Corrosion Protection Solutions for New and Deteriorating Structures

GalvaWrap

What is GalvaWrap Used For?

GalvaWrap is a self-contained, corrosion protection and durability enhancement system, designed to be fixed directly to atmospherically exposed steel surfaces to provide long-term protection from corrosion-related deterioration.

 

GalvaWrap provides multi-staged corrosion protection including active and passive corrosion control, which effectively protects against corrosion of atmospherically exposed steel surfaces.

 

GalvaWrap offers an alternative barrier control approach compared with traditional organic-based coating systems and offers similar corrosion protection and durability benefits as provided by hot-dip galvanizing.

 

Durable and effective, offering corrosion protection lives for atmospheric exposure as per BS EN ISO 12944 Paints and varnishes - Corrosion protection of steel structures by protective paint systems - Part 2: Classification of environments.

  • 71 - >100 years for environmental classification C3 (Medium - Urban and industrial atmospheres and coastal areas) 

  • 35 - 71 years for environmental classification C4 (High - Industrial and coastal areas) 

  • 17 - 35 years for environmental classification C5I & C5M (Very High - Industrial and coastal areas with an aggressive atmosphere or high salinity)

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GalvaWrap Product Description

GalvaWrap consists of high purity zinc (> 99.95% Zn), 150µm (0.15mm) thick foil, supplied with an electrically conductive adhesive layer, which can operate continuously up to 60°C.

 

The adhesive incorporates zinc metal micro granules within the adhesive layer, which provides electrical continuity between the zinc foil and the surface of the structure.

 

The tape is supplied with siliconized paper, covering the adhesive layer, which facilitates installation and protects the adhesive from getting damaged or polluted.

 

The product is available in standard roll form consisting of 10m x 0.3m wide rolls.

Other widths are available on request 

 

The steel surfaces to be protected are grit blasted or wire brushed to remove corrosion deposits and old loose coatings. Once cleaned and free from dust, grease, and moisture the backing paper is removed, and the zinc foil and attached to the substrate using the adhesive contact surface.

The installed zinc foil is then compressed using specialist magnetic rollers or other tools to ensure all air is excluded and complete adhesive contact with the substrate.

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Where Can GalvaWrap Be Used?

GalvaWrap is suitable for providing corrosion and durability enhancement for all new and existing metallic structures, except for magnesium and magnesium alloys.

 

GalvaWrap is designed to cover the surface of iron, steel, galvanized steel, stainless steel, and aluminum, preventing corrosion of the underlying surface. It is suitable as an alternative to conventional protective coating systems or hot-dip galvanizing, used for corrosion protection.

 

GalvaWrap is designed to rehabilitate existing galvanized steel elements, where the zinc has been consumed and are showing signs of ferrous corrosion or where the galvanizing is damaged during welding or cutting operations.

 

GalvaWrap is designed to provide corrosion protection between mating surfaces, bolted connections, and crevice areas, which are prone to wetting and localized corrosion and/or bi-metallic corrosion between dissimilar metal contacts. When incorporated between mating surfaces, GalvaWrap will corrode and provide galvanic cathodic protection to the metallic mating surfaces, preventing crevice and bi-metallic corrosion of the structural components.

 

GalvaWrap is designed can be used over existing coating systems, as an overall containment and durability enhancement system, without the need to removed sound un-damaged coatings.

 

GalvaWrap is suitable for atmospherically exposed components, it can be overcoated with traditional coating systems suitable for coating galvanized surfaces, to provide enhanced durability, operational life, and improved aesthetics.

 

GalvaWrap is surface tolerant, easy, and rapid to install, requiring basic surface preparation (wire brushing and surface degreasing) when compared with the requirements of grit blasting, associated with traditional organic-based coating systems.

 

It is naturally solvent and smell-free and can be successfully applied to structures within populated areas, confined spaces, or other high-risk hazardous areas.

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Technical Benefits of GalvaWrap

Zinc is naturally more corrosion resistant than iron or steel and zinc corrosion products are white, compared to the red rust of iron and steel alloys.

 

Zinc is anodic to iron, steel, galvanized steel, stainless steel, and aluminum, which leads to the preferential consumption of zinc when connected to these alloys.

 

When coupled with iron, steel, galvanized steel, stainless steel, and aluminum structures, GalvaWrap provides Active and Passive corrosion protection, thereby preventing corrosion, deterioration, and loss of structural integrity.

 

Active Corrosion Protection

By providing a direct electrical connection between the zinc foil and the structure surface, (through the electro-conductive adhesive), the zinc can act as a galvanic anode and provide cathodic protection to the substrate during wet conditions.

 

When the surfaces are wet, for example following a rain shower or surface condensation, the zinc will provide cathodic protection to the structure surface at holes or defects within the zinc foil and prevent corrosion of the exposed structure surface.

 

Due to this effect, GalvaWrap effectively prevents localized pitting or crevice corrosion at holes within the foil and provides a specific advantage, when compared with traditional organic type coatings systems, which are prone to pitting and crevice corrosion at coating defects.

 

Passive Corrosion Protection

The rate of zinc corrosion is much lower than steel in similar exposure conditions.

 

Zinc foil is impermeable to moisture or gasses and provides a direct barrier between the environment and the structure surface (when no holes are present).

 

The zinc micro granules within the adhesive, provide additional barrier effects, which enhances the natural barrier effects of the foil and provides a degree of protection when the zinc foil is completely consumed.

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