Duplex Coating Steel

Duplex Coating Steel

Surface Technologies

Steel can corrode, weaken, and fail due to a number of environmental and chemical factors. One of the best solutions to prevent steel from corroding or rusting in harsh environments, is to protect it with a powder coating or galvanizing process. These finishes help protect the steel without compromising the inner integrity of the metal. 

Although hot-dip galvanizing and powder coating are proven to provide superior corrosion protection, often for decades, the longest lasting method is known as duplex coating, combining these two effective anti-corrosion methods into one. First the steel is galvanized, which acts much like a primer. Then a polymeric ‘powder’ coating can be applied to further protect the metal and enhance the finish. AZZ offers duplex coating for a wide variety of applications, allowing your steel to look great and last longer in any environment. 

Duplex coating combines two effective anti-corrosion methods into one, to make steel over 2x more resistant to the elements than with just one of these methods alone. Galvanizing involves dipping the fabricated steel into molten zinc, where iron in the steel reacts with the zinc to form a tightly bonded alloy coating that is resistant to corrosion. 

Powder coating is a process by which a polymer based powder is applied electrostatically to the metal, and then cured with heat. The results of this process are both long-lasting and chip and fade resistant. Powder coated steel has a beautiful finish that is extremely durable and comes in a variety to custom colors. At their Crowley, Texas facility AZZ combines these two processes to extend corrosion protection 1.5 to 2.3 times longer than either process independently. This improved resilience means that the life of the steel, along with maintenance intervals, is dramatically increased, considerably lowering total life-cycle expenses.

At the moment, no other protection method matches this enhanced coating system. As an added benefit, steel can be powder coated in an unlimited number of colors, and the finishes are truly eye-catching. Steel utilizing this duplex coating process can be used in a number of applications, from specialty architectural cladding, where the color options allow for new creative options, to more industrial applications in the demanding Automotive, Aviation, and Petro-Chem industries, among others. 

Duplex coatings strengthen and extend the operational life of steel, whether it is being used architecturally or as part of an appliance. By enhancing its corrosion resistance, duplex coating also lengthens the product life and increases maintenance intervals, saving you money. Though steel is fantastically strong, it is still subject to corrosion, which can be accelerated by certain environmental conditions. AZZ’s duplex coatings offer you two layers of protection in a variety of colors to give extra life to your materials. To learn how AZZ can lower costs by making your steel components last for years longer, visit https://www.azz.com/products/powder-coating-new/duplex-coat.

Essential Zinc

Essential Zinc

Galvanizing

According to the International Zinc Association (IZA), zinc has been present since our planet formed over 4.5 billion years ago, and all life on Earth has developed in its presence.  Considered a “Life Saving Commodity” by the United Nations, zinc is the 24th most abundant element in the Earth’s crust and is a crucial element of “exceptional biologic and public health importance” on which all organisms depend. Zinc works at the cellular level by enhancing protein and enzyme function, and plays an important role in gene maintenance, the immune system, vision, and organ and tissue growth. Zinc also plays an integral role in supporting global agriculture and safeguarding the world’s infrastructure. 

Simply stated, zinc is essential. 

Health

Over 2 billion people globally lack zinc in their diet. This deficiency hampers the immune system and can lead to growth retardation, infections, hair loss, and skin rashes. Worse, zinc deficiency can be linked to over 1.2 million deaths annually. However, the 2006 Copenhagen Consensus rated vitamin A and zinc as the highest cost-effective solution to the world’s malnutrition epidemic. 

World Agriculture

While natural erosion processes transport zinc in soil, rock, and sediment, many regions lack an adequate dilution of zinc to provide for solid crop quality and yields, resulting in zinc deficient harvests that further compound the health of the consumer. Agricultural output must expand to meet the nutritional needs of the world’s ever-growing population; thus, zinc fertilizers are now being adopted to boost crop yields. In test crops fortified with zinc fertilizer, China reported a 20% increase in yields with an astonishing 40% boost in nutritional content. 

Energy

Known for its anti-corrosion properties, zinc has been protecting our nation’s steel-built electrical infrastructure for decades, and various zinc coatings are being employed to safeguard other structures, such as solar arrays and wind turbines, as well. In addition, due to the high specific energy, recyclability, safety, and zero emissions of zinc-based energy storage systems, zinc is used in the manufacture of a variety of battery chemistries, both primary and rechargeable, consumer and industrial, helping renewable power become 24-hour power. 

Zinc: more than natural; essential. 

Learn more at azz.com/galvanizing/essential-zinc. 

Source: International Zinc Association, 2017

AZZ: We Protect Steel from Corrosion

AZZ: We Protect Steel from Corrosion

Surface Technologies

AZZ is a multifaceted company providing cost-effective metal protection solutions that require zero maintenance.

There are very few places that exist in the country where you can get four different types of finishes at one stop—AZZ is an industry leader for a reason. Watch our video below shot at our facility in Crowley, Texas to learn more about the capabilities and expertise AZZ brings to corrosion protection.

Understand the Costs of Corrosion

Understand the Costs of Corrosion

Surface Technologies

This is unfortunate, because corrosion is much more than unsightly—it is destructive of your equipment, shortening the life of that equipment and requiring costly repairs or even replacement. That is because corrosion—which is a chemical reaction of oxygen with the metal to form oxides that can dissolve, disintegrate, and drive further corrosion—weakens the metal, making it thinner, making it wear faster, and even resulting in holes and breaks. 

While up-front costs exist associated with protecting steel products with metal coating solutions such as galvanizing, metalizing or powder coating, the long-term benefits from corrosion more than make up for the initial outlay. In addition to maintenance and monitoring costs, there are potential lost products, lost production time, property damage, injuries, environmental costs, and even damaged public relations. When these costs are considered, the price of long-term corrosion protection is even more compelling. 

Corrosion’s economic impact is staggering: A study titled “Corrosion Costs and Preventive Strategies in the United States,” conducted from 1999 to 2001 by CC Technologies Laboratories, Inc., with support from the FHWA and NACE, shows that “the total annual estimated direct cost of corrosion in the U.S. is a staggering $276 billion—approximately 3.1% of the nation’s Gross Domestic Product (GDP).” NACE International did a further study showing the global impact of corrosion to be $2.5 trillion—approximately 3.4 percent of global GDP. 

For highways and bridges alone, the cost of corrosion nationwide is $8.3 billion. Corrosion of transmission towers and poles for electric utilities costs the industry $6.9 billion, and in agriculture the corrosion of irrigation systems, livestock containment, and so on costs the industry over a $1 billion. Rather than replacing and repairing already-corroded equipment, we should take steps to proactively prevent corrosion. 

AZZ offers a variety of metal-coating solutions, including galvanizing, powder coating, metalizing, and GalvaBar, a galvanized rebar that both provides the protection of zinc and exceptional formability. These solutions are leading the way in protecting our nation’s infrastructure, helping to save billions of dollars annually and making our world safer in the process. 

Avoid the high costs of corrosion related maintenance and replacement. Keep your plants up and running, safe and secure from corrosion, with metal protection solutions from AZZ. 

To learn more about what AZZ Inc. can do for your business, visit us online at http://www.AZZ.com today!