Although unprotected steel products are cheaper and thus initially more cost-effective than galvanised corrugated steel, one has to remember that unprotected steel must be coated. The coating is all that protects the underlying surface against corrosion. This layer of protection must be maintained. This means having to apply a new coat every few years. The initial price difference is thus not worth going for the cheaper product.
Why Hot-Dip Galvanisation?
Unprotected steel rusts. The integrity of the material is compromised when it is exposed to moisture and air. Although protective coatings can be applied, the best way to ensure the longevity of the material is to hot dip galvanise it. The steel is thoroughly cleaned to remove dust, grime, and other types of particles that can affect the integrity of the galvanisation. The material is then placed in a hot molten zinc bath, where every part of the material is thoroughly covered. The galvanisation thickness is predetermined to ensure consistency in application and thus a uniform coating over the entire surface.
The hot-dip method allows for the fusion of the zinc with the steel, meaning the zinc metallurgically bonds with the surface. As such, a super-strong bond is formed to give the material a durable protective layer. A surface scratch does nothing to the protective layer. Indeed, the zinc offers itself and thereby prevents the steel from being corroded. Even if substantial surface damage is experienced, the zinc prevents the damage from spreading horizontally. The zinc coating is done in accordance with SANS 121:2011, while the testing is performed in accordance with the standard regarding the weight and thickness of the zinc coat. As such, galvanisation through the hot-dip method ensures high integrity of the protective layer. Every part of the product is evenly covered in standard specified thickness and consistency. This also means the corners of the material are well-covered for maximum protection.
Why Not Get Pre-treated Metal Covered with a Protective Paint?
The metal is already compromised once it has been exposed to air before treatment. This means some integrity has already been lost. The application of a protective layer of paint or rust protection can be expensive as several layers may be needed. The metal must be prepared for the application, adding to the high cost associated with such treatments. Whether the coat is brushed or sprayed, at the end of the day, this type of protection costs more than galvanisation of steel. When affordability, longevity and structural integrity are thus considered, it is more cost-effective to used galvanised steel for projects such as corrugated steel culverts.
Galvanisation also improves the aesthetic appeal of the material. Although one can add a paint coat, the galvanisation process leaves a matte silver colour. This colour can work with a wide range of colours. The products can thus be used in many types of construction projects and fit in with the surrounding environments. Self-healing is another characteristic of products that have gone through the hot-dip galvanisation process. If the surface is scratched, the zinc offers itself. The surface thus self-heals without you having to apply a protective coat for a surface scratch.
Longevity is an important characteristic of galvanised steel. The galvanisation process ensures a permanent bond between the zinc and the steel. As such, it is not necessary to repeat the process every few years. The products are thus low on maintenance as well. Galvanised steel products have lifespans exceeding 20 years.
With no additional treatments needed, the low maintenance and longevity of materials brought about through the galvanisation process, ensure sustainability. Firms that want to improve on their sustainability profiles regarding material usage in construction projects, thus benefit from using corrugated or conventional plate galvanised steel materials.
With the galvanisation process applied by the local manufacturers, the steel materials for construction projects are already protected against corrosion. The materials can thus be installed or used in construction projects without first having to apply protective treatments on-site. This helps to reduce the cost of construction, and the time it takes to complete construction, road, and engineering projects. The inspection process to determine whether a product has been fully covered through the galvanisation process is straightforward. This helps to save time. When it comes to inspection of the damage to the steel products in the field, it is as straightforward as a visual inspection.
Although galvanisation is all that is needed to prepare the corrugated steel materials for usage, one can apply a powder coat to give the surface another colour if so desired. Galvanisation is a well-tested and trusted method for protection of steel materials. It is done according to a proven method, and the results have been thoroughly tested in the field as well.
Corrugated Steel Culverts
Corrugated iron or steel is widely used by consulting engineers across the globe. These products have been in use for many years. As such, the materials have been tested in the field where the materials have been subjected to environmental factors such as rain, soil, light, chemicals and more. The galvanisation of the steel protects it to ensure the longevity of the corrugated steel products, which is essential when used for culverts where water flow through the culverts is a given.
The advantages of corrugated steel culverts include:
- Longevity because of the galvanisation of steel.
- Adds extra strength to keep the structure form and to carry extreme weight because of the corrugated design.
- Cost-effective transportation is possible because the products can be stacked.
- Pre-manufactured and galvanised corrugated steel culverts can be installed without mechanical plants.
- Unskilled labour can be used for the installation with minimum supervision.
- No breakage.
- Immediate backfilling can be done after the culvert installation.
- Results in easy extension, salvaging, and re-assembling of the culverts.
- Exceptionally long service period.
Corrugated steel pipe can withstand a considerable load, which is necessary when culverts are installed at embankments as airport traffic, railway, vehicle traffic, and soil loads must be carried. Many thousands of structures have been tested and inspected over six decades. The evidence from such inspections shows that the galvanisation, corrugation, and design of the structures are superb. The products meet and exceed performance requirements regarding structural strength, durability, and cost-effectiveness.
Importance of Buying from a Reliable and Leading Supplier
Buying locally from a firm that is known for its galvanisation expertise is the first step towards saving money. The durability of materials used in road-network infrastructure development and construction projects is crucial. The longevity of the materials equals a lower cost to the company over the long term. The products require less maintenance as well. Local manufacturers meet specific SANS and ISO standards. Such a supplier of note is Armco Superlite.
The firm is certified to the BSI ISO 9001:2015 Quality Management System. All the products from the firm can thus be expected to meet strict quality standards. The firm’s services also fall within the framework of the quality management system. This implies a higher level of customer satisfaction because specific management review policies are in place to ensure that improvements are made on all products and services for the best possible compliance with quality management standards.