hdg magazine 2_2008

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83 | Made to measure in Metzingen 8 | "Station Z" Memorial 10 | Blacksmith art 14 | Recycling of Zinc Hot Dip Galvanizing International Magazine | ISSN 1363-0148 | www.galvanizing.org.uk 2008 2/4

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Our quarterly magazine features an eclectic mix of projects from the UK, Ireland, Germany and Spain in order to inspire, educate and inform our reader.

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Page 1: HDG Magazine 2_2008

83 | Made to measure in Metzingen

8 | "Station Z" Memorial

10 | Blacksmith art

14 | Recycling of Zinc

Hot Dip GalvanizingInternational Magazine | ISSN 1363-0148 | www.galvanizing.org.uk2008

2/4

Page 2: HDG Magazine 2_2008

There is an expression that ‘what goes around

comes round’ and this is no truer than for art

and fashion. The Arts and Crafts Movement,

an aesthetic movement which occurred about a

hundred years ago, had a romantic idealisation

of the craftsman taking a pride in his personal

handiwork in the face of growing mass produc-

tion. Many of the works by proponents of this

movement such as Edwin Lutyens, Charles

Rennie Mackintosh, Frank Lloyd Wright and

William Morris can still be seen and reflect the

skills of craftsmen that they employed.

If Lutyens, Mackintosh, Lloyd Wright and Morris

were alive today they would be delighted to see

that their movement is safe and well today in

the hands of Phil Johnson and his company

(pp. 10 - 12).

As the article notes, the company ‘should

be applauded for keeping alive the skills of

a traditional industry in today’s quickfix

society’ – the very essence of the Arts

and Crafts Movement.

You wouldn’t normally see a connection

between Hugo Boss in Germany and a

transport interchange in England, but it exists

in the wonderful world of galvanizing.

Hugo Boss’ new building near Stuttgart has a

glass curtain wall system supported by galva-

nized steel and the new Transport Exchange

in Manchester has a very similar glass façade

also supported by galvanized steel.

Hugo Boss obviously like the look of galvanized

steel because they have also used it internally

in a purely aesthetic way for the floor face

plates and stair stringers as can be seen on

our front cover.

David Baron, Editor

Contents

2 Editorial

3 Made to measure in

Metzingen

Architecture and Fashion

6 Manchester Transport

Interchange

8 “Station Z” Memorial

Thought-provoking design

10 Blacksmith Art in the UK

Phil Johnson and Pete Hill

talk about their passion

13 Access Footbridge

Off-site modular design

14 Recycling of Zinc

16 Galvanizing Delight

Front cover:

Hugo Boss administration building, Metzingen

by Domino Planungsgesellschaft Architekten

und Ingenieure (page 3)

Editorial

2 | Hot Dip Galvanizing

2008

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Page 3: HDG Magazine 2_2008

Hugo Boss AG is internationally famous as the fashion industry’s big success story.

Even in times of slow consumer spending, the company is making record profits with

a dynamic range of high-quality brands from classic designs through sportswear to

trendy and glamorous outfits. Hugo Boss has made Metzingen into the ‘capital of

German factory outlets’ and has stayed loyal to the 22,000 inhabitants of the town.

Spread out over a substantial area off the

North Metzingen bypass, the Hugo Boss Cam-

pus is made up of company buildings serving

the various departments of the firm, which

have unusual names such as Moulin Rouge,

Kremlin, Vatican or Piccadilly.

Thanks to some long-term planning, a self-

enclosed company site has developed, divided

into areas such as administration, product

development and storage.

One significant aim was to improve the com-

munication facilities by creating a definite

centre. This also makes it easier for people to

find their way around the company’s premises.

Moreover, a central development creates an

attractive reception area.

In December 2006, a new administration buil-

ding was added, referred to as “d19” for short.

It is located in the vicinity of a structure called

the atrium, and reproduces important elements

of its design. From the outside, the building is a

simple cube and on the inside, it is adaptable.

De-materialisation was the overriding theme of

the architectural design.

The idea was to create as neutral an ambience

as possible for the changing design products

in the fashion range, so that these could be

shown to their best advantage.

This is achieved through standardisation of

the image and restriction to a few dominant

colours and materials. Silver, white and

black (concrete, glass and galvanized steel

respectively) mark the building out.

Hot Dip Galvanizing | 3

2008

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Architecture

Made to measure in MetzingenArchitecture and Fashion

By Holger Glinde

Page 4: HDG Magazine 2_2008

8 | Thermisch Verzinken

Architecture

With a total area of 21,000m² on four storeys,

“d19” provides office space, meeting rooms,

a company restaurant, a fitness studio, show

and event areas and an underground car park

for the 420 employees.

The building is a highly flexible skeleton,

which can be used to create individual, group

or large-scale offices as required.

The building envelope allows for large windows

within the working spaces. These serve a dou-

ble purpose; the building can be naturally venti-

lated and natural light floods into every area of

the building. This is made possible by a double

façade. It has a dual role as a “second skin”:

It is a form-giving element and is of central

importance for the climatic and energy aspects

of the building, as it uses solar energy.

The ventilation principle for “d19” is based on

so-called ‘free ventilation’ (manually operated

systems). An important factor here is the

generously proportioned atrium, around which

the working areas are organised.

The internal façade has been executed as a

strut and span structure, made from rectan-

gular hollow steel sections with a visible width

of 50mm and various structural depths. The

load-bearing sections are positioned within the

internal envelope.

The external façade of “d19” was attached to

the vertical façade columns using cantilever

arms made from flat steel sections. The panes

of glass of the secondary façade are fixed by

stainless steel point supports mounted on the

cantilever arms.

Grating fields have been screwed between the

cantilever arms for reinforcement purposes.

They also act as maintenance webs. The weight

of the external façade is suspended through

connecting rods from cantilever arms mounted

on the upper level of the building.

In addition to materials such as glass, exposed

concrete and polished concrete for the floors,

galvanized steel was also used in many ways

for design reasons. All the steel elements in

the internal and external façades, including the

cantilever arms, connecting rods and gratings,

were galvanized. Moreover, galvanizing was

used to excellent effect as a surface finish in

the internal area.

The floor face-plates of the open storeys, the

cover plate of the strings and the stair railings

were galvanized, which created an artistic

effect.

Externally, all the railings, together with the

canopy of the delivery area, were galvanized.

The living galvanized surfaces harmonise

perfectly with the glass and concrete areas,

and make a vital contribution to the

neutral atmosphere of the building.

Architects/photos: Domino Planungsgesellschaft

Architekten und Ingenieure mbH, Reutlingen

Steel construction/photos: Roschmann Konstruktionen

aus Stahl und Glas GmbH, Gersthofen

2008

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Page 5: HDG Magazine 2_2008

Architektur

Feuerverzinken | 5

2008

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Page 6: HDG Magazine 2_2008

Ian Simpson Architects were appointed to

propose a new concept for the Transport Inter-

change: To design a unified development that

would form a high quality and recognisable

landmark for the city, and improve the environ-

ment for the travelling public, maximising user

comfort, safety and security.

Jefferson Sheard Architects were subsequently

appointed to continue with the design develop-

ment and as Contract Administrator for the

construction of the project.

Design processThe design of the Transport Interchange has

been carefully considered in relation to its

setting within the Shudehill conservation

area and its proximity to a number of listed

buildings.

In order to identify the primary elevation and

entrance to the concourse the form of the

building is orientated so as to present a narrow

frontage.

The bulk of the building extends into the

depth of the site so as to relate to the larger

buildings associated with the surrounding

developments.

The perimeter of the site is bounded by a new

feature wall, which changes in colour, texture

and articulation in response to its adjacent

context, the activity behind the wall and the

historical street pattern.

The wall steps down following the contours of

the site and leads to the north platform of the

metrolink stop.

A high level steel and glass aerofoil shaped

canopy provides shelter to the tram stop and

defines the primary pedestrian entrance to the

concourse.

The multi-storey car park is accommodated

within a very spatially efficient concrete framed

structure. Vertical circulation within the car

park is achieved by an arrangement of tilting

floor plates, commencing at approximately 6m

above the ground floor level.

A façade of frameless glass panes on projecting bracketsAn unusual feature of the development is the

elegant glass façade that encloses the car

park structure. This not only creates a visually

interesting display of diffused colour of each

parked car but at a distance a shimmer of

reflected colour from its surroundings.

The envelope to the car park consists of an

arrangement of fritted glass panels, heavily

articulated within the horizontal plane and

varying in width and density of frit.

The Manchester Transport Interchange forms a key component of the Manchester City

Centre rebuilding strategy following the IRA bomb in 1996. It relocates the bus

station from within the Arndale Centre and allows for the creation of a new winter

garden. The interchange comprises of three primary components: the bus concourse

and passenger stops, a Metrolink Tram stop and a multi-storey car park.

2008

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6 | Hot Dip Galvanizing

Architecture

Manchester Transport InterchangeBy Iqbal Johal

Page 7: HDG Magazine 2_2008

Hot Dip Galvanizing | 7

The panes are positioned in three different

planes by means of projecting glazing brackets;

the air gaps between adjacent panes ventilate

the interior.

The glass is fixed to rows of galvanized steel

ladder-support frames bracketed back to the

concrete edge beam. Each frame consists of a

pair of 89mm diameter CHS transoms welded

top and bottom between vertical 150 x 12mm

steel flats.

Projecting fixing arms are welded to the

transoms to carry the glass support bracketry.

Each pane is supported and restrained by a

combination of galvanized and stainless steel

holding brackets. The intention is to achieve the

required natural ventilation, whilst presenting

an animated and varied façade; the translu-

cency of the glass will achieve visual order but

allow movement and structure to be subtly

expressed.

The concrete, glass and galvanized steel create

a simple harmony of materials and colours

while the design reconciles the needs of

operators and passengers to create a vibrant,

animated and beautiful building.

Architects: Ian Simpson Architects and

Jefferson Sheard Architects

Photos: Daniel Hopkinson

Drawing reproduced with permission of AJ Magazine

Architecture

2008

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Page 8: HDG Magazine 2_2008

During the second world war, the Sachsen-

hausen concentration camp in Oranienburg,

not far from Berlin, was used as a training

centre for concentration camp commanders

and SS squads. In the period after 1945, the

Soviet security services interned officials of

the National Socialist regime and dissidents

in the Sachsenhausen camp and used the

existing facilities, including those at “Station

Z”. In 1950, the German Democratic Republic

People’s Police took the site over and blew up

“Station Z”. In 1961, the East German Com-

munist regime converted part of the site into

a memorial, and roofed over what was left of

“Station Z” with a massive concrete structure.

Areas outside the memorial site continued to

be used by the National People’s Army.

In order to ensure that an appropriate memori-

al remained following re-unification, an

architectural competition was launched,

which was won by HG Merz Architekten und

Museumsgestalter of Stuttgart.

The artificial emptiness of the site, which the

architects were aiming to retain, and the

protective and thought-provoking structure

covering the remaining areas of the site,

designed as an abstract object, avoid any kind

of symbolism or pathos.

As regards the design of its ground plan, the

object-like envelope form is based on the relief

pattern of the original site, but avoids any exact

reconstruction of the original enclosed volume.

There is an attempt to create a

confined space, which is achieved by leaving a

minimal headroom clearance of 2.6m.

The compact structure provides no view of the

outside world – the surroundings can only be

imagined. The protective structure is column

free and has the appearance of a minimal

connection to the ground.

The steel structure of the building deliberately

fades into the background.

2008

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8 | Hot Dip Galvanizing

Architecture

“Station Z” memorialThought-provoking design

By Holger Glinde

Building memorials provides a challenge to their designers to achieve the right balan-

ce between creating a symbol of respect and remembrance without overstepping the

boundaries of emotion and good taste. This is especially true where the crimes of war

are involved. The architects and museum designers HG Merz have found a very unusu-

al and yet appropriate solution for the Sachsenhausen “Station Z” memorial.

Page 9: HDG Magazine 2_2008

The roof and wall surfaces are defined by

means of translucent PTFE film and the struc-

ture of the grids lying beneath. The primary

supporting framework for the 4.10m high

protective envelope is cantilevered, and spans

a square area 37.4m long. The lower limit of

the walls ends 60cm above the top edge of

the site. The supporting structure consists of

a steel spatial framework system with welded

connections, the homogeneity of which is inter-

rupted by a 22m x 10m aperture inside the

roof. Eight plain concrete bases at six-metre

intervals support the load-bearing structure.

One particularly challenging factor for the

architects lay in the fact that they wanted a

total cubic form, to be enveloped in a translu-

cent material. This was intended to give suffi-

cient illumination to the interior from natural

light alone, and simultaneously to let the struc-

ture fade into the background. The solution

which was arrived at involved a membrane,

that was stretched over a secondary structure

of galvanized steel. Whereas normally long-life,

the ability to withstand mechanical abrasion

and metallic aesthetics are the reasons for the

use of galvanized steel, in this project the most

important factor was that the grids were given

rigidity to maintain their dimensions.

The membrane, running both internally and

externally around the steel, is held to the

supporting structure by suction, and forms a

continuous flat surface. The entire structure

appears as a homogenous body, the translu-

cence and radiance of which can be seen

only in relation to natural light.

Architects/photos: HG Merz Architekten und Museums-

gestalter, Stuttgart

Feuerverzinken | 9

Architecture

2008

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Page 10: HDG Magazine 2_2008

Focus on Architecture

Blacksmith art in the UKPhil Johnson and Pete Hill talk about their passion

By Iqbal Johal

P. Johnson & Company, the creative collective of artist blacksmiths at Ratho

Byres Forge, a few miles west of Edinburgh, produce contemporary forged

metalwork utilising traditional skills as practised by blacksmiths over the last

two thousand years.

2008

2/4

Phil Johnson started the company more than

30 years ago when the site was no more than

a cowshed. A mechanical engineer by trade,

he turned his hand to blacksmithing and has

never looked back.

Their work, both functional and sculptural, has

won many prestigious awards, including

The Tonypandy Award and The Saltire Society

Award for Art in Architecture. The family-run

forge is world renowned amongst artist black-

smiths for excellence in both design and

skilled forging, and as such is visited by many

journeymen and travelling smiths.

“The quality comes from both ourselves and

the demands placed upon us by our clients”

says Phil. “We never make the same thing

twice unless it’s required, and we don’t have

pattern moulds or a standard range of designs.

Everything is unique - for the place or for the

person, each project evolves in its own way”.

“Each commission takes us down new and

exciting roads of discovery, in the two-dimensio-

nal form on paper at the design stage and then

again as we proceed to the three-dimensional

form of the metal, the design developing as the

metal itself suggests shapes and ideas to the

mind. Some of our projects can take months to

complete”.

“Over the years, our metalwork designs have

moved away from the traditional scroll and leaf

languages of the village blacksmith and have

taken on a much more sculptural style, often

encouraged by our clients once they realise the

potential of shaping and forming hot metal”.

GalvanizingThe preferred material that Phil and Pete work

with is mild steel, and all the exterior work

is galvanized, “We tend to rivet all of our

connections which makes our work suitable

for galvanizing”.

P. Johnson offer their clients a high quality

finished product and this is where their additi-

onal attention to detail plays a significant role

in their work. By galvanizing all of their external

work they automatically provide long term

protection for their client’s work. In addition to

this, a lot of their work is finished in a number

of interesting ways that adds to its character.

Finishing “We provide a variety of finishes to our work

depending on the requirements of our clients

and the context of the particular design that

we work on. One process that we find really

interesting is pre-treatment of the galvanized

coating which is normally carried out before

painting. This provides a varied dark grey/black

mottled effect to the coating which appeals to

our clients”.

“This works very well particularly with the old

stone buildings of Edinburgh where the natural

10 | Hot Dip Galvanizing

Page 11: HDG Magazine 2_2008

Hot Dip Galvanizing | 11

2008

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Page 12: HDG Magazine 2_2008

materials weather and change over time and

rather than having a flat paint finish to our

work that looks very modern, the mottled toned

effect that you achieve with the pre-treatment

helps to soften and blend the galvanized

coating with its surrounding materials.

The other aspect that you achieve by doing

this is the mottling actually changes with the

weather so when it rains it gets slightly darker

in colour and as it dries it goes back to a

lighter colour.

This complements the stone work which also

changes colour when wet or dry”.

“We also pre-treat some of our work and then

apply a clear lacquer. This again adds to the

overall appearance of the finished article.

The lacquer will break down over a period of

time due to Ultra Violet Light which would then

reveal the etched finish”.

When P. Johnson do paint their work, they

again try to be different. Pete explains a system

they sometimes employ “We follow our normal

painting procedures but for specific projects we

add graphite to the paint.

It depends really on the project, this finish is

a lot more labour intensive as we have to rub

the work to expose the graphite. The process

creates a metallic effect that brings life to the

coating rather than a homo-genous flatness.

We have used it quite a lot and clients like it

because it’s a wee bit different and more than

just a flat black piece of steel”.

“There is an issue with the graphite running off

on your hands, so this technique is used for

work that is visual rather than for physical use.

The rest of our work we do paint if that is the

requirement of the client”.

Over the years, P Johnson have created a good

working relationship with the galvanizers that

they use for their work. This is an important ele-

ment for achieving the required standard that

they expect for their work.

“Galvanizing goes hand-in-hand with what we

are trying to achieve with the natural finish.

Without the galvanizing, we wouldn’t get the

finish that we like.

Although we are predominantly using galvani-

zing as a means of protecting our work, we

are manipulating it afterwards in order to get

something extra out of it as well”.

Although the art of the blacksmith may be

waning, the success of P. Johnson has shown

that there are pockets across the country

where the old traditional skills are still burning

strongly.

The high quality of their work which combines

two old industries proves that there is still a

place in the modern world for these well-tried

and tested processes.

P. Johnson should be applauded, not only for

their work, but for keeping alive the skills

of a traditional industry in today’s quick fix

consumer society.

Photos:

P. Johnson and Iqbal Johal

12 | Hot Dip Galvanizing

Page 13: HDG Magazine 2_2008

Hot Dip Galvanizing | 13

2008

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Comprehensive conversion and renovation

work has been carried out to limit walking

distance for staff and to optimise the logistics

of production. A footbridge had to be erected

to create a link to an adjacent building.

The design for the bridge was based on the

following criteria:

• the bridge was to take the form of a light

steel construction

• a height differential of 26cm had to be

compensated for

• as much clearance as possible had to be

left for the passage to the rear of the

company’s site

• long term durability was to be a very

important aspect of the design criteria.

Knabe & Knabe, the architects and engineers

from Suhl who were selected to plan and

implement this project, solved the problem by

embedding the static bearing structure under

the bridge canopy and spandrel-bracing it on

slim tubular steel frames (80x6.3mm).

Each frame was given a different length, to

provide an inclined plane and overcome the

height difference.

The decision to use galvanizing for the corro-

sion protection of the steel was made very

early in the design process.

This allowed the engineers to design the bridge

components with galvanizing in mind.

For example, the overall design was symmetri-

cal and steel sections of a sufficient thickness

were selected.

As a fully welded structure, the 12m long

bridge had to be galvanized in one section.

For this reason, the maximum dimensions were

compared with the existing bath sizes of the

galvanizing plants in the surrounding area.

The bridge was galvanized and was swung into

position by crane and bolted together using

steel brackets, so that there was no significant

interruption to the factory’s routine during the

installation of the bridge on site.

In order for the bridge to be integrated into

the overall design of the adjacent production

buildings, the bridge was painted yellow.

Architects/photos: Knabe & Knabe Architekten

und Ingenieure, Suhl

Feinmess Suhl is one of the oldest companies manufacturing precision gauges in

Germany, and can look back on a great tradition which began in 1878. Nowadays,

the company manufactures measuring instruments which combine precision and

mechanical and electronic components. The company is currently located in a

production plant which dates back to 1937.

Architecture

Access FootbridgeOff-site modular design

By Holger Glinde

Page 14: HDG Magazine 2_2008

14 | Hot Dip Galvanizing

Sustainability

Zinc recycling plays a very important role in the life cycle of galvanized steel.

In fact, recycling features in every stage of that life cycle and the zinc recycling story

has a few surprises too!

Recycling of Zinc By Murray Cook, Director, European General Galvanizers Association

You probably didn’t realise that most cosmetics

contain fine zinc dust that has been recycled

from the drosses produced as a co-product of

the galvanizing process.

Tyre rubber relies on zinc oxide that has been

added to ensure correct properties for good

braking and wear.

That zinc oxide is also produced from ashes

that are recycled from the galvanizing process.

Zinc oxide is also used in protective sun creams

and other medical products.

You might also be surprised to know that zinc

is increasingly recovered during the recycling

of scrap steel and is used in refined zinc

production as an alternative to mined ores.

Finally, did you know that a lot of the zinc used

by galvanizing plants could be over 100 years

old and has spent a previous life as rolled zinc

roofing or gutters in cities such as Paris?

Over 98% of scrap zinc roofing and gutters

are collected and recycled in countries like

Belgium, the Netherlands and France. After

a simple cleaning and remelting process the

remelt zinc is used directly for galvanizing.

This article explores the zinc recycling story

and looks at the details behind those little

recycling surprises.

Zinc recyclingZinc is an inherently recyclable non-ferrous

metal and can be recycled indefinitely without

any loss of physical or chemical properties.

At present, approximately 70% of zinc comes

from mined zinc ores and about 30% comes

from recycled, or secondary, zinc (representing

80% of the zinc available for recycling).

The recycling level continues to increase as

technology improves.

Use of recycled zinc in galvanizingThere are two important sources of zinc used in

the galvanizing process:

• Primary (refined) zinc is produced from a mix

of both mined ores and secondary (recycled)

feedstock. It is estimated that, on average,

refined zinc contains about 15% of

secondary feedstock.

• Galvanizers are also important purchasers of

remelt zinc – that is scrap zinc from, for

example, old zinc roofs that has been

cleaned and remelted into ingot form.

So, the refined zinc purchased by galvanizing

plants contains a high proportion of recycled

zinc and fully recycled zinc is often purchased

to supplement use of refined zinc.

The production of one kg of primary zinc (from

ore) requires gross energy of about 50MJ,

although only 20MJ of this energy is used

directly in zinc production (Boustead 1999).

One Kilogramme of remelt zinc used by general

galvanizers requires just 2.5MJ to produce.

(source: Sachbilanz Zink, University of Aachen,

2002).

1 The zinc recycling circuit2 Zinc from scrap zinc-coated steel is recovered during

steelmaking and re-used in the production of new zinc.

2008

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Total scrap

Recycled zinc production

(oxide, dust, slabs)

Zinc ore frommine production

Refined zinc production

Zinc products

Process scrap offcuts,trimmings, galvanizing,

residues, ashes

Old scrap automobiles,appliances, die-cast,

parts, galvanized steel

Page 15: HDG Magazine 2_2008

HOT DIP GALVANIZING

An international journal published jointly by the galvanizing associations of Germany,

The Netherlands and Great Britain. It is licensed to associations in Spain.

Edited by: G. Deimel, H. Glinde (Editor in Chief), I. Johal, D. Baron,

Drs. G. H. J. Reimerink

Published by: Galvanizers Association, Wren’s Court,

56 Victoria Road, Sutton Coldfield, West Midlands B72 1SY, UK

Tel: +44 (0) 121 355 8838 Fax: +44 (0) 121 355 8727

E-Mail: [email protected] Internet: www.galvanizing.org.uk

This magazine may not be copied without the written permission of the editor © 2008.

Distributed in Australia by: Galvanizers Association of Australia, 124 Exhibition Street,

Melbourne, Victoria 3000, Australia, Tel: 0396541266, Fax: 0396541136,

E-mail: [email protected]

Sustainability

Recycling of galvanizing process residuesDuring the galvanizing process, iron or steel

articles are dipped into a bath containing

molten zinc just above its melting point.

Any zinc that does not form a coating on the

steel remains in the bath for further reuse.

There is no loss of materials that may occur

during spray application of other coating types.

Zinc ash (from surface oxidation of the galvani-

zing bath) and dross (a mix of zinc and iron that

accumulates at the bottom of the galvanizing

bath) are fully recovered.

Any zinc metal within the crude ash is directly

recycled for further use, often in the same gal-

vanizing process.

The fine ash and dross are then sold to make

zinc dust and compounds for a variety of

applications such as rubber additives, cosme-

tics and electronic components.

Some galvanizing plants have facilities for

on-site treatment of their ashes and can

reintroduce the zinc from those ashes into

their galvanizing process.

Reuse of galvanized steelworkMany galvanized steel products can be remo-

ved, re-galvanized and returned to use.

For example, highway guard rails are often

removed and replaced during routine highway

maintenance and resurfacing.

The redundant barriers are returned to the

galvanizing plant for re-galvanizing and are then

used again in similar applications. The zinc-

rich acid that is produced by stripping the

remaining coating can be used for production

of zinc compounds for the chemical industry.

Recycling galvanized steelworkGalvanized steel can be recycled easily with

other steel scrap in the steel production

process.

Zinc volatilises early in the process and is

collected in the electric arc furnace (EAF) dust

that is then recycled in specialist facilities

and often returns to primary zinc production.

In 2006, the European steel industry (EU27)

produced 1,290,750 tonnes of EAF dust, which

contained 296,872 tonnes of zinc (i.e., 23%).

93% of this zinc (276,920 tonnes) was

recycled. (source: Gesellschaft für Bergbau,

Metallurgie, Rohstoff- und Umwelttechnik,

Germany)

Further information: www.zincforlife.org/recycling.html

Photo: Institut Feuerverzinken, Düsseldorf

4 The life-cycle of hot dip galvanized steel: main areas of consideration

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3 Flows of recycled zinc within the galvanizing process and at end of life

Scrap Zinc,e.g. from roofs/gutters

Refined Zinc production (Zinc ores)

Long service lifeGalvanizing Bath

Zinc-rich EAF dust(Electric Arc Furnace)

Steel recycling

End-of-life recycling

Zinc and steel recoveredfrom construction waste

Regalvanizing andreuse of steel products

Rubber additivesCosmeticElectronics

Zinc ash & drossrecovered from bathproduce zinc compounds

In-process efficiency and recycling

Processconsumables &

their regeneration& recycling

Galvanizingprocess

Durability &service life

Zinc production

Re-use and/

or Recycle

Entrained zincsent for remelting

Page 16: HDG Magazine 2_2008

The tower consists of an 18 metre high tape-

ring brick shaft with a circular cross section.

A water reservoir with a capacity of 500 m3 is

located on top of the shaft. The 2 metre taper

which protrudes outside the shaft is covered

with a brick housing with crenels at the top.

Curved brickwork in which 16 steel brackets

have been included forms the transition

between the shaft and the water tank housing.

Restoration was particularly necessary because

the steel sections had been seriously affected.

Over the course of time, the built-in steel

columns and the built-in cast iron window

frames were also extremely corroded.

The surrounding brickwork was being damaged

as a result of the pressure caused by the

increase in volume of the corroded material.

New galvanized sections have been added to

form part of the restoration.

Opdracht restauratie: Hydron Midden-Nederland

Architect: ZZDP Archtitecten, Amstelveen

Uitvoering: Aannemingsbedrijf H.J. Jurriëns bv, Utrecht

Photos: Stichting Doelmatig Verzinken, Nieuwegein

Galvanizing in Detail

Galvanizing Delight2008

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