Corrosion Protection for 20 years or more - This is Zinga Film Galvanising
For GeM Customers, please refer below.
Please note -> Zingalu and Zingaluspray are Silver colour
Zinga and Zingaspray are Grey colour
Product
Description
Catalog ID
Technical
Data sheet
GeM Product ID
GeM Link
Zinga
Grey Colour, 96% Zinc in Dry film thickness, 99.995% Zinc Purity. We will supply in 5 kg packing if quantity required is more than 5 kg
GeM Product ID 5116877-96844560344
Catalog ID
5116877-96844560344-cat
Zingasolvent
Only solvent compatible for Zinga or Zingaalu. Buy in 10-15% proportion of Zinga or Zingaalu. We will supply in 5 litre pack if quantity of purchase of Zinga or Zingaalu is more than 50 kg, else in 1 litre pack
GeM Product ID
3012303-32007913440
Catalog ID
5116877-13128089103-cat
Zingaspray
Aerosol Spray - Grey colour finish. 500 ml packing. Life is 1 year
GeM Product ID
3012303-91074208000
Catalog ID
5116877-25328408081-cat
What is Film Galvanisation
While hot dip galvanizing coats iron and steel by immersion into molten Zinc bath, ‘Cold Galvanizing’ is the process of painting steel structures and exteriors with Zinc – rich paints. “Cold galvanizing” or Zinc painting is the application (by brush or spray) of Zinc dust mixed with organic or inorganic binders. Commonly containing 92-95% metallic Zinc in dry film, these Zinc-rich paints can be applied to structural steel and piping which are exposed to a wide range of corrosive atmospheric environments like refineries, power plants, bridges, buildings, mining equipment etc.
With a high percentage of Zinc in the dry film, these paints can synergistically combined with the corrosion inhibitive properties of metallic Zinc. The Zinc dust in paint is integrated with organic binders. These binders allow the Zinc particles to remain in contact with each other so the Zinc paint can provide cathodic protection. While Zinc protects structures from corrosion by hot-dip galvanizing or cold galvanizing, there is high intrinsic value in using both the techniques together, known as a duplex system.
What is Zinga?
ZINGA is a one component zinc rich coating or Film Galvanising System containing 96% zinc (dust) in its dry film. It is a metallic coating and not a paint. The purity of the zinc used, is so high that dry ZINGA does not contain any toxic elements.
ZINGA is a unique form of corrosion protection because it provides both Active and Passive protection in a form that’s as easy to apply as a paint.
ZINGA was originally invented at the University of Ghent (UGent), Belgium, in the 1970s and has since been used in a wide variety of projects throughout the world.
ZINGA is an active zinc performance coating which works in conjunction with the metal beneath, whereas paints are only passive barriers. Regardless of how thick paints are applied, they remain as barriers. Once they are breached, corrosion sets in immediately. Despite this significant difference ZINGA is still often mistaken for a paint simply because it’s liquid and comes in a tin. But there are other more subtle differences. For example it does not “skin over” in the tin because ZINGA has an unlimited pot-life and it doesn’t go “tacky” like a paint.
Zinga versus Paint
Characteristics
ZINGA®
Paints
Active cathodic protection
ZINGA® has the most important advantage that it offers a real cathodic (galvanic) protection. ZINGA® has a concentration of 96% special zinc in its dry layer which gives it its galvanic characteristics. The film galvanising system ZINGA® (also called “Zinganisation®“) distinguishes itself from cold galvanisation because of its higher quality. Only the application method of ZINGA® can be compared to traditional paint products, and not its protective properties.
Not even paints with a relatively high zinc content can provide cathodic protection. It has been scientifically proven that a concentration of at least 92% of distilled zinc in the dry film is required to rightfully use the terminology “cathodic protection throughout the dry layer”. Most of these zinc rich paints have only a small percentage of zinc, which does not guarantee a galvanising protection throughout the layer.
Active cathodic protection
ZINGA® has the most important advantage that it offers a real cathodic (galvanic) protection. ZINGA® has a concentration of 96% special zinc in its dry layer which gives it its galvanic characteristics. The film galvanising system ZINGA® (also called “Zinganisation®“) distinguishes itself from cold galvanisation because of its higher quality. Only the application method of ZINGA® can be compared to traditional paint products, and not its protective properties.
Not even paints with a relatively high zinc content can provide cathodic protection. It has been scientifically proven that a concentration of at least 92% of distilled zinc in the dry film is required to rightfully use the terminology “cathodic protection throughout the dry layer”. Most of these zinc rich paints have only a small percentage of zinc, which does not guarantee a galvanising protection throughout the layer.
Easy application on site
ZINGA® can be applied in the same way as paints.
Paints can applied on site using a brush or roller or spraying (airless, conventional).
Reloadable
A cured ZINGA® layer, will reliquidise if a new layer of ZINGA® is applied. This ensures the creation of 1 ZINGA® layer with a continuous electrochemical contact between the Zinc particles and thus galvanic protection. If the ZINGA® layer is very old, the Zinc salts on the surface (ensuring a passive protection), need to be removed to ensure complete reliquidisation; this can be obtained by performing a light sweep blast.
Apart from reversible paints (e.g. vinyl paints), most paints cannot be overcoated with a paint without creating two separate layers. This can cause interlayer moisture and consequently weakening of the system. If a painted steel structures needs to be repainted, the entire structures needs to be blast cleaned.
Zinga versus Hot Dip Galvanization
Characteristics
ZINGA®
HDG
Active cathodic protection
ZINGA® has the most important advantage that it offers a real cathodic (galvanic) protection. ZINGA® has a concentration of 96% special zinc in its dry layer which gives it it’s galvanic characteristics.
ZINGA® (also called “Zinganisation”) shows comparable protection as HDG.
Steel members which have been hot dip galvanized have proven cathodic protection by the sacrificial action of the the zinc on its surface. Damages to the HDG steel substrate show protection by the throwing power of the zinc layer.
Easy application on site
ZINGA® can be applied in the same way as paints, on site or in workshops.
Hot dip galvanization cannot be realized on site. The steel structures or beams have to be transported to and from the HDG plant. In case of repairs they have to be de-mounted or dismantled, transported to the HDG plant, hot dipped again, transported to the workplace or building site and re-mounted.
Reloadable / Rechargeable
A cured ZINGA® layer, will reliquefy if a new layer of ZINGA® is applied on top of it. This ensures the creation of one homogenous ZINGA® layer with a continuous electrochemical contact between the Zinc particles, providing full galvanic protection. If the ZINGA® layer is very old, the Zinc salts on the surface (ensuring a passive protection), need to be removed to ensure cleanliness of the surface and complete reliquefication with the old ZINGA® layer; this can be obtained by performing a light sweep blast or a high pressure hot water washing.
Hot dipped structures can be hot dipped again but will require demounting or dismantling, blasted eventually and dipped into the Zinc bath. ZINGA®‘s mechanism of protection is so similar to conventional galvanizing that they work in complete unison, as they are merely different forms of zinc. Rather than replacing galvanized assets, structures can simply have their protection “re-charged” by applying ZINGA® to the rough surface of the old galvanizing after appropriate decontamination and removal of the salts.
Catalog ID
Zinga versus Metallizing
Characteristics
ZINGA®
Metallisation
Active Protection
Offers a cathodic protection throughout the layer, comparable to the cathodic protection of hot dip galvanising (Prof. Defrancq - University of Ghent).
Offers a cathodic protection throughout the layer.
Passive Protection
A layer of zinc salts slowly builds up on the ZINGA surface. This creates a barrier protec- tion for the metal substrate. Next to this, a supplementary barrier protection is provided by the binder in ZINGA. The binder reduces the disintegration of the zinc.
The 100 % zinc in the thermal zinc spray system is a naked zinc, without the barrier protection of the zinc particles in ZINGA.
Unique System
Does not need a topcoat. A single layer of ZIN- GA is in itself a Duplex system offering on one side an ACTIVE-CATHODIC protection, on the other side a PASSIVE-BARRIER protection.
Has porosities and the zinc in a metallisation layer is a naked zinc, therefore it is neces- sary to apply a stabilisation coating before applying one or two topcoats.
Zinganised Re-bars Versus Fusion Bonded Epoxy
Zinga Coated Rebars
Fusion Bonded Epoxy Rebars
There is loss of only 2-3% bond strength due to zinga coating which is negligible.
Lower bond strength to concrete than uncoated steel. Pull out tests indicste a loss of 15 to 17 % bond strength due to epoxy coating
No degradation in coating on long-term exposure to sunlight. Can withstand stress induced due to thermal cyclic variation
Undergoes degradation on long-term exposure to sunlight, requires storage under shelter
ph resistance of 4.5 to 12.5 hence it can resist the alkaline environment inside the concrete.
ph resistance of 5.5 to 9 It cannot resist the high alkaline environment inside the concrete which has a ph of 12.5
How does it work?
When two different metals come in contact with each other in presence of an electrolyte (e.g. water), they form a galvanic cell in which the lesser noble metal (e.g. Zn) corrodes in favour of the more noble metal (e.g. steel). This electrochemical reaction is the base for the complex field that is cathodic protection.
Galvanic, cathodic protection, or active protection, arises from zinc (the anode) sacrificing itself in favour of the base metal -steel (the cathode) with the resulting flow of electrons preventing steel corrosion. In this way the protection of the metal is guaranteed, even when the zinc layer is slightly damaged.
Other well-established methods of cathodic protection include hot-dip galvanising (HDG) and zinc thermal spraying, both of which exhibit a constant sacrificial rate of the zinc layer.
With ZINGA the sacrificial rate reduces dramatically after the zinc layer has oxidised and the natural porosity has been filled with zinc salts. Additionally the zinc particles within the ZINGA layer are protected by the organic binder without adversely affecting the electrical conductivity. This enables ZINGA to create nearly the same galvanic potential between the zinc and the steel as hot dip galvanising but with a lower rate of zinc loss because, put simply, the binder acts as a “corrosion inhibitor” to the zinc.
How can it be used?
Stand Alone System :
ZINGA provides comparable protection to conventional galvanising without the need for topcoats. Although ZINGA is only available in grey (the natural colour of zinc), the significant advantage of this form of application is that the ZINGA layer can be re-coated at any point in the future with the bare minimum of preparation and without compromising the integrity of the coating (see Re-charging of ZINGA). ZINGA on its own is often used, because the structure is already on site or too big for the molten zinc baths. Additionally ZINGA is commonly specified on delicate structures (wrought iron gates, sculptures) or when architectural demands require a higher standard of surface finish (no need to drill to de-gas, fettle).
For optimal protection, ZINGA should be applied in two layers of 60 or 90 µm DFT each.
As A Primer in a Duplex & Triplex System :
ZINGA and the topcoats work in harmony to extend the lifetime of the system. As the ZINGA layer will not begin to sacrifice itself until the topcoat is breached, the original zinc thickness is maintained whilst affording the topcoat protection from under-creep and blistering.
In a duplex and triplex system (Active + Passive), ZINGA should be applied in 1 layer of min. 60 to 80 µm DFT.
For more information and application instructions, see ‘Overcoating ZINGA’.
As Shop Primer :
At 30-40 µm DFT, ZINGA can be used as a shop primer. The big benefit is found in the fact that the steel structures do not require reblasting before coating if ZINGA is applied as a shop primer. The steel structure can be overcoated with ZINGA to obtain a cathodic protection or with any other paint without the need for reblasting!
Zinganised steel structures can be welded and bent during assembly.
Repair for worn and damaged Hot-Dip Galvanized or Metal sprayed structures :
This method is probably the most common use of ZINGA as it requires the simplest surface preparation. ZINGA’s mechanism of protection is so similar to conventional galvanizing that they work in complete unison, as they are merely different forms of zinc. Rather than replacing galvanized assets, structures can simply have their protection “re-charged” by applying ZINGA to the rough surface of the old galvanizing after appropriate decontamination of the surface and removal of the salts.
On Rebars :
ZINGA is used globally in the construction industry on steel rebars prior to assembly and immersion as it delivers increased corrosion protection without compromising pull-out strength in even the lowest quality of concretes.
Independent laboratory testing performed by multiple institutes has proven ZINGA can guarantee twice the corrosion protection compared to that of galvanised or epoxy coated rebars.
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