Asia Pacific Edition

HOT DIP GALVANIZED STEEL

Associate of International Zinc Association

83
galvanize February 2021
BEST PRACTICE CORROSION
PROTECTION FOR BCA
VOLUME 2 PART 3.4.4.4
In this issue
1 Introduction
2 National Construction
Code
4 Hot Dip Galvanizing
4 Environmental
conditions for
corrosion of steel
9 Increasing durability
at the Soil/Concrete/
Galvanized steel
interface
11 HDG Steel in contact
with timber

Introduction
This issue of Galvanize provides additional advice to the Building Code of Australia
for the corrosion protection of structural steel in housing and related applications.
Editorial It deals with the common issues but cannot describe all situations and independent
Peter Golding
professional advice must be sought if there is any doubt.
Prepared by
Galvanizers Association of Australia The National Construction Code 2019 Building Code of Australia – Volume 2 (Amendment 1) (1) sets out the requirements
for corrosion protection of certain structural steel members such as:
To read other • Bearers supporting a timber floor or non-loadbearing stud wall
• Strutting beams supporting roof and ceiling loads
Galvanize stories
• Lintels supporting a roof, ceiling, frame, and timber floor
Go to our website • Columns
www.gaa.com.au
2 BEST PRACTICE CORROSION PROTECTION FOR BCA VOLUME 2 PART 3.4.4.4

Table 3.4.4.4 of the Building Code of Australia (BCA) sets outs the minimum Structural steel members in the BCA
requirements for protective coatings where the degree of corrosion A range of structural steel members are included in the Acceptable
protection is determined by the described environment and location. The Construction Practice section of Part 3.4.4 of the BCA. Hot formed sections
BCA rules relating to external environments and the minimum corrosion included are a range of taper flange beams, universal beams, parallel flange
protection required do not fully describe the corrosivity experienced by channels, taper flange channels, equal angles, and unequal angles. Cold
structural steel in all common situations and can lead to poor outcomes for formed sections in the BCA structural steel section include a range of
service life of the coating and, in some cases, early failure of structural steel standard tubular sections (rectangular, square, and round hollow sections).
members, even if they have been supplied and installed to the requirements Structural steel members covered vary in thickness from 1.6mm for a limited
of the BCA. selection of tubular sections to well over 6mm thickness on various hot
Users should also be aware there are multiple types of coatings that are formed sections. The steel thickness is important as it affects the hot dip
claimed by their suppliers to be a form of galvanizing. Most of the common galvanized (HDG) coating thickness formed on batch hot dip galvanized
coatings available in Australia will not meet the minimum requirements of sections which, in turn, directly influences the durability of the structural
the BCA, except in moderate internal exposures or with the addition of a steel member and therefore the durability of the structural steel member.
paint topcoat. Only batch hot dip galvanized steel coatings produced
to AS/NZS 4680 (2) always meet the minimum requirements of the Corrosion protection of structural steel members in the BCA
BCA for structural steel members without the addition of a topcoat. The BCA provides for mandatory corrosion protection of structural steel
It is important that the correct specification is selected and supplied to members in Volume 2 Part 3.4.4.4 where two atmospheric environments
ensure adequate performance of the galvanized coating. In addition, if a (moderate and severe) are described (Table 1 of this document). In addition,
paint coating option is selected, the BCA does not provide a full specification the concept of breaking surf is introduced, and a definition of heavy
and it may be difficult to assess conformance to the requirements of the BCA industrial areas is provided. The BCA does not provide any mandatory
without an expert opinion. requirements related to micro-environments, except where steel in the roof
Note: Section 3.4.4.4 of the BCA does cover structural steel members used space is exposed to moist exhaust gases from kitchen or bathroom fans.
in masonry construction but does not cover corrosion protection of structural A moderate environment is defined as being more than 1km from breaking
steel built into a masonry wall such as lintels. For lintels and other structural surf or more than 100m from salt water not subject to breaking surf or non-
steel elements built into masonry, specifiers must refer to AS 3700 (3), the heavy industrial areas.
AS 2699 (4) series, and Part 3.3.5 of the BCA.

A severe environment is defined as being

National Construction Code within 1km of breaking surf or within
The National Construction Code (NCC) is Australia’s primary set of technical
design and construction provisions for buildings. It is a self-described 100m of salt water not subject to
performance-based code which primarily applies to the design and breaking surf or heavy industrial areas.
construction of new buildings and is used by architects, builders, building
surveyors, engineers and other building related professions and trades. The
NCC is given legal effect through relevant State and Territory legislation and A severe environment is defined as being within 1km of breaking surf or
the applicability of the NCC for a particular situation should be assessed within 100m of salt water not subject to breaking surf or heavy
against the relevant local legislation. industrial areas.
The Building Code of Australia (BCA) makes up 2 volumes of the NCC, with Breaking surf is defined as any area of salt water where waves break on an
Volume 2 the subject of this issue of Galvanize. Volume 2 primarily covers average of 4 days per week but does not include white caps or choppy water.
the design and construction of houses, small sheds, carports, and some This normally occurs in open seas and would usually preclude sheltered
other associated structures. The NCC allows either a Performance Solution locations in the vicinity of Port Philip Bay, Sydney Harbour and near coastal
or a Deemed-to-Satisfy Solution to meet the requirements of the BCA. The rivers such as Derwent, Swan, and Brisbane Rivers.
differences can be complex, and these are described in Part A2 of Volume 2
of the BCA. Heavy industrial areas are defined as the industrial environments around
major industrial complexes. Corrosion of steel from industrial effects is no
Part 3 of Volume 2 deals with acceptable construction for Deemed-to-Satisfy longer an important factor as heavy industrial areas are relatively few in
Solutions. It is this aspect that is clarified in this issue of Galvanize. The Australia and are known from surveys to be restricted to the areas nearby to
guidelines discussed here are not a Performance Solution but do provide the processing plants at Mt Isa and Port Pirie (see AS 4312 (5) for
more information that will assist professionals in the development of a more information).
suitable corrosion protection system for structural steel in some
common applications. Structural steel members in the outer leaf and cavity of an external masonry
wall of a building, including walls under open carports are external
environments for the purpose of the BCA, while a part of an internal leaf of
an external masonry wall which is in the roof space is considered to be in
an internal wall. For lintels and other structural steel elements built into
masonry, specifiers must use AS 3700, the AS 2699 series, and Part 3.3.5 of
the BCA.
 BEST PRACTICE CORROSION PROTECTION FOR BCA VOLUME 2 PART 3.4.4.4 3

Figure 1 A severe environment located within 1km of breaking surf.

Additional Notes (from the BCA):

Table 1: BCA Volume 2 Table 3.4.4.7 Protective coatings for steelwork
1. Where a paint finish is applied to the
Environment Location Minimum protective coating surface of the steel, work must be hand or
power tool cleaned to remove any rust
Moderate Internal No protection required in a permanently dry location immediately prior to painting.
More than 1 km from 2. All zinc coatings (including inorganic zinc)
External Option 1. 2 coats alkyd primer require a barrier coat to stop conventional
breaking surf or more
than 100 m from salt water Option 2. 2 coats alkyd gloss domestic enamels from peeling.
not subject to breaking Option 3. Hot dip galvanize to 300 g/m2 min 3. Refer to the paint manufacturer where
surf or non-heavy Option 4. Hot dip galvanize to 100 g/m2 min plus - decorative finishes are required on top of the
industrial areas minimum coating specified in the table for
1 coat solvent based vinyl primer; or the protection of the steel against corrosion.
1 coat vinyl gloss or alkyd 4. For applications outside the scope of this
table, seek specialist advice.
Severe Internal Option 1. 2 coats alkyd primer
Within 1 km from breaking Option 2. 2 coats alkyd gloss The description of paints (alkyd primer, alkyd
surf or within 100 m of gloss, solvent based vinyl primer, vinyl gloss and
salt water not subject to External Option 1. Inorganic zinc primer plus 2 coats vinyl inorganic zinc primer) in the above table are
breaking surf or heavy gloss finishing coats considered by the GAA to be incomplete and
industrial areas Option 2. Hot dip galvanize to 300 g/m2 min unsatisfactory for a specification. This is because
there is no coating thickness requirement, the
Option 3. Hot dip galvanize to 100 g/m2 min plus -
surface preparation requirement is inadequate
2 coats solvent based vinyl primer; or and will allow the steel surface to be poorly
2 coats vinyl gloss or alkyd prepared (while conforming to the instructions in
note 1 above), often leading to early corrosion,
and not all the paint types are available. Users
should request that a performance solution be
prepared if the drawings recommend a painted
solution for structural steel members.
4 BEST PRACTICE CORROSION PROTECTION FOR BCA VOLUME 2 PART 3.4.4.4

Hot Dip Galvanizing Environmental conditions for

Hot dip galvanizing is the process of dipping a structural steel member or
fabrication into molten zinc. The process forms a metallurgical bond
corrosion of steel
between the zinc and the steel to create a long lasting and abrasion
resistant coating that protects against corrosion in atmospheric conditions. Corrosion of steel in housing applications
More detail on the process can be found at the GAA’s website The corrosion of steel in housing is generally related to the atmospheric
(www.gaa.com.au). corrosivity experienced by steel, known as the macro-environment, plus any
localised effects, known as the micro-environment, such as sheltering of
For all hot formed structural steel members (taper flange beams, universal
unwashed surfaces in corrosive locations, defects in the corrosion protection
beams, parallel flange channels, taper flange channels, equal angles, and
from steel fabrication or installation, and design defects.
unequal angles), hot dip galvanizing can only be applied by the batch hot dip
galvanizing process governed by Australian Standard AS/NZS 4680
The macro-environment
(Table 2). Batch hot dip galvanized tubular sections are also covered by
AS/NZS 4680. Although other galvanized coating solutions are marketed in The general atmospheric condition in an area is usually the main driver
Australia, none of the continuous galvanized coatings applied over SHS or affecting the corrosion rate of steel and this is known as the
RHS tubular sections meet the coating mass and thickness requirements of macro-environment. Australian Standards AS 4312 and AS/NZS 2312.2 (6)
the BCA without the addition of a paint topcoat. provide excellent guidance on the macro-environment in Australia.
For ease of design, the macro-environment is generally broken up into
Corrosivity Zones. The zones are generally related to the distance from the
Hot dip galvanizing is the process of dipping coast and the type of coast, where the corrosion rate of steel increases
a structural steel member or fabrication into dramatically as the distance to the coast decreases (see Figure 2 and
Table 3). The type of coast is important, while the conditions around
molten zinc. sheltered bays are usually less corrosive, exposure to surf increases the
corrosion rate of steel. Category CX (as described in Table 3) mainly occurs
at the shoreline of severe surf conditions and is therefore not generally
Table 2 Hot dip galvanized coating thickness requirements for applicable for domestic housing.
AS/NZS 4680
Steel thickness HDG coating thickness HDG coating mass
(mm) average minimum average minimum
(μm) (g/m2)
0.1 km
>6 85 600 Ocean Sheltered
Coastal Bay 1 km
> 3 to ≤ 6 70 500
≥ 1.5 to ≤ 3 55 390
Note: The coating thickness is the usual method of checking compliance of a galvanized
coating application and can be converted to mass by multiplying by 7.14. The galvanized
coating mass is rounded for convenience of description. C5 C4 C3 C2
Very high High Medium Low
The requirements of AS/NZS 4680 are such that even the thinnest batch
0.2 km
HDG coating will exceed the requirements of Table 3.4.4.7 of the BCA, and
the actual thickness received will provide for a HDG coating service life 1 km
significantly more than envisaged in the BCA.
As noted above, other types of hot dip galvanized coatings are readily
available for tubular sections with most of these tubular sections not
meeting the minimum requirements for hot dip galvanized steel in the BCA 10 km
(300 g/m2). Further, only hot formed sections which are hot dip galvanized to
meet the requirements of AS/NZS 4680 will conform to the minimum Figure 2 Corrosivity Categories as shown in AS 4312 and AS/NZS 2312.2.
requirements for corrosion protection shown in the BCA. It is critical that the
designer specifies the correct material and the builder orders and receives
the correct material to ensure long term durability of the coating.
 BEST PRACTICE CORROSION PROTECTION FOR BCA VOLUME 2 PART 3.4.4.4 5

Figure 3 Batch hot dip galvanized structural steel posts in combination with a continuous galvanized sub-floor located in a BCA moderate zone (more than 1km from breaking surf).

Table 3 Corrosivity in Australia as described in AS 4312 and AS/NZS 2312.2

Category Generic examples Specific examples

CX Severe surf shoreline Surf beach shoreline regions with very high salt deposition. Some Newcastle beaches
C5 Surf Seashore Within 200 m of rough seas & surf beaches. More than 500 m from the coast in some
May be extended inland by prevailing winds & local conditions. areas of Newcastle

C4 Calm Seashore From 200 m to 1 km inland in areas with rough seas & surf. All coasts
May be extended inland by prevailing winds & local conditions.
From the shoreline to 50 m inland around sheltered bays.
In the immediate vicinity of calm salt water such as harbour foreshores.
C3 Coastal From 1 km to 10 km inland along ocean front areas with breaking surf Metro areas of Perth, Wollongong,
& significant salt spray. Sydney, Brisbane, Newcastle, & the
May be extended inland to 50 km by prevailing winds & local conditions. Gold Coast

From 100 m to 3 – 6 km inland for a less sheltered bay or gulf. Adelaide & environs
From 50 m to 1 km inland around sheltered bays. Port Philip Bay & in urban & industrial
areas with low pollution levels
C2 Arid/Urban Inland Most areas of Australia at least 50 km from the coast. Canberra, Ballarat, Toowoomba & Alice
Springs
Inland 3 – 6 km for a less sheltered bay or gulf. Adelaide & environs
Can extend to within 1 km from quiet, sheltered seas. Suburbs of Brisbane, Melbourne, Hobart
C1 Dry indoors Inside heated or air-conditioned buildings with clean atmospheres. Commercial buildings
6 BEST PRACTICE CORROSION PROTECTION FOR BCA VOLUME 2 PART 3.4.4.4

Table 4 Comparison of distance from salt water for BCA and AS 4312

BCA Table 3.4.4.7 (External Locations) AS 4312

Environment Specified distance from salt water Corrosivity category Typical distance from salt water
Surf coast Sheltered coast Surf coast Sheltered coast
Moderate >1km >100m C2 >50km >10km
10km to 50km 1km to 10km
C3
1km to 10km 50m to 1km
Severe ≤1km ≤100m C4 200m to 1km <50m
C5 <200m N/A

Combining the information from Table 1 (BCA) and Table 3 (AS 4312 and
Table 5 Rate of corrosion of structural steel and HDG coatings
AS/NZS 2312.2), and assuming a conservative position for the change of C4
to C3 at 200m for sheltered coasts, designers can refine the BCA definitions Corrosivity category, description Structural HDG
into Moderate C2, Moderate C3, Severe C4 and Severe C5 (Table 4). & typical environment steel coatings
The distance of C2 and C3 zones from the coast do vary around Australia, members
and this can influence the best solution for corrosion protection. More
importantly, the severe zone defined in the BCA covers a very wide range of (AS 4312 & AS/NZS 2312.2) Typical corrosion rate for the
corrosion rates for steel and galvanized coatings, directly influencing the first year (µm/y)
durability of the solution. The GAA recommends that designers take the time
C1 Very low Dry indoors ≤1.3 ≤0.1
to understand the distance of the house or structure from corrosive
influences before deciding on the coating solution. This is discussed further C2 Low Arid/Urban inland >1.3 to ≤25 >0.1 to ≤0.7
in the next section.
C3 Medium Coastal >25 to ≤50 >0.7 to ≤2.1
Corrosion rate of steel and HDG coatings in the
macro-environment C4 High Calm seashore >50 to ≤80 >2.1 to ≤4.2
The rate of corrosion for uncoated structural steel members and HDG C5 Very High Surf seashore >80 to ≤200 >4.2 to ≤8.4
coatings is provided by AS 4312 and AS/NZS 2312.2 (Table 5). The corrosion
rate can be compared to standard HDG coating thicknesses to determine the CX Extreme Ocean/Offshore >200 to ≤700 >8.4 to ≤25
estimated service life of the HDG coating. Using this information and the
options available in Table 3.4.4.7 of the BCA, the estimated service life of
The corrosion rates shown in each Corrosivity Category of Table 5 are
each option can be determined.
provided as a range where, for normal Australian washed atmospheric
exposures, the distance from the coast is the driving force.
The distance of C2 and C3 zones from the Table 6 shows the same information in the form of life to first maintenance
of the galvanized coating and also shows the BCA minimum galvanized
coast do vary around Australia, and this coating requirement as a comparison. For galvanized coatings this should be
can influence the best solution for considered the time at which major maintenance of the item is required to
reinstate corrosion protection to the steel.
corrosion protection.
 BEST PRACTICE CORROSION PROTECTION FOR BCA VOLUME 2 PART 3.4.4.4 7

Table 6 Expected range of life to first maintenance of HDG coatings in the macro-environment for commonly available corrosion
protection methods according to AS/NZS 2312.2
Product and type Steel HDG coating mass Corrosivity category & calculated life of galvanized
thickness & thickness coating (min-max, years)
mm g/m2 µm C2 C3 C4 C5
2
BCA Table 3.4.4.7 HDG 300 g/m All 300 42 60->100 20-60 10-20 5-10
AS/NZS 4680 HDG390 >1.5-≤3.0 390 55 78->100 26-78 13-26 6-13
HDG500 >3.0-≤6.0 500 70 >100 33-100 16-33 8-16
HDG600 >6.0 600 85 >100 40->100 20-40 10-20
AS/NZS 47921 ZB100/100 All 100 14 20->100 6-20 3-6 1-3
ZB135/135 All 135 19 27->100 9-27 4-9 2-4
AS 47502 ZE50 All 50 7 10-70 3-10 1-3 0-1
Notes:
1. AS/NZS 4792 (7) galvanized coatings are only available for cold formed tubular sections and use pre-galvanized strip which is then formed into a welded
tube. The welded area is repaired by the tube manufacturer to restore corrosion protection to the AS/NZS 4792 Standard. Any subsequent fabrication
will also require repair to this Standard.
2. AS 4750 (8) ZE50 is the Australian Standard for electrogalvanized tubular sections commonly available in Australia. While the coating mass (50 g/m2) does
not meet the minimum requirements of the BCA for hot dip galvanizing before paint topcoats are applied, the life of the electrogalvanized coating
according to AS/NZS 2312.2 is included here for information. Electrogalvanized coatings are also not strictly hot dip galvanized as the coating is
mechanically bonded to the underlying steel and does not form the hard, abrasion resistant zinc-iron alloy layers formed by other galvanized methods.
These coatings would generally be only suitable for internal applications or with an engineered performance solution with additional paint coatings.

Using the data in Table 6, products conforming to the BCA could provide as Examples of structural steel which is readily accessible and economical
little as 5 years galvanized coating life (HDG 300 g/m2) in a severe (C5) to maintain or replace include verandah posts. However, if the verandah post
environment, and over 100 years for the same product in a moderate (C2) is embedded into a tiled verandah (Figure 4), corrosion may occur due to a
environment. While complete consumption of the galvanized coating after 5 micro-environment out of sight of the homeowner and failure could occur
years does not mean the structural failure of the steel member, it would relatively early in the expected structural life.
almost certainly attract the ire of most homeowners, purely on appearance.
A simple extrapolation of the corrosion rates for steel indicates the
structural steel member, once fully exposed in the top end C5 environment,
loses 1mm of section on each exposed face every 5 years, and this certainly
provides a risk of structural failure. The two questions that then need
answering are:
1. What is an acceptable life for the coating and the structural member?
2. What maintenance to the galvanized coating can be reasonably
expected by a homeowner?
To answer these questions, we need to understand the accessibility of the
member for maintenance, the difficulty in providing the required maintenance
and/or the cost of simply replacing the member.
Examples of structural steel members which are generally not accessible
or economical to replace are floor piers/stumps embedded in concrete and
load bearing steel members within the building envelope. These structural
members should reasonably be expected to last 50 years, or the life of a
normal building, with minor maintenance of the accessible areas.
Figure 4 A verandah post embedded into a tiled floor in a wet area. Water has seeped
Examples of structural steel members which have moderate ease of into the gap between the tile and the steel through capillary action, leading to
access but are difficult or costly to repair include floor piers/stumps which accelerated corrosion and early failure. This is a design defect where separation of the
are bolted to a base plate or attached to, but not embedded in, a concrete water from the steel was not considered.
footing. These structural members should reasonably be expected to last 15
years with minor maintenance including regular maintenance of the coating.
A house on tall piers will be easier to maintain than one where the piers are
close to the ground and a degree of common sense is required.
8 BEST PRACTICE CORROSION PROTECTION FOR BCA VOLUME 2 PART 3.4.4.4

Figure 5 The galvanized structural steel members (verandah posts and edge members) have good access and would be expected to provide structural support with regular maintenance
of the galvanized coating for 50 years in moderate locations, while regular maintenance, plus repairs to the galvanized coating would be expected during the life of the building in
severe environments.

The micro-environment
Buildings are known to offer a shielding effect when the steel is fully
enclosed, and the corrosion rate of steel when it is fully enclosed (for
example, in the dry roof space of a house) is very low, even in the harshest
of external environments.
If the steel is not fully enclosed in the building and is exposed to wind-driven
salt in an area which is not exposed to cleansing rain (for example a beam
under a verandah or an edge column of a subfloor), the corrosivity of the
micro-environment can be significantly higher than the overall, or
macro-environment. This aspect is critical for estimating the design life of
structural steel. The BCA instructs designers to consider structural steel
members in the outer leaf and cavity of an external masonry wall of a
building, including walls under open carports as external environments,
while a part of an internal leaf of an external masonry wall which is in the
roof space can be considered to be in an internal wall. This means that the
tops of verandah posts should be generally considered external, as should
any structural members in the open roof space of an open carport.
Design of the ground/steel interface is also critical as ponding of moisture
can significantly accelerate the corrosion of the coating and the structural
steel. This effect is known as ring barking or collar corrosion and is common
where water or moisture can pond at the base and in areas where water can
seep into gaps around the steel post and soil, concrete, paved, or tiled joints.
Defects in the corrosion protection can also lead to accelerated corrosion.
For example, this can occur when hot dip galvanized steel has been welded
and not properly repaired, or when a painted steel member has had the paint
coating damaged on installation or during use, or when the paint used was
not appropriately specified and applied. Figure 6 The top floor of this house overlooking the ocean is enclosed, while the
underside of the balcony is open providing for different micro-environments in the same
house. In addition, the plants may offer sheltering from rain but not wind-blown salt,
leading to a complex corrosion design.
 BEST PRACTICE CORROSION PROTECTION FOR BCA VOLUME 2 PART 3.4.4.4 9

Soil Galvanized steel Paint coating or wrap

Soil Concrete Galvanized steel Paint coating or wrap Elastomeric

Sealant

Figure 8 Showing the best design (left) to worst design (right) for galvanized steel
embedded in soil and concrete. See also Figure 11 for more details on the best design
practice for posts embedded in concrete in a corrosive location.

Figure 7 This large post bolted to a concrete pad will finish below the ground level and
will be at risk of collar corrosion reducing the durability of the structure.

Increasing durability at the Soil/Concrete/Galvanized steel interface

The galvanized steel to concrete and galvanized steel to soil interface is a Additional barrier protection
common site of accelerated corrosion in external environments, especially Hot dip galvanized structural steel members are embedded in concrete
when the corrosivity of the local micro-environment is C3 or higher. This footings to extend life and provide a higher tolerance to the overturning
failure is known as ring barking or collar corrosion. Numerous steps can be moment. For this design to be effective the concrete/steel/air interfaces
taken to help a galvanized steel member embedded in concrete and soil must be designed and built correctly. This includes extending the concrete
reach the desired service life. Some or all the following measures may be below the bottom of the pier, according to the engineer’s specification,
required depending on the corrosivity of atmospheric environment and ensuring the concrete extends above the natural ground level and slopes
potential issues identified during the design process. away from the steel by at least 10° to prevent ponding, and adding
additional barrier protection when the exposed atmospheric corrosivity
Embedded structural steel members category is C3 or above (Figure 10 and Figure 11). This method is especially
If water can pool at the interface between the galvanized steel and concrete useful when long-term corrosion protection is required in a corrosive
or soil, a localised corrosion cell forms which results in higher-than-expected atmosphere and for housing posts, piers or stumps which are at the
corrosion rates. Ponding can be minimised by building up concrete or soil perimeter of a sub-floor.
around the interface to promote a natural water run-off, and by preventing
Concrete, bricks, and mortar are susceptible to corrosion in acid sulfate soils
water from running down the member to the interface. If ponding cannot be
and will not provide significant protection in these circumstances unless the
avoided through a design change, additional barrier protection is
concrete is designed for these soils. The best solution is to modify the fill
recommended at the interface. Figure 8 shows examples of the range from
and/or increase the cover if concrete use is required (see also GAA Advisory
best to worst protection of the galvanized coating in soil and concrete.
Note AN 42 (9)). If the concrete footing finishes below the finished ground
level, then the protection of the galvanized steel to soil interface with a
barrier coating is always recommended to increase the durability of the
steel structure.
10 BEST PRACTICE CORROSION PROTECTION FOR BCA VOLUME 2 PART 3.4.4.4

Paint coating or wrap to

engineer’s specification

Elastomeric Sealant Paint coating or wrap

100mm (minimum) above
finished ground treatment
Approx >10°

Paint coating or wrap

250mm below finished
ground treatment or
extend to the full
depth of the post

As detailed by
Structural Engineer

Figure 9 A galvanized post without additional protection at Figure 10 Denso Ultraseal tape wrapped around the base Figure 11 Recommended design for protection of steel to
the steel and concrete interface showing accelerated of a newly embedded post. concrete interfaces for long-term durability.
corrosion which has reduced the overall durability of the
structure. Note the galvanized coating above the ground
remains in excellent condition.

There are several options for protecting the galvanized steel with an Installing posts on elevated concrete pads
additional barrier at the galvanized steel and concrete or soil interface. The An alternative to embedding structural steel into concrete footings is to bolt
normal methods are by using a suitably thick paint or tape wrapping, such the steel to concrete pads. This means that there is no chance of collar
as Denso “Ultraseal” cold applied bituminous tape (10) (Figure 10). Tapes and corrosion but does introduce other corrosion design issues that need to
paint allow the concrete base to end at or below the interface to the be resolved.
atmosphere, but it will be necessary to consider the corrosivity of the soil in
these designs. The barriers are also more susceptible to accidental damage The underside the base plate needs to be protected to ensure water is not
in use. For this application, while probably more expensive than a paint drawn into the inevitable gap between the galvanized steel base plate and
coating, the Denso Ultraseal is easier to apply in the field than other tapes, concrete pad. This can be done using a suitably thick epoxy paint coat on the
faster to apply than paint coatings with little to no curing time and has the underside of the base plate or a plastic spacer.
additional benefit of being able to be selectively overcoated where required. A base plate will be either welded or bolted to the upright steel section. In
As noted above, there are several suitable alternative solutions for barrier the welded case this should be done before galvanizing to ensure the best
coatings and the best solution will vary depending on the exposure protection of the welded area, or the welded areas will need repair with a
environment, aesthetic requirements, and availability of materials. If the suitable zinc-rich paint. Almost certainly a post-galvanized welded area will
micro-environment is C3 or higher, including an aggressive internal location, require more regular maintenance, so this should not be done unless access
the GAA recommend embedding the steel in concrete and: to the repaired area is easy or the welded area is in a very low corrosion
area (that is, internal to the building). For bolted connections, all swarf from
1. Apply to at least 100mm above the finished height of the concrete or drilled holes needs to be removed to avoid unsightly rust spots and any cut
soil and at least 250mm below the concrete: structural steel will also need to have bare steel repaired to avoid edge
a. a non-conductive abrasion resistant high build epoxy paint layer at corrosion. For tubular sections exposed to rainwater it may also be
approximately 350µm dry film thickness (DFT) without zinc or necessary to seal the joint at the top and between the base plate and the
aluminium pigment (AS/NZS 3750.14 (11)), or tube with an elastomeric sealant to stop water entry.
b. Denso Ultraseal tape wrapped around the structural steel section
2. Slope the concrete surface away from the steelwork to facilitate
drainage of water away from the steel to concrete interface
3. Once the concrete has cured apply an elastomeric sealant around the
interface of the concrete to seal any existing shrinkage cracks
 BEST PRACTICE CORROSION PROTECTION FOR BCA VOLUME 2 PART 3.4.4.4 11

Figure 12 A galvanized steel subfloor (with inbuilt ant caps) where the hot dip galvanized posts bolted down onto elevated concrete pads.

HDG Steel in contact with timber

In structural applications in atmospheric or embedded conditions, galvanized
steel may be required to be isolated from timber through suitable paints, HDG steel is not recommended for use to
wraps or other isolating barriers to increase the durability. A common
application here is as I-beam or channel retaining wall posts with timber
support decks in the wet zones around
sleepers, where the timber facing elements are painted with an saltwater pools due to the high risk of salt
isolating paint.
The Engineered Wood Products Association of Australia (12) says timber
saturated wet timber resulting in
products treated with cured copper-based preservatives (ACQ, CCA, CuAz) accelerated corrosion of the galvanized
are suitable for use with galvanized steel where the building is protected by
a eve overhang of minimum 600mm, average rainfall does not exceed coating and structural steel.
1000mm (e.g. Melbourne, Adelaide & Perth but not Sydney or Brisbane) and
the building or structure is designed and built to exclude ‘moisture traps’
both during erection and in subsequent use.
Boron treated timber is suitable for indoor applications only and galvanized
steel of all types is well suited for use in this application.
LOSP treated products are excellent for use with galvanized steel, although
exposure of products to coastal areas will reduce durability of the structure
and is not recommended.
HDG steel is not recommended for use to support decks in the wet zones
around saltwater pools due to the high risk of salt saturated wet timber
resulting in accelerated corrosion of the galvanized coating and
structural steel.
12 BEST PRACTICE CORROSION PROTECTION FOR BCA VOLUME 2 PART 3.4.4.4

Figure 13 An example of galvanized steel posts being used in combination with a traditional timber frame and subfloor.

Summary References
The BCA sets outs the minimum requirements for corrosion protection using 1. Australian Building Codes Board. NCC 2019 Building Code of
protective coatings for structural steel members. Hot dip galvanized coatings Australia. Amendment 1. Canberra : (C) Commonwealth of Australia
of 300 g/m2 are identified as the minimum requirements for an unpainted and the States and Territories 2020 Published by the Australian
structural steel member in external moderate and severe environments. Building Codes Board, 2019. Vol. 2.
Only hot dip galvanized coatings meeting the requirements of AS/NZS 4680 2. Standards Australia & New Zealand Standards. Hot dip
can meet the requirements of the BCA without the addition of paint galvanized (zinc) coatings on fabricated ferrous articles. Sydney &
topcoats. Maintenance of the galvanized coating will be required in some Wellington : Standards Australia & New Zealand Standards, 2006.
environments to maintain structural performance. AS/NZS 4680.
A moderate environment covers both C2 and C3 Corrosivity Categories, 3. Standards Australia. Masonry Structures. Sydney : Standards
while the severe environment includes the C4 and C5 Corrosivity Categories. Australia, 2018. AS 3700.
Additional protection will be required for housing located in the C5
4. —. Built-in components for masonry construction (3 parts).
Corrosivity Category (that is severe environments within 200m of surf) and
Sydney : Standards Australia, 2020. AS 2699.
may also be required when accessibility for maintenance is impossible or
difficult and the local environment is also severe. 5. —. Atmospheric corrosivity zones in Australia. Sydney : Standards
For house piers and other structural steel embedded in the ground, Australia, 2019. AS 4312.
additional barrier protection of the galvanized coating is required at the 6. Standards Australia & New Zealand Standards. Guide to the
concrete interface, extending 100mm above and 250mm below the concrete protection of structural steel against atmospheric corrosion by the
surface. In addition, the bottom of the pier should be fully encased in use of protective coatings, Part 2: Hot dip galvanizing. Sydney &
concrete according to the engineer’s specification, and the top of the Wellington : Standards Australia & New Zealand Standards, 2014.
concrete sloped to prevent ponding. AS/NZS 2312.2.
7. Standards Australia and Standards New Zealand. Hot-dip
galvanized (zinc) coatings on ferrous hollow sections, applied by a
continuous or a specialized process. Sydney & Wellington : Standards
Australia and Standards New Zealand, 2006. AS/NZS 4792.
 13
GALVANIZE
MAGAZINE
8. Standards, Australian. Electrogalvanized (zinc) coatings on galvanize is a free magazine produced
ferrous hollow and open sections. Sydney : Standards Australia, by the Galvanizers Association of Australia
2003. AS 4750. and features projects from Australia and
9. Galvanizers Association of Australia. Technical Publications around our region. To have your project
(Advisory Notes). Galvanizers Association of Australia. [Online] featured simply email us some details at
[Cited: 21 January 2021.] https://gaa.com.au/technical- [email protected].
publications/. AN 42.1 Hot dip galvanized steel embedded in soil. You can also view the current issue and back copies at the Case
10. Denso. Denso Ultraseal Tape. [Online] [Cited: 21 January 2021.] Studies tab on our website www.gaa.com.au.
http://densoaustralia.com.au/pdfs/DensoBitumenButylTapes/ To request your own free subscription or to update an existing
Denso-Ultraseal-Tape.pdf. subscription simply email us at [email protected].
11. Standards Australia and Standards New Zealand. Paints for
steel structures High-build epoxy (two-pack). Sydney & Wellington : Asia Pacific Edition
HOT DIP GALVANIZED STEEL
Standards Australia and Standards New Zealand, 1997 (R 2013). Associate of International Zinc Association

AS/NZS 3750.14.
12. Engineered Wood Products Association of Australia. Suitable
Fasteners, Metal Flashings, Studs and Joists for use in Conjunction
with EWPAA Branded Preservative Treated Cladding, T&G Flooring
and Structural Plywood. [Online] [Cited: 15 February 2015.]
https://ewp.asn.au/technical-resources.
82
galvanize February 2020
INNOVATIVE USE OF DUPLEX
COATED GALVANIZED STEEL
WINS 2019 SOREL AWARD
In this issue
1 Innovative Use of
Duplex Coated
Galvanized Steel Wins
2019 Sorel Award

This issue of Galvanize is intended to keep readers 3 North Western Program

Alliance: Frankston
abreast of current issues and developments in the field of Train Station Upgrade
5 The Level Crossing
galvanizing. The Galvanizers Association of Australia has Removal Project
(Carnegie, Clayton,
made every effort to ensure that the information provided Hughesdale,
Murrumbeena and
is accurate, however its accuracy, reliability or Noble Park)
8 CDC Data Centre
completeness is not guaranteed. Any advice given, 10 Civmec Main
Assembly Hall
information provided, or procedures recommended by
GAA represent its best solutions based on its information Welcome to the latest edition of Galvanize! This edition profiles
and research, however may be based on assumptions the 2019 Sorel Award winners, with detailed case studies
illustrating the skill and expertise clearly present in each of
which while reasonable, may not be applicable to all the award-winning projects.
The Sorel Award is designed to highlight the high standards of design, fabrication,
environments and potential fields of application. construction and corrosion protection achieved when hot dip galvanizing features as a key component of a project.
In 2019, there were four entries into the Sorel Awards, all of which were evaluated by our expert judges, Arun Syam
(InfraBuild) and Peter Dove (GHD).
According to Syam and Dove, “All projects showed innovation in handling and service, while several projects delivered
Due and proper consideration has been given to all Prepared by
outstanding market development potential.”
Galvanizers Association of Australia Entered by Geelong Galvanizing, the North Western Program Alliance – Frankston Train Station Upgrade
information provided but no warranty is made regarding Peter Golding
Sally Wood, wordly.com.au
in Melbourne won the 2019 Sorel Award.
As a major hub linking the Mornington Peninsula to the city of Melbourne, Frankston Train Station was upgraded as
the accuracy or reliability of either the information To read other
part of the Victorian Government’s $6.9 billion Level Crossing Removal Project. This project is highly innovative,
demonstrating the use of an array of duplex coated galvanized steel to deliver one of the most durable and visually

contained in this publication or any specific Galvanize stories

Go to our website
striking structures in Frankston.

Continued on page 2
recommendation made to the recipient. Comments made www.gaa.com.au

are of a general nature only and are not intended to be

relied upon or to be used as a substitute for professional
advice. GAA and its employees disclaim all liability and
responsibility for any direct or indirect loss or damage
which may be suffered by the recipient through relying on
anything contained or omitted in this publication.

“House in Hamilton” by Phorm Architecture + Design (Australia) and Tato Architects

(Japan) using 100% Australian-made steel. This project was an entrant into the
Queensland 2016 ASI Steel Excellence Awards and received a Commendation in the
2016 National Architecture Awards: Residential Architecture – Houses (New)
category. Image by Christopher Frederick Jones.
ABN 60 004 579 828
Other images by Galvanizers Association of Australia and/or its members and courtesy
Uni-Pier Australia Pty Ltd. We provide information, publications and assistance on all aspects of design,
performance and applications of hot dip galvanizing.
All images are © copyright of the original authors and must not be reproduced
124 Exhibition Street Melbourne Victoria 3000 Telephone 03 9654 1266
without permission.
Email [email protected] Website www.gaa.com.au