Marketing Guru 2008 Excellence In Hot

Protecting Steel for Generations
March/April 2008 | Volume 96
American Galvanizer
Marketing Guru
2008 Excellence in Hot-Dip Galvanizing
Award Winners Announced!
Read about this year’s winners in
“Marketing Guru,” pages 12-15.
75th Anniversary Spotlight
This year-long celebration of the AGA’s 75th Anniversary will
include a brief biography and words of wisdom from past
presidents and board members of days gone by.
Richard Brooks, Duncan Galvanizing Corp.
A Beantown resident of many years with his wife Beverlee, Brooks served the AGA
as a Market Development Committee member from 1993-1994, Member Services
Committee member from 1983-1985, board member from 1983-1986, 1989-1993,
and 2001-2005, and, finally, as president from 1989-1991. With this record of service,
he has myriad memories; some great when times were good, and some difficult when the
industry went through rough years.
One of his fondest memories includes achieving an independent organization managed
by AGA members. Richard also was bestowed the Hall of Fame Award, one of the AGA’s
highest honors, in 1994. His current hobby – and to no one’s surprise that knows him – is
work. He still has a deep passion and fire for the industry and has this advice for everyone
currently involved in the galvanizing industry: “Work hard and be innovative.”
James A. (Jim) Cole, Zaclon LLC
Jim started in the galvanizing industry in 1981 with the DuPont Company, and without
a break, joined Zaclon LLC when it purchased the Dupont business segment in 1987.
Since that time he has been a mainstay in the chemical area of the industry and within
AGA committees and activities. Jim served on the Technical Services Committee from
1984–2005 and the Members Services Committee from 1996–1997.
Never one to seek the spotlight, Jim was simply a concerned member and caretaker of
our great industry, and for that he was recognized in 2005 with the Hall of Fame Award.
According to Jim, the “award was the culmination of my AGA days.” Ever the politician,
Jim identifies no specific character as his favorite, and everyone has been a friend to
him. Besides golfing, traveling, and walking the beach in his quasi-retirement, Jim found
time to offer this pearl of wisdom: “Everyone keep working together to advance the
galvanizing industry and its great association.”
Nick de Raadt, Silver City Galvanizing, Inc.
A proud Canadian still living in the Vancouver, British Columbia, area, Nick worked for
Canron, Inc. from 1969-1992 and was co-owner of Silver City Galvanizing from 19932002. With the permission of his effervescent and beautiful wife Rita, Nick served on the
AGA’s Technical Services Committee from 1990-1991, the Member Services Committee
from 1991-1993 and 1996–1997, the board of directors from 1991-1992 and 19962003, the executive committee from 1991-1992 and 1998-2002, and as president from
2000-2002.
Known as a gregarious and outgoing fellow, it is no surprise Nick’s fondest memories
of his AGA days are the annual meetings, which “were always a highlight in our yearly
activities.” His most memorable character is Richard L. Brooks, “certainly the most
controversial, but with a focus.” With a swing that would raise Bobby Jones from the
dead, Nick remains an avid golfer and dabbles in making his own wine, as well as curling.
Travel adventures remain at the top of his hobby list, too. His words of wisdom: “The
best thing in my mind is that we (AGA) built and bought the premises we are presently
occupying. I hope to be present when we burn the mortgage papers in 2020.”
3 Phil’s Point of View: Fraud, Vigilence, and Sleep
4 Ask Dr. Galv: Effects of Differing Steel Chemistry
12 Marketing Guru: 2008 Excellence Award Winners
Phil’s Point of View - Phil Rahrig
v Fraud, Vigilence, and Sleep
I am happy to report the recent independent
audit of the association’s FY 2007 finances
went very smoothly, thanks in large
part to the excellent organization of our
bookkeeping and general office records by
Sue Bieber. As you may have experienced
also during the audit process of the last
few years, there is a “trickle down” effect of
Sarbanes Oxley (SOX), originally intended
to increase oversight of large corporations.
This usually takes the form of extensive
testing of A/P, A/R, and bank statements
far beyond pre-SOX days, as well as
significantly higher audit fees.
But, if you are a glass half-full person,
you may glean something good out of the
entire onerous process, and for me it is the
extensive interview related to identifying
occupational fraud and abuse. It is simply
another level of control that ensures the
funds entrusted to me by you are secure,
and we have implemented measures
making it very difficult for fraud and
abuse to occur. It should be noted AGA’s
independent auditor was very quick to
point out they are not the primary party
responsible for detecting fraud and abuse,
but rather they present a different set of
eyes and perspective.
As part of the audit process I was given a
64 page report produced by the Association
of Certified Fraud Examiners (ACFE) based
on information compiled from 1,134 cases.
It contains some interesting information
specifically about not-for-profit associations
and manufacturing, the sector where
galvanizing is positioned.
1. The median loss caused by occupational
fraud in this study is $159,000 USD.
2. Participants in the study estimate
organizations lose 5% of their annual
revenues to fraud.
3. The median length of schemes was 18
months from the time the fraud began until
the time it was detected.
4. Occupational fraud is more likely detected
by a tip than by other means such as internal
audits, external audits, or internal controls.
By accident is the second most common
means of detection.
5. Small businesses suffer disproportionate
fraud losses; a median loss of $190,000 USD
per scheme.
6. The most common occupational fraud
in small businesses involve employees
fraudulently writing company checks,
skimming revenues, and processing
fraudulent invoices. Small businesses suffer
such high fraud losses because they generally
do a poor job of proactively detecting fraud.
7. Frauds committed by owners or executives
caused a median loss of $1 million USD. This
is nearly five times more than the median loss
caused by managers, and almost 13 times as
large as the median loss caused
by employees.
8. Less than 8% of perpetrators have convictions
prior to committing their frauds and so
background checks are not as important
as surprise audits, fraud training, and
anonymous reporting mechanisms.
9. Fraudulent billing and expense
reimbursement comprise the vast majority of
schemes in the manufacturing sector.
Based on the data in the ACFE report,
small businesses tend to have lax internal
controls, no tip line, and often no external
audit. In that order these are the three most
important tools in preventing occupational
fraud. At the AGA we spend significant time
implementing internal controls involving
executive committee members as well as
staff. The point is such time is well spent
to not only prevent fraud but to act as a
sleep aid. Are you getting your sleep?
ELIMINATE ACID DISPOSAL
13 GALVANIZERS NOW USING PRO-pHx
PRO-pHx Is An Environmentally Sustainable Product From
Wagner Environmental Technologies LLC
Q:
A:
I know steel chemistry can affect the quality of a galvanized coating. Why does steel chemistry differ, and what advantages and disadvantages
do these differences offer?
In order to answer your question I must first define several
terms commonly referred to by metallurgists. First, physical
metallurgy can be described as the physical and mechanical
properties of metals as affected by composition, processing
and environmental conditions.1 Hardness is the measure of a
metal to resist deformation by indentation. Hardenability is a
measure of the property in a ferrous alloy that determines the
“range” of hardness induced into steel by quenching. Tensile
strength is the maximum tension that can be applied to a
metal without the metal breaking.
The predominant constituent in steel is iron. Iron as an
element is soft and ductile. Adding as little as 0.5% carbon by
weight to iron can dramatically increase the tensile strength
of the steel. Carbon is added to iron in quantities up to 2% by
weight to create what is commonly known as “carbon steel.”
Increasing the hardness of steel can increase brittleness
and decrease weldability. Manganese, like carbon, is added
to steel to increase its strength. Manganese also increases
hot working properties, and increases hardenability and
toughness of steel.
Glossary of Metallurgical Terms and Engineering Tables.
1
Ask
Dr. Galv
In addition to carbon and manganese, several other elements
are commonly added to iron. Alloy steels with differing
chemistry can have very different material properties. To
account for these differences, a formula was devised to
compare one alloy steel to another with different elemental
additions. This formula is called the carbon equivalent (CE.)
There are several different versions of this formula – here is
one commonly used:
CE = C% + (Si%)/25 + (Mn%+Cr%)/16 +
(Cr%+Ni%+Mo%)/20 + (V%)/15
Dr. Galv, cont’d. page 5
Ask Dr. Galv: Effects of Differing Steel Chemistry, cont.
Figure 1:
Rough surface due to excessive
silicon content
Figure 2: Black steel
Figure 3: Rough surface due to excessive
phosphorus content
When carbon is added to iron, oxygen in the air reacts with and
consumes the carbon. To prevent this, silicon is added to the iron
as a deoxidizing agent. This prevents the oxygen from reacting
with and consuming the carbon. When silicon is used in this
fashion, it is said to “kill” the steel. Silicon can also make steel
harder; however, in excessive quantities, silicon can create rough
galvanized coatings (see Figure 1).
up to the specified level, phosphorus can increase the strength and
corrosion resistance of steel.
Most steel (Figure 2) is made from scrap iron, which can introduce
impurities into the steel. In small amounts, impurities usually do
not have a detrimental effect on steel properties. Phosphorus,
one such impurity, is allowed by many steel specifications in
levels up to 0.04%. In levels higher than 0.04%, phosphorus can
negatively impact hot-forming operations in the steelmaking
process, increase the tendency for steel to crack during welding
and create rough galvanized coatings (see Figure 3). In amounts
As you can see, elemental additions made to steel are not arbitrary.
They help to create steel with specific properties. When these
elemental additions are limited to the ranges listed in ASTM A385,
they should not negatively impact the quality of a galvanized
coating. These recommended ranges include a carbon content less
than 0.25%, manganese content less than 1.3%, silicon content less
than 0.04% or between 0.15% and 0.22%, and phosphorus content
less than 0.04%.
Phosphorus and silicon can act synergistically to cause rapid
growth of zinc-iron alloy layers in galvanized coatings. This
happens because the two act as catalysts during the metallurgical
reaction of zinc and iron during the galvanizing process.
AGA
75th Anniversary
Diamond
Perfect for your office desk
or display case!
Commemorative Program
Order your complementary 75th Anniversary
Program today! Programs include photos and
information from throughout the AGA’s history.
Email requests to jclawson@galvanizeit.org
$10.00 + shipping
E-mail requests to Robyn at
rburke@galvanizeit.org
How to Become an AGA Board Member
v Continue a tradition of wisdom and experience
Clockwise from lower left: Mike Hettleman, Jim Wyatt, Bill Phillips, Jim
Klein, Leon Ponte, Chuck Perry, Harry Jones, Ray Lloyd, Bob Hall, Clarence
Willard, Pat Gregory, Bill Tunney, J.W. Piatt, Boyd Dean, Tom Brown, and
Roland Mattson attend a past board meeting.
At the recent AGA Annual Conference in Las Vegas, several of
the “old timers,” i.e. current members with 20 or more years of
commitment to the AGA on committees and the Board of Directors,
mentioned they noticed an age gap amongst the attendees. It
appeared to them there was a lack of 30- to 50-year-olds involved
in the sessions and networking with other industry professionals.
Each of those making a comment readily acknowledged they were
one of those 30- 50-somethings a long time ago, and they simply
want to ensure the wisdom and experience they have obtained
is transferred to others who will be around to secure the AGA’s
future.
It is common knowledge there are many volunteers-in-waiting
for charities and civic organizations, and they simply need to be
asked to step forward. If you are one of those people and have
thought about service to the AGA, consider yourself asked. Here is
a brief explanation of how to become a board member and become
instrumental in guiding our industry in the next decade.
Using zinc shot for your next kettle
fill eliminates labour intesive hand
packing in-between jumbo blocks.
The new charge melts faster, creates
less thermal stress on your kettle, and can
get you back to production 30 percent
faster than traditional packing. Not bad
for a little 3/8” diameter disc-shaped
piece of zinc.
Call Martin Gagné at (416) 775-1413
for more information about zinc shot. It’s
just one more way Xstrata works for you.
To be eligible for board service, you must be a galvanizer in
good standing and have actively served on any one of the many
committees (technical services, market development, member
services, regional marketing, focus group) for a minimum of two
years. (Sometimes, the committees have a full complement of
members, but you are encouraged to sit in and audit the committees,
learn, and prepare yourself to be a valued contributing member.)
The logic of this requirement is simply to ensure incoming board
members have a working knowledge of the committees, budget
process, and staff responsibilities. Once you have fulfilled
this requirement, any other member may place your name in
nomination, and you will be asked to serve if elected. If you agree,
your name will be placed on the official ballot along with all other
eligible candidates – and you are on your way to becoming an
esteemed member of the AGA Board of Directors.
~ ~ Congratulations! ~ ~
Howard A. Levine of Duncan Galvanizing was notified
he will become a Fellow of the Construction Specifiers
Institute. He will be elevated to Fellowship on June 6,
2008, during the Honors and Awards Gala at CONSTRUCT
2008 & the CSI Annual Convention in Las Vegas.
Congratulations to Howard on this esteemed honor.
Xstrata, First Canadian Place - 100 King Street West, Suite 7050
Toronto, Ontario, Canada M5X 1E3
Tel: (416) 775-1413 Fax: (416) 775-1492
The World is Running Out of Zinc! - Another Legend Dispelled
In this article, provided by the International Zinc Association, discover the true status of zinc production
From time to time, someone with little
knowledge of zinc mining claim the world
“will run out of zinc” in the next few
decades. Nothing could be further from the
truth. The fact is, despite greatly increased
consumption of zinc produced from ore in
recent years, increases in zinc ore reserves
have grown more than this increased
consumption. There is more zinc available
to the world today than at any other time
in history.
If they were right, we would be running close
to empty now – but they were wrong
The doomsayers believe the way to measure
the remaining life of zinc ore reserves is to
take present reserves and divide by annual
mining production to yield years left. That
static, alarmist, analysis is wholly belied
by the objective facts. The International
Lead Zinc Study Group (ILZSG) reports
6,798,000 metric tons (mt) of zinc mined
worldwide in 1994 (ILZSG Bulletin,
Feb. 2008, Table 56).1 According to
the U.S. Geological Survey (USGS), in
1994 the world’s zinc reserves were
140,000,000 mT (Mineral Commodity
Summaries, Jan. 1996).2
Therefore, assuming everything had stayed
the same from 1995 through 2005, the
world would have mined an additional
75,009,000 mT of zinc, leaving reserves of
only 74,869,000 mT. In other words, over
half of the 1994 reserves would have been
erased – forever – and the world would be
looking at approximately 11 more years
of mining until all the zinc reserves were
gone forever. But that is not what happened.
As distinct proof, the USGS reports that 2005
zinc reserves were not 74,869,000 mT as
the doomsayers would have had it, but were
instead 220,000,000 mT – a 57% increase
over the 1994 level and approximately triple
the doomsday scenario (Id., Jan. 2007).3
Despite increased mining, reserve levels
continue to increase
Mining actually increased significantly
in recent years. In 2006, according to
ILZSG, 10,469,000 mT of zinc were mined
worldwide – 53% greater than the amount
mined in 1994 (ILZSG Bulletin, Feb. 2008,
Table 56). Despite this steady increase in
the amount mined annually since 1994,
reserves still increased by over 50%, wholly
undercutting the shortage argument.
Thus, the argument the world was running
out of zinc on a static model was wrong,
and the notion that the world is running out
2005 zinc reserves were 220,000,000 mT – a 57% increase over the 1994 level and approximately
triple the doomsday scenario of 74,869,000 mT
of zinc because of increasing consumption
is wrong, too.
Improved commodity prices are responsible
for a good bit of the new reserves
It is a given profitable operations make
more money available for exploration
and development. And it is also a given
mineral commodity prices were depressed
for a good bit of the last ten years. For
example, in 2002 the average zinc price on
the London Metal Exchange was $778.38
mT (USGS, Mineral Industry Surveys, Zinc,
Table 1, Oct. 2003). In 2006, by contrast,
the average price was $3,274.42 (USGS,
Mineral Industry Surveys, Zinc, Table 1,
Dec. 2007).
As a result of the low price for zinc and
other metals, exploration budgets suffered.
“Driven by surging commodity prices,
2005 expected expenditures for mineral
exploration reached a level not seen in
nearly a decade, according to findings in
the May 2006 edition of the Society for
Mining, Metallurgy and Exploration’s (SME)
Mining Engineering.” (National Mining
Association, Mining Week, May 26, 2006).
And this continued in 2006:
“Metals Economics Group’s (MEG)
analysis of 2006 worldwide exploration
budgets shows an increase to $7.5 billion
USD this year – the fourth consecutive
yearly increase since the bottom of the
cycle in 2002…”
“Years of stagnant and declining
metals prices in the late 1990s and the
resulting lack of exploration and mine
development…”
(Commodities Now,
Dec. 2006, 1).
Additionally, what this clearly shows
is higher price levels for zinc have not
resulted in a lowering of zinc reserves,
to the contrary. In 2002, the recent price
trough for zinc, reserves were 200,000,000
mT (USGS, Mineral Commodity Summaries,
Jan. 2003). From then until 2005,
despite increased prices and increased
consumption, reserves grew, as indicated.
Out of Zinc?, cont’d. page 8
Out of Zinc?, cont.
Improved recycling has also helped reduce
demand for ore, and will continue to grow
Zinc in the form of scrap and other
secondary materials constitutes an aboveground mine, reducing the demand for
natural ore to produce refined zinc. In
1996, 509,000 mT of refined zinc were
produced from secondary materials; in
2006 that number had grown to 551,000
mT. (ILZSG, Lead and Zinc Statistics, Table
40, Jan. 1998, Dec. 2007).
And, as more zinc comes into the recycling
stream because of increased consumption,
this number will continue to grow.
Summary
Zinc reserves have increased dramatically
in recent years despite increased mining
and consumption of zinc, and until
recently, despite low zinc prices shrinking
exploration and development budgets.
Some healthy years to restore those budgets
plus increased recycling of zinc-containing
materials will continue to ensure the world
has plenty of zinc for many years to come.
Footnotes
The International Lead Zinc Study
Group (ILZSG) is a non-ferrous metals
intergovernmental organization created by
the United Nations in 1959 with 29 member
countries accounting for about 90% of total
worldwide lead and zinc tonnage. The Study
Group’s main responsibility is to maintain
transparency of production, usage and
foreign trades for concentrates and refined
metals through statistics, studies and wideranging consultation.
1
“Reserves” are defined by USGS as, “That
part of the reserve base which could be
economically extracted/produced at the
time of determination. Reserves include
only recoverable materials; thus, terms such
as ‘extractable reserves’ and ‘recoverable
reserves’ are redundant and are not a part
of this classification system. The reserve
base includes those resources that are
currently economic (reserves), marginally
economic (marginal reserves), and some
of those that are currently subeconomic
(subeconomic reserves).
Zinc and aluminum bars
2
Extraction from a zinc mine
Moreover, the world reserve base had
increased from 330,000,000 mT to
460,000,000 mT.
3
Technical Program Update
v
A look at current and upcoming programs/projects being prepared by the AGA Technical Department.
outside inspector at the galvanizing plant. The CD version include
san online test certifying the course material was understood by
the student. A list of inspectors who have taken the course and
received a passing grade will be posted on the AGA website. This
course can be given at any member’s facility. Presentations are
given by the AGA staff, in particular, Dr. Tom Langill.
Chromate Study
The AGA began the chromate study in October, and the draft
note is currently undergoing review. The chromate study was
developed to measure the quantity of chromate 6+ ions on the
surface of the galvanized steel. The results will help to provide
a reading of how safe it is to handle products that have been
chromate quenched. The study will also show how long the
chromate passivation remains on the surface of the galvanized
coating. Results from the study show the chromate 6+ ions are
on the surface of the galvanized coating immediately after being
quenched in the chromate bath, but within a week there is very
little chromate 6+ ions on the surface. After four months, there
is no hexavalent chromium on the surface of the galvanized steel.
Results of the study will be published in a Galvanizing Note. The
program is being planned and executed by the Health and Safety
Subcommittee of the TSC and is open to any member galvanizer.
Slip Factor Study
The use of galvanized steel for faying surface connections has
been limited by the slip coefficient measurements that have
been performed on galvanized plates. The measurements have
all been performed immediately after connecting the galvanized
plates and the results have indicated the plates can experience
some movement during this initial period. The slip coefficient is
based on the force needed to separate the two plates. Initially this
force is fairly low unless the galvanized surfaces are roughened,
and this roughening increases the force necessary to separate the
plates, giving a higher slip coefficient. The longer-term effects of
placing two galvanized plates in contact under tension have not
been measured. The fact the two zinc surfaces can form a cold
fusion bond and significantly raise the slip coefficient has not been
demonstrated. This program will measure the short- and longterm slip coefficients of galvanized plates in contact.
The first round of tests was performed on plates that had no free
zinc layer, so there was no bonding between the plates during the
testing. The slip coefficient was the same after the plates were
connected for a week as the initial slip coefficient for newly bolted
plates. A new batch of steel was obtained to produce plates that
will have a free zinc layer after galvanizing. Once these plates
are fabricated and galvanized, they will be tested initially with a
roughened surface and then put under dynamic load and tested
again to measure the increase in slip. This program is being
monitored by the Coating Performance Subcommittee of the TSC
and is open to any member galvanizer.
The Galvanizing Handbook will provide quick reference information and
charts addressing quality and process issues.
Hydrogen Embrittlement of High Strength Bolts
The specification for ASTM A
490 bolts specifically forbids
the use of galvanized coatings
as
corrosion
protection
systems on these bolts. The
rationale for this prohibition
is the potential for hydrogen
embrittlement with the high
strength A 490 bolts. This
prohibition is not followed in
Europe, where high strength
bolts are galvanized by using
mechanical cleaning rather
than acid pickling to prepare
the bolts for galvanizing. The
ASTM committee that amends
the A 490 bolt specification
has voted to allow Dacromet
coatings on bolts after reviewing
the results of a test program very similar to the project the AGA
is conducting on hot-dip galvanized bolts. The hot-dip galvanized
bolts for the hydrogen embrittlement testing are being hardened
to the maximum allowable hardness per the specification to make
the bolts more sensitive to any entrapped hydrogen. Once these
Galvanizing Handbook
The Technical Services Department has developed a number of
educational materials for plant personnel. The latest project in
this area is the Galvanizing Handbook. This project will develop
a guide for galvanizing supervisors to use as a handy reference
manual to address quality and process issues within the galvanizing
operation. The purpose of the handbook is not to over-analyze
the galvanizing process, but rather to provide relevant charts and
references for specific issues within the flow of work through the
plant. This material will be available in either binder hard copies
or on CD. The content of this handbook comes from issues at
member companies. In order to include the correct material, the
TSC is planning a survey of members to determine the day-to-day
issues on the galvanizing line to be included in this handbook.
This program is being planned and executed by the Processing
Subcommittee of the TSC and is open to any galvanizing member.
Inspection Course
The Inspection Seminar has been developed by the Technical
Services Department to educate outside inspectors on how to
use ASTM specifications correctly when applying them to hotdip galvanized products. The course has been given to many
galvanizing members and to a few outside groups, including 45
inspectors at the NASCC meeting in Nashville. The course is also
available in a CD version to all members and can be handed to any
Technical Program Update, cont’d. page 11
10
Technical Program Update, cont.
rough draft form for all ten sections. The first seven are approved
by the TSC, and the next three are still in the approval process.
This effort is being assisted by the Health and Safety Subcommittee
and is open to any member galvanizer.
bolts have been prepared, they will be tested using step stress
testing to measure their threshold for hydrogen embrittlement.
If the numbers are in line with the same tests for the Dacromet
coating, which is a zinc/nickel epoxy material cured at 500 F, then
the ASTM committee should allow the use of hot-dip galvanized
coatings on A 490 bolts. This program is being monitored by the
Coating Performance Subcommittee of the TSC and is open to any
member galvanizer.
Updated Environmental, Health and Safety Note for PPE
An updated Environmental,
Health & Safety Note for PPE
is now available. The changes
that were made include
testing information provided
by Valmont on protective
clothing around the kettle.
Molten zinc tests were done
on several different types of
material to see what provided
the best protection. The note
is available on our website by
linking to the members’ only
section and selecting EHS
notes. Testing suggests the
best material for protection
around
the
galvanizing
kettle is Banox and not the
previously
recommended
Nomex.
This note is
monitored by the Health and
Safety Subcommittee.
Process Survey
The survey results have been analyzed by AGA Corrosion Engineer,
Bernardo Duran. After comparing the data from previous surveys
to the 2007 survey, the results are being drafted into a report that
will be available to all survey participants. The report is more
than 50% complete, and the trends are quite interesting. There
were more than 60 participants in the 2007 version of the Process
Survey.
OSHA Manual Update
The AGA has been updating the OSHA Manual was first produced
back in 1994. Although there have not been a significant number
of changes in the OSHA regulations since that time, the update
includes new looks at some old requirements and makes good
use of the many OSHA inspections reviewed by the AGA staff.
Safety issues directly associated with the galvanizing industry are
detailed, as well as copies of many of the directly applicable OSHA
Regulations. The new format includes Tips Pages, and makes it
much easier to review the details that are the direct responsibility
of the galvanizer. This updated manual has been written up in
11
Marketing Guru - Jenny Clawson
2008 Excellence in Hot-Dip
2008 WINNERS
v INDIANAPOLIS MOTOR SPEEDWAY
MOST DISTINGUISHED
Indianapolis Motor Speedway-
Aztec Galvanizing Services
Witt Galvanizing - Muncie & Plymouth
ARTISTIC
City of Surrey, Floraform Project-
Silver City Galvanizing, Inc.
Nashville Children’s Theatre Dragon-
Bristol Galvanizing
BRIDGE & HIGHWAY
MI/M-102 Bridge-
V&S Detroit Galvanizing LLC
BUILDING & ARCHITECTURE
Kuujjuaq, Nunavik Airport Terminal-
Corbec Corp.
CIVIC CONTRIBUTION
Decorative Flower Boxes-
Young Galvanizing, Inc.
DUPLEX SYSTEM
Chinatown Park-
Duncan Galvanizing Corp., American Galvanizing Co., Inc.
ELECTRICAL, UTILITIES, &
COMMUNICATION
Aero Solutions Pole Max-
Galvan Industries, Inc.
San Joaquin Irrigation Dist. Solar Farm- Los Angeles Galvanizing Co.
FOOD & AGRICULTURE
Indiana Packers Quick Chill Cooler Expansion-
Aztec Galvanizing Services
Witt Galvanizing - Muncie
Most Distinguished
Utilizing more than 500 tons of galvanized steel, the Indianapolis Motor Speedway is one of the
largest sport facilities in the world. Originally, the Northwest Vista was painted for corrosion
protection; however, as the paint failed over the years, the owner began searching for a better
corrosion protection system. This newly galvanized structure will be visible to nearly one half-million fans onsite, and tens of millions viewing the sport worldwide.
v KUUJJUAQ AIRPORT
v CHILDREN’S THEATRE DRAGON
INDUSTRIAL
National Gypsum-
Galvan Industries, Inc.
ORIGINAL EQUIPMENT
MANUFACTURING
EFCO Deck Systems-
Valmont Coatings Valley Galvanizing
Pro-Tote Bellway Wrecker Converter-
Aztec Galvanizing Services
Witt Galvanizing - Plymouth
RECREATION & ENTERTAINMENT
Expocite
Corbec Corp
TRANSPORTATION
Chicago Transit Authority Brown Line Sedgewick Station-
Valmont Coatings Empire Galvanizing
WATER & MARINE
Savage Residence Dock-
Duncan Galvanizing Corp.
Building & Architecture
Galvanizing accommodated the work
schedule for this project by protecting
the incomplete structure, neccesarily
left exposed through the arctic winter.
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Artistic
The extra effort of skip welding under the scales and
adding holes disguised as part of the sculpture helped
breathe life into this dragon, which stands in front of
the Nashville Children’s Theatre in Tennessee.
Marketing Guru, cont.
Galvanizing Award Winners
From towering dragons to solar energy panel systems,
the submissions for the 2008 “Excellence in Hot-Dip
Galvanizing Awards” spanned the gamut of galvanizing
possibilities.
Seventy applications submitted by 19
companies rounded out another great year of competition
with more than five projects present in almost every
category. Projects ranged from the artistic to the
functional, with many showing a growing emphasis on
“green” contributions.
With a tie in the Artistic category, this year’s submissions
sent out a strong message – galvanizing can be beautiful.
With the sleek, innovative design of the City of Surrey
Floraform Project (Artistic – tie) and the intricate detail
of the Nashville Children’s Theatre Dragon (Artistic – tie),
it is obvious galvanized steel can be a nuanced, functional
artistic medium. Projects such as the Chinatown Park
sculpture (Duplex), a striking tribute to Chinese tradition,
and the Kuujjauq, Nunavik Airport (B&A), tastefully
erected in the shape of an Inuit kayak, show both cultural
awareness and stunning form. The Decorative Flower
Boxes (Civic) now lining main street in West Middlesex,
Penn., will grace the town for decades to come.
Not just another beauty contestant, however, galvanizing
was also represented as cost-effective and functional by
the new submissions. Aero Solution’s Pole Max (EUC – tie),
EFCO Deck System (OEM – tie), and Pro-Tote Bellway
Wrecker Converter (OEM – tie) all were original choices for
galvanizing applications, each identifying a new product
that would greatly benefit from the galvanizing process.
Showcasing durability and corrosion protection, Expocité
(R&E), Indiana Packers Quick Chill Cooler Expansion
(F&A), and the Savage Residence Dock (W&M) each shone
as examples that will surpass the test of time and corrosive
elements. Consider the CTA Brownline Sedgewick Station
(Transportation) for example – originally galvanized more
than a century ago, the station was only recently in need
of refurbishment. Galvanizing was the obvious choice for
the restoration. This year’s Most Distinguished winner,
the Indianapolis Motor Speedway, utilized 500 tons of
galvanized steel not only to keep the structure looking
attractive, but also to prevent any hazardous structural
failure associated with corrosion.
Finally, this year’s applications illustrated just how earthfriendly galvanizing can be. The MI/M-102 Bridge
Reconstruction demonstrated how a project can be both
environmentally conscious
and save taxpayers a lot of
CITY OF SURREY
their OWN green. Thanks to
FLORAFORM
the initially galvanized pieces
used in the structure, this
PROJECT
project was able to recycle
80% of the original material –
saving enough money for the
city to begin a new project
originally slated for next
year. The South San Joaquin
Irrigation Distribution Solar
Farm (EUC – tie), one of the
largest solar projects in the
nation, and National Gypsum
(Industrial), a facility used to recycle waste
material, both continued the green efforts
of their projects by utilizing recyclable,
sustainable, earth-friendly, galvanized steel.
v
Many thanks to all of this year’s participants. Keep
up the good work! Don’t be content to rest on your
laurels, though - there could be winning submissions
sitting in your plant this very moment! Don’t wait
to claim your bragging rights. Start preparing your
2009 submissions today!
v MI/M-102 BRIDGE RECONSTRUCTION v IRRIGATION DISTRIBUTION
Bridge & Highway
When the Michigan DOT learned how many states have
been taking old guardrail, stripping, regalvanizing, and
returning the pieces to service, they decided to regalvanize
the 300 tons of existing steel in this project.
Energy, Utility, & Communication
Nearly 9,000 pieces were galvanized on this
project, which utilizes 11,040 solar modules
to produce 3.7 million kilowatt hours of
electricity output annually.
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Artistic
The tall, blossoming flowers
created for this project function
not only as art, but also as solar
powered light stands.
Marketing Guru, cont.
2008 Excellence in Hot-Dip
v AERO SOULTION’s POLE MAX
v CHINATOWN PARK
Energy, Utility, & Communication
Duplex System
Aero-Solution’s Pole-Max serves as a simple solution to
add antennas onto existing towers. Nearly 24,000 of
the approximately 80,000 monopoles throughout North
America could benefit from the Pole-Max retrofit to upgrade
poles to higher load designs, making the market for this
long-lasting, galvanized product wide open.
Located in the heart of Boston’s Chinatown, the Chinatown Park project has a great
deal of public exposure, an element that made quality and craftsmanship important
components in the choice to utilize galvanizing on the project. As a landmark project
representing a major neighborhood in Boston, longevity and appearance were major
considerations. Using a duplex system allows the structure to have the best of both worlds – aesthetic appeal and corrosion protection.
For more information and photos of these award-winning projects,
visit www.galvanizeit.org/awards and click on “2008 Winners.”
v DECORATIVE FLOWER BOXES
Civic Contribution
In a small town in northwest Pennsylvania Amish
country, the main thoroughfare through town is now
artfully adorned with large galvanized flower planters.
All 2,600 lbs. of steel was donated.
v NATIONAL GYPSUM
Industrial
As is often the case, the initial and
life-cycle cost of galvanizing the
3,461 tons of steel offered superior
economics for this project.
14
v EFCO DECK SYSTEM
Original Equipment Manufacturing
A newly developed way of cycling large deck
panel systems from floor-to-floor by crane, the
EFCO Deck System is designed so one person
can erect the shoring system without the
assistance of an entire crew.
Marketing Guru, cont.
Galvanizing Award Winners
v QUICK CHILL COOLER EXPANSION
v EXPOCITE
Food & Agriculture
v CTA BROWNLINE SEDGEWICK STATION
Recreation & Entertainment
ABOVE: Renovated to attract a major hockey tournament in 2008, the massive
hot-dip galvanized steel trusses of Expocite sport stadium can be seen from
Highway 73 (the main artery entering the downtown corridor of Quebec City).
TOP RIGHT: The Indiana Packers Quick Chill cooler expansion required all metal
building materials be aluminum, stainless, or hot-dip galvanized to comply with
USDA food processing requirements. To protect their $70 million expansion
investment, IPC chose galvanizing to safeguard the facility from daily contact
with the corrosive elements associated with beef and poultry production.
RIGHT: To secure their $530 million restoration investment, the Chicago Transit
Authority specified galvanizing for this project, just as it was originally selected
for corrosion protection in 1900.
v PROTOTE BELLWAY WRECKER CONVERTER
Transportation
v SAVAGE RESIDENCE DOCK
Water & Marine
Original Equipment Manufacturing
The Pro-Tote Bellway Wrecker Converter enables any fifth-wheel semi to be
converted into a heavy duty wrecker. The complex fabrication and moving
parts of this project made ensuring complete coverage and movement of the
parts a considerable challenge during the galvanizing process. 15
Because steel was the material of choice to support the wooden
cross members making up the surface of the dock, the owner of
this project desired a protective coating with proven capabilities
that would also blend into the rural surroundings.