A galvanização e os investimentos em portos

byFrank GoodwinWilliam Marques

International Zinc Association

Shipyards in Brazil

January 2012

• 47 Shipyards • 11 New yards under

construction • 59,000 workers

directly employed • 6.2 Million DWT

order book • 18 Offshore Oil

Platforms under construction

The most important ports

• Porto de Santos – SP• Porto de Vitória – ES• Porto de Paranaguá – PR• Porto de Rio Grande – RS• Porto de Rio de Janeiro – RJ• Porto de Itajaí – SC• Porto de São Sebastião – SP• Porto de Itaqui – MA• Porto de Aratu – BA

Port of Santos

Brazilian Shipyards DWT under construction

Brazilian ShipyardsToday’s Order Book and New Orders as of January 2012

BrasFELS - Angra dos Reis (RJ) specializes in offshore production platforms.

Atlantico Sul Shipyard – Suape (PE) Large crude carriers, offshore platforms and drill ships

Port Facilities

Portos e Navios

Port of Vancouver, BC

Delta Port- Vancouver’s largest container terminal

Delta Port handles the largest container ships afloat and features dual-hoist gantry cranes – a first in the Americas - along with super post-panamax cranes, 3 berths and advanced computer systems.

Delta Port – galvanized structures

Delta Port – galvanized structures

Dredge “Ned Edwards”Port of New Orleans, USA

Galvanizing used for handrails, stairs, walkways, and platforms

Dredge “Ned Edwards”Port of New Orleans, USA

Arbon MarinaLake Constance, Switzerland

Arbon Marina

Arbon Marina

Bottighofen marinaLake Constance

Bottighofen Marina

Bottighofen Marina

Galvanized boat trailers at Bottighofen Marina

Bottighofen marina

Duplex Coating

• The protection of steel by a layer of zinc which is overcoated by a non-metallic coating

• The purpose is to provide additional corrosion resistance, easy visibility, camouflage or a pleasing aesthetic appearance

• Corrosion resistance of a properly applied duplex coating can provide corrosion protection outside the pH or Cl- range normally acceptable for galvanizing.

• Zinc products of Corrosion far less than RED Rust

• Blistering (corrosion creep) of paint therefore far less than when it is direct onto steel

• Zinc products of corrosion tend to seal the pours in the top paint coating

• Results in the “Synergistic effect”, which is:

Why does a Duplex System Work?

Duplex Service Life = Factor x (Zn Life + Paint Life)

e.g. Service Life = 1.5 x (9 years + 5 years)

= 21 years to 5% rust

Synergistic factors

• Industrial/Marine 1.8 to 2.0• Sea water (immersion) 1.5 to 1.6• Non-aggressive climate 2.0 to 2.7

• Paint is not there to protect the zinc, but zinc is there to support the paint when it starts to fail!

Atmospheric corrosive environments classified in terms of ISO 9223

Galvanized & Painted Weed Bars in a LockLocation: Delfzijl, The Netherlands

After17 years, stillno sign ofrust

Specify type and thickness of paint in accordance with ISO 12944:1998

Part 5 Table A.9

S te p 3

* S e le c t a n IS O 1 2 9 44 c om plia nt s ys te m

Th e p a in t s ys te m s g iven in th e fo l low in g tab le a re o n ly e xa m p les ,. O th e r p a in t s ys te m s h a vin g th e s a m e pe rfo rm an ce

a re p o s s ib le .

If th e s e e xa m p le s a re u s ed , i t s h a ll b e e n s u re d tha t the p a in t s ys te m s ch o s e n co m p ly w ith the in d ica te d du ra b ili ty w h e n e xecu tio n o f the p a in t w o rk ta ke s

L M H L M H L M H L M H H L H

S9.01 - - 1 80 1 80

S9.02 1 40 1 80 2 120

S9.03 1 80 1 80 2 160

S9.04 1 80 2 160 3 240

S9.05 - - 1 80 1 80

S9.06 1 40 1 80 2 120 -

S9.07 1 80 1 80 2 160

S9.08 1 80 2 160 3 240

S9.09 - - 1 80 1 80

S9.10 1 40 1 80 2 120

S9.11 1 80 1 80 2 160

S9.12 1 80 2 160 3 240

S9.13 1 80 2-3 240 3-4 320

1-pack 2-pack

PV C x PV C = Po lyvinyl chloride

A Y x

EP x

PU R x

1) Th e m e ch a n ica l o r ch e m ica l s u rfa ce p re pa ra tion re rq u ire d is d es cribe d in ISO 1 2 94 4 -4 .

2) Th e d u ra b il i ty is in th is cas e re la te d to th e p a in t s ys te m ad h e s io n to th e h o t-d ip -g a lva n ize d s u rfa ce .

3) N D FT = N o m in a l D ry Film Th ickn e s s . S e e 5 .4 fo r fu rth e r d e ta ils .

4) If co lo u r a nd g los s re te n tio n is re q u ire d , it is re com m e n de d tha t th e las t co a t s h o u ld b e b a s e d o n a lip ha tic PU R .

5) Fo r e xp la n a tio n o f ab b re via tio n s , s e e fo o t o f ta b le

6) L igh t g re y s h a d in g in d ica te s th a t th e p a in t s ys te m s con ce rn e d w o u ld n o t n o rm a lly b e u s e d fo r th e s e co rro s ivity ca te g o rie s .

Th ey a re n o t l is te d in tab le A.2 an d /o r A.3 .

E N IS O 12944-5:1998T ab le A9: P a in t system s co rro siv ity ca teg ories C 2 to C 5-I an d C 5-M

S ub strate: H o t-d ip -g alvan iz ed s tee l¹)

Paint S ys tem

N o

Priming co at(s) T o p co at(s)) inc lud ing intermed iate co at(s ))

Paint system E xp ected durab ility 2 ) 6 )

(see 5.5 and ISO 12 9 4 4 - 1)

B inder 5) Number of coats

NDF T 3)

µm

B inder 5) Number of coats

NDF T 3) µm

A Y A Y

C 5-I C 5-M

PV C PV C

C 2Total NDF T 3) µm

C 3 C 4

EP or

PUR

EP or

PU R 4)

B inders fo r p riming co at(s) Paints ( l iq uid )

No o f components W ater borne

possible

B ind ers fo r to p co at(s)

x

Paints ( l iq uid )

No. o f components W ater borne

possible 1-pack 2-pack

EP = Epoxy

= A crylic x A Y = A crylicx x

= Po lyvinyl chlo ride

xx

= Po lyurethane PUR = Po lyurethanex x

= Epoxy x

When to paint the galvanized structure

• Apply the paint system as soon as possible after galvanizing, after correct pre-treatment

• Weathered galvanizing, which is suitably cleaned, can provide a satisfactory surface on which to apply paint but this should only be considered if material is situated on a site where corrosion is relatively mild and a stable weathered zinc surface has developed.

• Painting of freshly galvanized structures should never be deferred in a marine environment where the need to remove unstable zinc corrosion products, prior to painting, could render the system less effective.

• Or, apply a suitable primer at this stage, followed by a compatible top coat on site.

Conclusions

• Galvanized steel is not well known, or much used, in Brazilian ports

• Case studies show this could be an important market for the galvanizer

• Severe marine climates suggest duplex coatings may be required to give 20 years before significant maintenance is required.