Mixture for metal galvanizing «Galvanol»
«Galvanol ES» offers the highest quality mixture «GALVANOL®», which is used as galvanizing.
This mixture ensures 100 per cent anticorrosive protection of the metal, which is typical for other ways of metal galvanizing. We offer protective decorative metal polymeric aluminium-rich mixture «ALINOL®» as well. Bothe mixtures are ready-to-use and are easily applied on the metal surfaces by any convenient way of application at temperature from -30°С up to +50°С at any humidity.
TYPES OF PROTECTIVE MIXTURE «GALVANOL®» PACKING
THE PURPOSE OF «GALVANOL®» MIXTURE AND AREAS OF ITS USAGE
Protective coating «GALVANOL®» is broadly used in such areas as civil and industrial construction, transport, engineering, energy sector and gas-and-oil industry. This protective mixture is used in the railways engineering projects, ports and hydro-constructions, galvanizing of auto-transport.
This mixture protects from corrosion of the metal constructions and elements, which are exploited in various environment of different macroclimate zones, with different types of atmosphere and different categories of allocation according to GOST15150-69.
Galvanizing coating «GALVANOL®» is resistant in fresh and sea water, aqueous salt solutions (pH = 6.0-10.0), ethanol and its aqueous solutions, usage in centralized cold-water supply system is allowed.
The coating is not resistant in gasoline and some organic solvents.
SPECIFICATIONS OF GALVANIZING MIXTURE «GALVANOL®»
«GALVANOL®» coating is single-component, liquid (ready for use), consists of chemically pure electrolytic zinc, volatiles and binding agents.
The coating is supplied in tightly closed packaging.
Each packing item has a label indicating:
- Product identification code;
- Lot number and date of manufacture;
- Net weight.
Guaranteed storage life is unlimited, if stored in unbroken original package at temperature range from — 40 °С up to + 30 °С. It is recommended to tightly close package during the further storage.
TECHNICAL SPECIFICATIONS OF GALVANIZING MIXTURE «GALVANOL®»
|Application||Application pressure||Orifice||Number of layers|
|Top tank spray gun||3 bar||2,0-3,0 mm||1-2|
|Lifetime||Unlimited, dilute with solvent, if necessary|
|Dry film layer thickness||40-60 mkm|
|Holding time between layers||10-40 min|
|Painting by protective-decorative coatings||Only solvent-borne paint materials, drying time before application on «GALVANOL®»: 4-6 hours|
|Drying time at:
|Heat resistance||-60°С — +160°С (shortly till 210°С when powder painted over galvanizing)|
|Transverse film elasticity||1 mm|
|Density at 20°С||2400 kg/m3|
|Rate of uniform, open corrosion in sea water||0.020 mm/year|
|Filing||Obtains metallic luster, but loses 5 mkm of coating|
|Operational conditions||-35°С +50°С|
|Packing||Aerosol spray 520ml. Can: 2 kg, 10 kg, 40 kg|
|Use as||Protective, zinc-rich, anticorrosive coating (galvanizing) for metals and also as foundation for decorative paint materials|
|Coverage rate||280-300 g/m2 at 40-60 mkm thickness|
|Color||Matt grey, tone is not rated|
|Appearance of dry coating||After drying the film should even, homogenous, without foreign matters and stains, matt|
|Solvent||Solvent (petroleum, coal-tap), xylene|
|Viscosity, when applied (20°С)||60 с (viscometer ВЗ-3)|
COMPATIBILITY OF «GALVANOL®» MIXTURE WITH OTHER COATINGS
Zinc-rich special mixture «GALVANOL®» is easily compatible with 90% solvent-borne finishing coatings. Compatibility with polyurethane, urethane-acrylic, acrylic, epoxide, vinyl, chlorinated rubber and alkyd coatings. It is strongly recommended to wait 4-5 hours after application of galvanizing mixture «GALVANOL®» to achieve ideal compatibility, during this period a solvent will volatilize and not prevent further adhesion.
In aqueous salt solutions (pH = 6-9), fresh and sea water, zinc-rich special mixture «GALVANOL®» effectively protects steel against corrosion. Due to non-toxicity of components it can be used for drinking water vessels. Zinc corrodes and runs out in time thereby protecting steel. Uniform corrosion rate in sea water is app. 10 mkm per year. For obtaining the best results and to prolong lifetime in sea water it is better to cover coating with polyurethane or epoxy lacquer.
Zinc-rich special mixture «GALVANOL®» shows better steel protection below ground if it insulated from media by lacquer.
The coating is not resistant in gasoline and some organic solvents so it is recommended to cover it with finishing coating, which is resistant to such media.
TECHNOLOGY OF APPLICATION OF «GALVANOL®» MIXTURE
Application procedure of anticorrosion coating attaining based on zinc-rich special mixture «GALVANOL®» consists of the following step-by-step operations:
- Surface preparation for application of anticorrosive coating;
- Preparation of mixture for application;
- Application of protective coating;
- Layer drying of coating;
- Quality control of anticorrosive coating;
- Final holding of anticorrosive coating before commissioning.
During carrying out of outdoor anticorrosive protection in wintertime it is necessary to:
- Build shelter to protect from precipitation;
- Metal surface temperature should be on + 3°С higher than dew point.
It is recommended to apply anticorrosive coating at the temperature not lower than 30°С.
PREPARATION OF METAL SURFACE FOR THE APPLICATION OF «GALVANOL®» COATING
All parts of articles that are subject to protection should be accessible for inspection, surface preparation, and application of protective coating and its quality control.
Surface that is subject to preparation before application of coating should be free of burrs, sharp edges (radius less than 0.3 mm), welding splashes, rolls, burn-through and residual flux. Metal constructions’ welding areas (standard sections, plates, etc.) should be free of hidden cracks and cavities. If there is any oil or fat containment clean them using detergents.
The metal surface should be prepared before applying «GALVANOL®» coating:
- New steel (metal-roll) with heavy scale is subject to sandblasting to the second degree according to GOST 9-402 and should be degreased.
- New steel (metal-roll) without scale should be degreased.
- Old rusty surface – loose rust is eliminated manually or mechanically (scrubbing) or by highpressure fresh water (10-20 mPa) and then the surface is degreased.
- Previously zinc-coated surface – containment and upper layer of zinc salts are is eliminated manually or mechanically (by high pressure fresh water 10-20 mPa) and then the surface is degreased.
- Previously painted surface – paint should be eliminated chemically, by remover (manually or mechanically by extra-high pressure water 175-275 mPa) and then degreased.
In manual abrasive machining of surface with fine wheel or sand paper, abrasive grit should be in 5-6 range according to GOST 3647-71 or in 180-220 range according FEPA standard. Remove dust from surface after manual and mechanical cleaning. Presence of bare places is not allowed.
Compressed air used for cleaning should be dry and clean and meet the requirements of GOST 9.010-80.
During degreasing of small areas of surface use brush wetted with solvent, xylene.
The mixture is applied on clean and degreased surface not later than after 12 hours, if metal constructions are outdoors and 48 hours, if indoors.
PREPARATION OF «GALVANOL®» MIXTURE
«GALVANOL®» mixture is ready for use and application by brush, roller, and spray gun. The material can be diluted with solvents (petroleum, coal-tap), xylene, if necessary. Dilution of «GALVANOL®» mixture with other solvents is not allowed.
«GALVANOL®» mixture should be should be thoroughly stirred with mixer till total homogeneity.
APPLICATION OF «GALVANOL®» MIXTURE
The mixture is applied on clean and degreased surface not later than after 12 hours, if metal constructions are outdoors and 48 hours, if indoors. Despite of chosen method of application of mixture on prepared surface, welds and hard-to-reach places should be firstly painted by brush.
In case of cracks and hidden openings after welding eliminate possibility of ingress of moisture into them (by any nonpolluting means of waterproofing).
«GALVANOL®» mixture can be applied on the surface by brush, roller, and spray gun or by means of dipping:
A brush should be from natural bristle, free of dust and containment. Dilution «GALVANOL®» mixture under standard conditions is not required.
- Roller application:
A roller should be made from organic solvent resistant material, free of dirt and previously used painting materials. Dilution of «GALVANOL®» mixture under standard conditions is not required.
Equipment should be free of containment and previously used painting materials. Dilute, if necessary, with solvent or xylene in the ratio till 5% by weight. Air pressure – 0.2 – 0.3 mPа (2 – 3 bar). Nozzle diameter – 2.0 – 3.0 mm.
- Airless spraying:
Equipment should be free of containment and previously used painting materials. Dilute, if necessary, with solvent or xylene in the ratio till 4% by weight. Air pressure – 8 – 12 mPа (80 – 120 bar). Nozzle diameter – 0.0015 – 0.025 inches, 0.38 – 0.68 mm.
Dilute, if necessary, with solvent or xylene in the ratio till 15% by weight.
If applied by any of above-mentioned methods «GALVANOL®» mixture should be stirred regularly (each 20 – 30 minutes).
The material is to be applied layer-by layer, covering edge of previous line.
Total thickness of coating should be min 40 mkm – max 160 mkm. When applied on constructions with minor mechanical strains, maximum thickness of application can be increased to 200 mkm.
All application works are carried out at –30° — +50°С and relative humidity up to 90%.
The mixture can be applied on wet surface. But the surface should be free of moisture as drops and at negative temperatures avoid crust of ice. It is recommended to use shelters in application of coating under rain or snow conditions.
ANTICORROSIVE WORKS QUALITY CONTROL
Quality of anticorrosive works is controlled both during implementation of separate operations and after completion of whole set of works.
Quality of coating is controlled by means of external examination. After polymerization the coating should be free of through pores, blisters and visual damages.
Thickness of coating is controlled after drying with thickness gauge.
DEFECT ELIMINATION AND REPAIR
Defect spots (peeling, blistering) occurred during coating application and operation is subject to immediate elimination.
Rub down the defect spot with sandpaper, degrease and dry.
Apply anticorrosive coating on prepared surface according to application procedure.
Thickness of coating on metal surface is measured with thickness gauge.
TRANSPORTATION AND STORAGE
«GALVANOL®» mixture is shipped by any means of transportation in covered transportation means according to shipping rules applicable on each type of transport.
The material to be stored in close ventilated warehouses or under shelter at maximum temperature 35°С. If stored under higher temperature manufacturer does not guarantee meeting of specification requirements.
«GALVANOL®» material should be stored in tightly closed containers, excluding ingress of moisture, dust and other containment.
Manufacturer guarantees meeting the requirements of specification under meeting the transportation and storage requirements and application guide.
Guaranteed storage life of material is unlimited.