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Zinc is one of the most popular protective coatings used on structural steel. Zinc coatings are applied to steel in a hot-dip galvanising process, where the steel is submerged in a kettle or vat of molten zinc.
The zinc alloy layer that forms on the steel when it is withdrawn provides corrosion protection in several ways. Zinc is more reactive than steel, so it corrodes first, acting as a sacrificial layer. It also forms a barrier between the steel and moisture. The zinc coating expands when it corrodes, maintaining the protection of the underlying steel.
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Pros - The main advantages of hot-dip galvanised zinc coatings are excellent corrosion resistance and long service life, with estimates ranging from 40 to 100 years in atmospheric environments before maintenance is required. The initial cost is moderate.
Cons - While zinc coatings have good impact resistance, they can become brittle over time when exposed to sunlight. Appearance can be a drawback, as the coatings have a dull grey finish. Suitability for painting over the coating is moderate, requiring blasting to prepare the surface.
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