Hot-dip galvanized steel has been around since 1742. In the nearly-280 years since a French chemist named Paul Jacques Moulin first described the galvanizing process, fabricators and construction engineers all over the world have gathered a tremendous amount of evidence on the durability of galvanized steel. But the million-dollar question — or depending on the size of your project, maybe the $10 million or $100 million question — is how long does galvanized steel last?
ASTM International, formerly known as the American Society for Testing and Materials, has a precise answer for this critical question.
Time to First Maintenance, or TFM, is defined as the appearance of rust on 5 percent of a galvanized steel surface. At this point, 95 percent of the steel surface is still covered with zinc but preventive maintenance is necessary to prevent deterioration of the structure.
TFM varies by thickness of the coating of zinc put on the steel during the galvanizing process and by the severity of pollution in the atmosphere to which the galvanized steel is exposed. Thinner zinc offers less protection. Industrial air pollution destroys zinc faster, but not very fast.
ASTM Standard A123 requires any galvanized steel more than 1/4-inch thick to be coated with at least 3.9 mm of zinc. According to the Time to First Maintenance Chart, steel treated with this thickness of zinc will reach TFM only after decades of service, depending on environment. (Here “environment” refers to relative air quality.)
TFM for standard galvanized steel in an industrial environment is 72 to 73 years. Example of an industrial environment include Newark, Atlanta, and Houston.
TFM for standard galvanized steel in a tropical marine environment is 75 to 78 years. Examples of a tropical marine environment include Miami and Mazatlan.
TFM for standard galvanized steel in a temperate marine environment is 86 years. Examples of temperate marine environments are Seattle and Charleston, South Carolina.
TFM for standard galvanized steel in a suburban environment is 97 years. Examples of a suburban environment include Minneapolis and Orlando.
TFM for standard galvanized steel in a rural environment is over 100 years. Examples of a rural environment include Fargo, North Dakota and Las Cruces, New Mexico.
In locations with minimal air pollution, galvanized steel will not need maintenance for a full century or more! And because the Time to First Maintenance Chart is based on data collected since the 1920s, before major improvements in air quality, these longevity estimates for galvanized steel used for construction in the twenty-first century are likely to be conservative.
Galvanized steel is a construction material for the truly long term. The longevity of galvanized steel is so well documented that financial planners can build expected TFM into their return on investment models for different sites and different real estate costs. The longevity of galvanized steel may give construction in a high-pollution location an acceptable ROI, but galvanized steel may justify long-term ROI at low-pollution sites that financial planners can find spectacular.
Don’t be misled by claims of manufacturers using other protective processes that their products last as long as galvanized steel. These claims are based on short-term tests, usually involving exposure of the steel to salt spray, that don’t run long enough to capture data about the three ways galvanized steel is protected against corrosion:
. Zinc provides a molecularly dense protective coating over steel. Paint develops pin holes that leave it susceptible to underfilm corrosion. Zinc maintains a continuous coating that extends the life of the steel beneath it by 25 to 40 times.
. Rusting is an electrochemical process. Metals donate electrons to oxygen to form oxides. Iron, for example, donates electrons to oxygen to form iron oxide, or rust, that is, unless an electrical current keeps it from interacting with iron. When zinc is in physical contact with iron, it generates a tiny electrical current that interferes with the corrosion process. Zinc protects against water, acids, and salt.
. Even zinc slowly corrodes when it is exposed to air. The interaction of zinc and the oxygen in the air forms a thin layer of gel-like, slippery, viscous zinc hydroxide. As the zinc hydroxide dries out, it interacts with the carbon dioxide in the air to form a stone-like compound known as zinc carbonate. Crystals of zinc carbonate, or patina, offer yet another layer of protection for the steel beneath them.
Salt spray tests keep steel constantly wet so the protective patina never forms, at least for the duration of the test. In real-world applications, the protective layer of patina appears only after six to twelve months of exposure to the weather.
If you are looking for a competitively priced construction material that you can use to build or fabricate for generations to come, choose galvanized steel. There is no longer-lasting steel for your construction and fabrication needs.
We have answers to your questions about galvanized wire rope. This article will tell you how it works, when to use it, and how to store it. Read on for the full scoop!
What is Galvanized Wire Rope?Galvanized wire rope is galvanized steel wire that is stranded. The galvanizing process makes the galvanized iron wire rope resistant to corrosion and allows it to last longer before needing replacement, which can be up to twenty times as long! The galvanization causes a thin layer of zinc oxide or equivalent material to surround the wires for they do not rust or corrode. There are many different galvanizing materials and processes, but some of the most common include zinc coating on steel wire!
Why Is It Called “Galvanized Wire Rope”?It’s called galvanized wire rope because of its overall appearance. The term “galvanized” comes from the fact that this type of wire is protected by zinc coating. You’ll also often see this type referred to as “galv steel.”
How can you store galvanized steel wire rope?Galvanized metal ropes are best kept in their original packaging until they are needed for use. The ropes may be stored in a dark, dry place to prevent oxidation of the coating. The wires need to be stored in a sealed plastic bag or container with air removed to prevent rusting on the steel wires.
What Are Uses of Galvanized Wire Ropes?Galvanized wire rope is used for almost any kind of tension or compression application! It works great for: – Tying down objects – Connecting multiple objects – Even suspending and hoisting equipment in mines! It’s also worth mentioning that the hardness of galvanized wire rope makes it a great choice as an anchor for standard chain and rope.
What are galvanized wire rope’s advantages?The standard galvanized steel wire rope is 6 to 7 mm in diameter and can be manufactured to sizes by twisting two wires together. The size of the galvanized steel wire ropes is specified according to the diameter of the wires. Galvanized steel wire ropes are fabricated in diameters from 6 mm onwards. Galvanized wire rope is typically shipped in long strands (coils). However, galvanized steel wire rope may also be manufactured in coils.
What is the tensile strength of galvanized steel wire rope?The tensile strength of galvanized steel wire rope is always lower than that of uncoated round steel wire ropes due to zinc coating on its surface and the manufacturing process used to create it. As a result, the value for steel wire rope will vary depending on the size and coating used during production.
How much does galvanized steel wire rope weigh?The weight of galvanized steel wire ropes is specified in kilograms/meters. The weight of galvanized steel wire ropes can vary greatly based on diameter.
Who Uses Galvanized Wire Rope?Farmers, ranchers, loggers, miners, and many others use galvanized wire rope in their day-to-day activities. Specifically used for: – Corralling cattle – Foraging for food and other resources – Attaching freshly felled logs to rolling skidder tracks – Attaching cables to heavy machinery – Hoisting equipment up to inaccessible places like coal mines.
Why Doesn’t Galvanized Wire Rope Corrode?Galvanized steel does not rust because galvanizing oxidizes the steel, thereby forming a new layer of the surface. This new layer of surface protects the steel from future corrosion from humidity exposure precisely that you see rust on a car.
What’s the Difference Between Galvanized Iron Wire Rope and Steel Wire Rope?Galvanized iron wire rope is made of steel coated with zinc. This coating acts as protection but also makes the rope harder to bend and more brittle. Steel wire rope is made of steel coated with plasticizers that make it easier to bend while also protecting against corrosion.
Do Galvanized Wire Ropes Rot?You’d think that the answer is “no,” but there are a few concerns that make this difficult to determine. First, the zinc coating can wear away over time, exposing the bare steel. If you doubt how old your rope is, you can always get a rope tag from us to keep in your gear bag! Secondly, galvanized wire rope does not rust the same as other types of steel – it will oxidize instead. Oxidation occurs when moisture is present in outdoor environments where galvanized wire rope is used. The result is that galvanized wire rope will not rust as other steel products do.
How Do You Clean Galvanized Wire Rope?Cleaning galvanized wire rope is sometimes a messy process, but one that can greatly impact the longevity of your wire rope! The best way to clean galvanized wire rope is with a Nylon brush – be sure not to brush against any metal surfaces! You can also use abrasive pads if you like, but this will wear out much quicker than steel wool. However, We do not recommend using metal wire brushes or wire wheels to clean galvanized wire rope. Although the zinc will prevent the steel from rusting, the abrasive action of these tools might damage the zinc coating and render it useless.
Does galvanized steel wire rope have any unique properties that need to be taken into consideration?Yes, galvanized steel wire rope is a corrosive-resistant material that is resistant to wear and tear. The galvanized metal rope is used in applications such as structural strength or support in automotive applications or as an economical alternative for binding objects such as heavy loads in shipping containers during maritime transport.
What is the cost of galvanized steel wire rope?The cost of galvanized steel wire rope is specific to the size and thickness specified for production and may be supplied in finished coils or as unfinished material. If you are looking for a custom-made quantity or have other special requirements, please inquire with our sales team about possible pricing.
Our galvanized wire rope FAQs should provide you with the information you need to know about this type of cable. If we’ve missed anything, please let us know! We are happy to answer any questions that may come up in your search for a supplier or manufacturer of galvanized wire rope. If you’re looking for high-quality gi wire at an affordable price point, we have all the answers you need right here on our website! Contact us today if you want more information on how to help with your galvanized wire rope needs.
Resources: https://en.wikipedia.org/wiki/Wire_rope
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