Defeating the rust - How steelsubstructures defy danger
21.01.2020
Agenda
1. Introduction
2. Rules and Standards
3. Special conditions in coastal areas
4. Special conditions soil
5. New methods of corrosion protection
6. Ground mounted system Gen III
7. Summary
Seite 2
costs of hot dip galvanized steel
steel zinc
1. Introduction
Seite 3
Corrosion creep Surface corrosion (at topsoil zone)
Erosive loss Poor quality of galvanizing
2. Rules and Standards
EN ISO 1461 (hot dip galvanized)
DIN 55928-8
7. Corrugated zones, cross sections, edges, fasteners
7.1 Corrugated zones
The required corrosion protection must also be ensured incorrugated zones.
7.2 Cross sections and edges
(1) Cross sections should be at right angles to the sheet metalsurface and without burr. When cutting and processing coatedcomponents, procedures are to chosen that do not affect theprotective effect against corrosion (for example by peeling off,sparks, burns). The gap of the cutting tool is to be set diligently.
(2) Experience has shown that the cross sections and edges ofstrip-galvanized and strip-alloy-galvanized metal sheets with athickness up to 1.5 mm do not need any extra corrosionprotection.
Dacromet
ISO 12944-22. Rules and Standards
C3: yearly loss 2,1 µ with 55 µ 26 yearsC4: yearly loss 4,2 µ with 80 µ 19 years
3. Special conditions in coastal areas (C5-M)
Coast distance in km
Chloride Concentration
Salt spray
surf
log
ch
lori
de
co
nte
nt
µg
/m³
salt layer on aluminium corroding inox A2 layer on steel
4. Special Conditions Soil
time (years)
Soil class II
thickness zinc layer
mate
riallo
ss
inm
m
Source: Romanov Report
Magnelis® (Arcelor)
5. New Methods of Corrosion Protection
EN 55634
Wzm (Wuppermann)
Super Dyma (Nippon Steel)
C3 C4 C5sea
C5tropical
avarage loss per year in µ
Zinc Magnesium ZM
thickness
classtype expected protection duration
Magnelis ® as example
New Methods of Corrosion Protection
Zinc Magnesium ZM
Rules for planning
• undamaged, evenly distributed coating• no permanent dirt accumulation• no constant contact with soil or permanently moist areas
Cut areas across the cross-section of sheets up to 1.5 mm thick may remain unprotected. Forsheets with the Magnelis® ZM250, Magnelis® ZM310 and Magnelis® ZM430 coatings, this alsoapplies to thicknesses of up to 3 mm, provided that there are no requirements regarding opticalchanges.
comparable rules for Wuppermann Wzm
coating expected protection duration in years
general technical approval in Germany
SMAC (Posco)
New Methods of Corrosion Protection
Zinc Magnesium Aluminium (ZMA)
Internal salt spray
test after 1440 hours
SMAC 140 up to C3
SMAC 310 up to C5
Optimization and reengineering of existing products focuses on further design tomarket and cost reduction without compromising Schletters core principles
Area
Coreprinciples
Measures
Design to MarketCost Reduction
CapexRiskManagement
Operations PurchasingEngineering/Sales
Quality Management SustainabilityStructural safety
Sourcing■ Make or buy
Supply chain■ Organization of supply
chain worldwide
Automation■ Improve efficiency
Logistics and freight■ Align global value
streams
Global sourcing■ Group wide contracts
■ Pooling of demand
Local sourcing■ Professional automotive
standards
Customs■ Alignment of global
supply chain
Lead times■ Bundling of global
demand standard parts
Material strengths/quality■ Usage of high strength
steel
Profile geometry■ Optimize to reduce
weight
Corrosion protection■ Alternatives to
galvanizing (e.g. SMAC)
Mounting effort■ E.g. simplification of
joints and connections
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6. Ground Mounted System FS Gen III
Focus today
Features
- Fast Mounting progress
- Health & Safety requirements
- Integrated cable duct
- Less components
- Larger span width
- Flexibility (E.g. module change)
- Fault tolerant
- No corrosion problems
- Lead times
- More cost effective
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Purlin design Trade in Salt Lake City
screwless purlinconnector
Purlin can be usedas cable duct
Material strengthS350/S550/S700
No self-drillingscrews
Design of module clamps (Rapid 16)
Page 13
movable
FEM analysis
Testing
Grounding of modules (combined layout)
4 GroundingPins
Design of purlin-binder connection
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keyhole
locking
Castedconsole
preassembled
Inlay system for landscape configurations
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7. SummaryCorrosion protection design of Gen III
Thank you for your kind attention!
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