In Galvanized Rebar and other market opportunities

Transcription

1 New Development In Galvanized Rebar and other market opportunities Mik Gilles International Zinc Association May

2 Continuous Galvanized Rebar CGR 2

3 IZA Activities Process Research Facilitating Investment in Lines Market Development 3

4 Outline The Problem The Solution IZA Activities 4

5 The Problem with Rebar Initially: Cosmetic Staining Later: Structural Weakening 5

6 Cape Town sea wall 6

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8 Outline The Problem The Solution: continuous galvanized rebar IZA Activities 8

9 Research and field experience Compared to black steel, galvanized rebar provides: significant delay in the initiation of corrosion of the zinc coating; long term protection until coating is dissolved and totally lost; sacrificial cathodic protection of exposed areas of steel. 9

10 Opportunity for Galvanized Rebar Epoxy coated rebar has been banned by agencies in 5 US States and two provinces in Canada Looking for alternatives 10

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13 Protecting Rebar: Available Products Epoxy Coating: strictly a barrier coating any cuts in the epoxy coating give a pathway to corrosion vulnerable to damage, in handling or service, unrepaired cut ends Stainless Clad: barrier protection similar to epoxy, but more resistant to handling damage 13

14 Protecting Rebar: Available Products Batch Galvanized: Sacrificial and barrier protection offered must be formed before coating Zn Spraying followed by Epoxy Coating (Gerdau Ameristeel Z Bar): A semi continuous process requires manufacture of Zn wire 14

15 Cost Relative to Black Rebar (BR) 15

16 New Approach: Continuous Galvanized Rebar (CGR) Reduce cost Keep advantage of Zn coating Other advantages: bending after coating on customer s site 16

17 Two Products Continuous Galvanized Rebar (CGR) CGR with Epoxy Coat 17

18 Unique Process Use Al containing Zn bath to control of coating structure Use of Al tolerant galvanizing flux (US Patent ) 18

19 Video 19

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21 Bending tests on CGR bars at Hong Kong Poly U. Coating defects noticed on rebar ribs Bending tests carried out with 40mm mandrel 135 degree bend showed only small lines of cracks, judged good 21

22 Further developments at Newsteel mm rebar coating production Increase to 3 rebars in parallel Increase to faster line speed Low and high Al coating trials Galvanized rebar standard submitted to National Standardization administration Newsteel and Rob White have communicated with Ministry of Housing and Urban Rural Development of China. 22

23 At 0 C At 23 C 23

24 After aging 24

25 Outline The Problem The Solution IZA Activities 25

26 CRG and CGR+Epoxy Very Competitive 26

27 IZA Activities Process Research Facilitating Investment in Lines Market Development 27

28 Product Research Establish lifetime equivalency of 50 micron CGR zinc coating and 137 micron (3 ounce) HDG coating in concrete. Establish comparative performance for CGR vs. epoxy only coated bar and black bar. Establish new tighter bend radii specifications for CGR. 28

29 Production Lines Ximen New Steel China Super Galvanizing Dubai (Nov 2013) Hong Kong Strong Interest in North America and elsewhere 29

30 Market Development Activities Standards (ASTM, ISO etc.) Case studies Marketing literature 30

31 Tappan Zee Bridge Project 31

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33 USA trademark application made by IZA 33

34 Zinc Market Potential 200 million tpy rebar 10% coated = 20 million tpy With 2% zinc pickup = 400,000 tpy zinc 34

35 Savings Sustainability Safety Summary 35

36 Other market opportunities New post treatment for galvanized steel Ionic liquid assisted sol gel coatings Innovative nano structure FP7 funded project Advisory partners: EGGA and IZA 36

37 Other market opportunities Attractive properties expected Wear resistant Corrosion protection Aesthetic appearance Attractive cost Respecting health & environment Follow the project: 37