Professional Documents
Culture Documents
PROTECTION OF
Plants & Equipments
Presented By
R.K. BHATIA
John Galt Zinga Technologies, Mumbai
A Case
For
Film Galvanization
Technology
ZINGA PRESENTATION
ZINGAMETALL
CORROSION SOLUTIONS
Middle-East,
Asia,
Africa,
Australia,
North-America,
South-America
What is ZINGA and how does it work?
- protected zinc
What is ZINGA and how does it work?
- one pack
- easy to apply
- re-loading capacity
- re-coatable
- non-toxic ( BS 6920 )
What is ZINGA and how does it work?
- mechanical flexibility
- UV resistant
- roughness Rz 50-70µm
What is ZINGA and how does it work?
reliable efficiency
easy application
easy maintenance
Reliable efficiency
Hot-dip after 1000 ZINGA after 2000
hours salt spray test hours salt spray test
Easy Application
Easy Maintenance
A new layer of ZINGA re-liquidises the old layer.
Gold film on
first ZINGA layer
Field op applications :
- old hot-dipped
- existing structures
- workshop
Galvanising with ZINGA
Applications all over the world
OFFICE TOGOLAIS DES PHOSPHATES
PHOSPHATE MINE OFFSHORE CHARGING CRANES - TOGO
The phosphate mine Office Togolais
des Phosphates has placed 2 offshore
charging cranes at 1.6 km in the sea.
These cranes are linked
to the stock department
by means of a conveyor.
These cranes are very mobile
and weigh 325 tonnes each.
The Office Togolais
des Phosphates produces
2.400.000 tonnes
of phosphates per year.
An average of 5 ships
per month are charged.
In 1994 the cranes were repaired by the French company Africaine de Montage.
A permanent service and maintenance was obligatory during the repair of the cranes.
After grit-blasting, the structures needed to be repaired by welding. These two cranes
and their passing link (the conveyer) were heavily corroded and it was decided that
they had to be protected by an anti-corrosion system providing cathodic protection:
System:
ZINGA 2 x 60 µm Surface preparation: GRIT-BLASTING
In 2006 an inspection was done because an overall maintenance program was
planned to extend the lifetime of the structure.
6-8
2 - 3 µm
µm
Distilled zinc Atomised zinc
PAINT ZINGA®
YES* CATHODIC PROTECTION YES
NO LONGTERM RESISTANCE YES
PROTECTION AGAINST CREEP
NO RUST AND BLISTERING YES
APPLICATION AT LOW
NO TEMPERATURES YES
Coatings
& splash zones
Testimonials & Reports
2. ZINGA (film galvanisation)
d) Report/certificates
Report and certificates from all over the world.
Some of them are:
British Board of Agrément
major approval body in the UK
“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
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.”
Conclusion:
“The system Zinga, dry film thickness 60/60 IJm, meets the evaluated
requirements of Norsok M·SOI Rev. 5 system 7”
Amirkabir University
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.
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.
Inside :
Zingaceram EP 1 x 80 µm
Outside :
Zinga 1 x 60 µm
Zingaceram PU 1 x 80 µm
Transformer - Pakistan
09 -2007
Kiev Energo Power Plant (Ukraine
Offshore Wind Farm Foundations 2003)
(Denmark 2003)
Chernobyl Nuclear
Power Station
(Ukraine 2002) Bridge (Canada)
Offshore Wind Farm
(Denmark 2002)
80 piles, ~35 meters each,
~40,000 liters coating......
Rebars of
the Hangzou Bay Bridge
(China 2005)
System:
ZINGA 1 x 60 µm
Alufer N 1 x 80 µm
Pu local
TAIWAN POWER COMPANY
ZEPHYROS WIND MILLS - TAIWAN
System:
Inside :
ZINGA 1 x 60 µm
Zingaceram EP 1 x 100 µm
Outside :
ZINGA 1 x 60 µm
Zingaceram EP 2 x 100 µm
06 - 2005
BRAITHWAITE TANK –UNITED KINGDOM
• 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.
Reference information (specifically defence structures)
System:
Zinga 1 x 40 µm 9-2008
Harbor Cranes - Iran
Rail Wagon - Senegal
07 - 2006
SCHWENK – CEMENT FACTORY - GERMANY
In 1992 the new plant of the cement factory Schwenk was treated with ZINGA.
Application technique: airless spraying. These pictures were taken during construction.
30 tons of ZINGA were used for this application.
In February 2003, the condition of the ZINGA layer
was inspected. On the pictures you can see that the
ZINGA is still in perfect condition and shows no
trace of rust after more than 10 years.
System:
ZINGA 2 x 60 µm
LAFARGE – SOUTH AFRICA
Pictures of the infrastructure of the company
Lafarge, treated with ZINGA,
dated September 1997.
System:
ZINGA 2 x 60 µm
System:
ZINGA 2 x 60 µm
GREENVIEW CEMENT – GHANA 2004
03 - 2009
PAESEN CONCRETE MILL - BELGIUM
These are pictures of a concrete mill of the company Paessen taken
in April 2006. The silos were sandblasted and coated with ZINGA and
topcoated with 2c Pu Primer Finish mist coat and full coat.
System:
ZINGA 2 x 60 µm
2c Pu Primer Finish mist coat
full coat
Zingametall references
Road Bridges
Rail Bridges
CANADA: OVERLANDER BRIDGE
CONFERATION
BRIDGE
CANADA:
QUEENSLAND MAIN ROADS - AUSTRALIA
Customer: Queensland Main Roads, Queensland Rail - Department of Infrastructure, Energy & Resources
System:
Blasting SA 2,5@ 60 µm
ZINGA 1 x 60 µm
ALU ZM 1 x 60 µm
System :
Zinga 2 x 60 µm
Watersaturation
Queensland Rail – Australia
Tooley Footbridge
System :
Zinga 2 x 60 µm
Watersaturation
Queensland Rail – Australia
Rathdowney Rail Bridge
System:
Zinga 2 x 60 µm
June 2003
Fly-over Bridge - Taiwan
07 - 2005
Fly-over Bridge Taiwan
06-2005
Biloxy Bascule Bridge - USA
08 - 2008
Zingametall references
Stadiums and
Airports
5. Reference information
Other structures
• Bird’s nest (China)
In 2006
On sensitive parts
ZINGA 2 x 40µm DFT
(+ sealer + topcoat)
Other structures
• Mumbai domestic airport (India)
In 2006
On all steel structures in the halls
ZINGA 1 x 60µm DFT + PU topcoat
Other structures
• Guangzhou New Baiyun Airport (China)
In 2002
Touch up of new hot-dip
ZINGA 1 x 60µm DFT
MUMBAI DOMESTIC AIRPORT - INDIA
The domestic terminals in Mumbai with the same name as its international wing are
located in Santa Cruz, East. There are two domestic terminals - Terminal 1A
(with an area of 28960sqm), and Terminal 1B (with an area of 45000 sqm).
Here, peak traffic occurs during daytime.
All steel structures including the huge curbed spans of the new airport of Mumbai
Domestic Airport are coated with Zinga and finished with a white PU.
System:
ZINGA 2 X 60 µm
Topcoat Pu white
GUANGZHOU NEW BAIYUN AIRPORT - CHINA
Touch up of HDG
Zinga 1 x 40 µm 02-2002
Düsseldorf Airport – Germany
Engine test area
System :
Zinga 2 x 60 µm 1990
BIRD’S NEST – CHINA
Olympic Games 2008
System:
Blasting Sa 3 @ 60µm
Zinga 2 x 40 µm 9-12 2006
ACCRA LIGHT POLES - GHANA
On these pictures you can see light poles of
a sports stadium, the application of ZINGA
started in April 2007 by Zinga Ghana.
System:
ZINGA 1x 65 µm
Alufer WR 1 x 80 µm
Zingametall references
System:
ZINGA 1 x 60 µm
Alufer N 1 x 80 µm
Pu local
OIL STORAGE TANK - EXXON MOBILE
UNITED KINGDOM
This oil storage tank is located in an area called Fawley, one of Esso’s biggest
refineries in the United Kingdom, which is actually south of Southampton
on the south coast of England.
The application was done in August of 2007,
the oil storage tank has been blasted
with a profile average of 75 µm.
System:
after application
METRONCO - GHANA
On these pictures you see a pipeline (1,5 km long) for
the transport of harsh oil in Tema, Ghana.
System:
ZINGA : 1 x 60 µm
ZingaCeram EP Mio : 1 x 80 µm
ZingaCeram PU : 1 x 60 µm
Zingametall references
Industrial
Steel Structures
Cocoa silo Barry Callebaut - Ghana
System :
Blasting Sa 2.5
Zinga 2 x 60 µm
05-2008
Airconditioning system -Thailand
07-2005
System :
Blasting Sa 2.5
Zinga 2 x 60 µm
Roof coating test Barry Callebaut - Ghana
HP cleaning + Sweeping
EP PA Primer 80 µm
Zingaceram EP Mio 120 µm
Zingaceram PU top 60 µm 08-2008
KUMBA RESOURCES COAL MINES - SOUTH-AFRICA
08 - 2007
Coating of feet conveyor belts
Sishen Ore Mine – South Africa
08 - 2007
Conveyors Exxarro Grootegeluk
CoalmineSouth Africa
01 - 2008
5. Reference information
Bridges
• QR Railways Burdekin river bridge (Australia)
Since 2001
Maintenance program (Queensland Rail)
ZINGA 2 x 60µm DFT
Bridges
• MDOT Mississippi bridge (US)
In 2002
2500m²
ZINGA 2 x 75µm DFT
An inspection in 2007 showed no sign of rust.
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
Bridges
• El Salaam Bridge (Egypt)
Bridge to carry a gas pipeline (from GASCO)
In 2007
ZINGA 2 x 60µm DFT
5. 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
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
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
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)
Storage tanks
• Exxon Mobil oil storage tank (UK)
In 2007
Floating roof of a crude oil storage tank
ZINGA 2 x 60µm DFT
5. Reference information
Korea Institute of
Machinery and Materials,
South Korea
Tests on mechanical resistance
• Adhesion tests by cross-cut
Salt spray test
3000 hours
on ZINGA
Stangers Consultants, UK
Flexibility tests on nuts and bolts
Hedley Purvis, UK
Tests on mechanical resistance
• Adhesion tests by cross-cut
• Adhesion tests by pull-off
• Flexibility tests
• Tests on resistance to abrasion
Tests on mechanical resistance
• Adhesion tests by cross-cut
• Adhesion tests by pull-off
• Flexibility tests
• Tests on resistance to abrasion
• Tests on resistance to impact
Impact test
Stangers Consultants, UK
Tests on mechanical resistance
• Adhesion tests by cross-cut
• Adhesion tests by pull-off
• Flexibility tests
• Tests on resistance to abrasion
• Tests on resistance to impact
• Tests on weldability
Test on weldability
40 µm ZINGA
Soudometal, Belgium
Tests on resistance to liquids
• Immersion tests
Immersion test on sea buoys
System
1 x 60µ Zinga
1 x 80µ Alufer N
1 x 60µ Zingaceram ZM PU
Total = 200 µ
ISO 12944-6 C5M-H
The south viaduc : 160.000 m²
The north viaduc : 100.000 m²
The Bridge : 220.000 m²
Total : 480.000 m²
Zingametall
ISO 12944
www.zinga.eu
2. ISO 12944
a) What is ISO 12944
Before ISO 12944, people responsible for corrosion tenders needed to
specify in high detail:
What composition of the system (2, 3 or more layer systems)?
ISO 12944 is
Progressively superseding
regional standards
To become a truly
global benchmark in
corrosion control
2. ISO 12944
b) Purpose
Selecting specifications that comply with ISO 12944 provides:
Confidence that the corrosion protection you specify will be fit for purpose
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.
This agrees with the ISO 12944-6 test results for ZINGA 2 x 60µm DFT predicting a life expectancy of >15
years in an industrial zone.
3. Zingametall results
a) ZINGA 2 x 60µm DFT
Atmospherically:
C5-I: industrial zones with high humidity and aggressive environment
(continuous condensation and high pollution)
80µm hot-dip
+ 1 x 80µm DFT primer (epoxy or polyurethane)
+ 3 layers adding up to 240µm DFT epoxy or polyurethane
Total thickness: 400µm → 400µm
100µm metallisation
+ 1 sealer coat (epoxy or polyurethane)
+ 3 layers adding up to 320µm DFT epoxy or epoxy combination
Total thickness: 420µm → 420µm
3. Zingametall results
a) ZINGA 2 x 60µm DFT
Immersion:
Im2: sea or brackish water
(harbors with locks, jetties, offshore structures;
make sure there is no stray current)
Im3: soil
(underground storage, iron poles)
Immersion: Im2-Medium
and Im3-Medium
Medium: life expectation between 5 and 15 years
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.
This agrees with the ISO 12944-6 test results for ZINGA 2 x 90µm DFT predicting a life expectancy of >15
years in an industrial zone with high humidity and aggressive environment.
3. Zingametall results
b) ZINGA 2 x 90µm DFT
Atmospherically:
C5-I: industrial zones with high humidity and aggressive environment
(continuous condensation and high pollution)
80µm hot-dip
+ 1 x 80µm DFT primer (epoxy or polyurethane)
+ 3 layers adding up to 320µm DFT epoxy or polyurethane
Total thickness: 480µm → 480µm
100µm metallisation
+ 1 sealer coat (epoxy or polyurethane)
+ 3 layers adding up to 450µm DFT epoxy or epoxy combination
Total thickness: 550µm → 550µm
3. Zingametall results
b) ZINGA 2 x 90µm DFT
Immersion:
Im2: sea or brackish water
(harbors with locks, jetties, offshore structures;
make sure there is no stray current)
Im3: soil
(underground storage, iron poles)