot be attained with
structures and aluminium structures Part
any zinc-silicate coating. Because of that, it is
2: Technical requ for the execution of steel
important, prior to implementation of coating in
structures, Institute for standardization of
the friction joints, to determine friction coefficient
Serbia, 2012.
which can be attained. In the case of zinc-sili-
cate coating Resist 86 manufactured by Jo- 4) W. Husson: Friction Connections with Slot-
tun the best results are achieved by tightening ted Holes for Wind Towers, Licentiate The-
the bolts 72 h after applying the coating and by ses, Luleå University of Technology, 2008,
loading the structure 10 days after that, which 192p.
was confirmed by the experimental research for 5) ISO 8501-1:2007: Preparation of steel sub-
the purposes of reconstruction of the Gazela strates before application of paints and relat-
bridge in Belgrade. Such system of protection of ed products Visual assessment of surface
friction surfaces, applied in the described way, cleanliness Part 1: Rust grades and prep-
provided good results and facilitated shorten- aration grades of uncoated steel substrates
ing of time needed for application of anti-corro- and of steel substrates after overall removal
sive protection. Certainly, technology of bridge of previous coatings, International organiza-
construction differs from their reconstruction, in tion for standardization, 1998.
terms of dynamics. Therefore, it will be useful to 6) Hot-rolled weather resistant COR-TEN,
determine friction coefficients for longer period http://www.ruukki.com/Steel/Steel-products/
between application of the coating on the steel Hot-rolled-steels/Hot-rolled-weather-resis-
structure elements, bolt tightening and exposing tant-COR-TEN, dostupno 30. septembra
those elements to service loads. By following the 2014., 17:30
analogy of the presented results of experimental 7) GP Mostogradnja AD, Vlajkovi#eva 19a,
researches, it can be expected that the attained Biro za kontrolu kvaliteta, Laboratorija za
friction coefficients will be even higher, i.e. more ispitivanje: Izvetaji o ispitivanju koeficijenta
favorable from the aspect of slipping resistance trenja µ tarnog spoja pritegnutog V.V. vijc-
of the joints.
Primenom cink-silikatnih premaza kao antikorozione zatite tarnih povrina skrauje se vreme izgrad-
nje konstrukcija i obezbeuje zatita od korozije. Ovakav sistem zatite ima niz prednosti u odnosu
na iroko primenjivan postupak metalizacije, pre svega u smislu brzine sprovoenja, zahtevane kvali-
fikovanosti radne snage i cene. U ovom radu prikazani su koeficijenti trenja za razliite sisteme an-
tikorozione zatite tarnih spojeva, sa akcentom na cink-silikatne premaze i njihove tehnike karakter-
istike i nain primene.
Kljune rei: Cink-silikatni premaz, Koeficijent trenja, Tarne povrine, SRPS, Evrokod