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)

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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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