The Southern African Institute of Mining and Metallurgy

8th International Corrosion Conference

R.E. Wilmot

TITLE: Performance Update of Hot Dip Galvanizing in the

Corrosive Environment of South African Gold Mines
Mr. R.E. Wilmot
Hot Dip Galvanizers Association Southern Africa

Abstract: This paper is based on the experiences, over many years, on the part of
numerous authors in the South African mining industry and that of the hot dip
galvanizing process and its application as a corrosion protection system. The paper sets
out the extensive development, financial resources and stringent operating requirements
of the South African mining industry. After many years of research and operational
experiences, hot dip galvanizing and when necessary, duplex systems, have been found
to meet the demanding requirements of this particular industry.

The paper sets out the requirements from the standpoint of corrosion criteria and is
followed with a practical example; “case history” where the corrosion protection
properties of hot dip galvanizing are demonstrated. This case history traces the early
investigation of the expected corrosive conditions to be encountered in a new mining
operation (now 10 years on) and concludes with two follow up visits to the mine in
order to examine actual performance of the corrosion protection system after ten years
in service.

Introduction

The original paper under this title was presented at the European General Galvanizers
Association International Conference (Intergalva 2003) in June 2003. The paper
presented on that occasion was co-authored by:
R.H.C. Andrew – Consulting Value Engineer
W.G.S. Barnett – Technical Consultant to HDGASA and
R.E. Wilmot – Executive Director HDGASA.
I was given responsibility for the presentation of the paper at Intergalva 2003. I thank
my co-authors and acknowledge their valuable contributions not only for the previous
paper, but also for the vast amount of work relating to hot dip galvanizing in the mining
industry.

By way of a background sketch to this update, a brief review of the paper that was
presented at Intergalva 2003 would be useful as an introduction to what follows.
(Ref No.1)

A brief Background Review

South African gold and platinum mines generally employ vertical shafts, extending to
depths of between 500m and 3000m. Alternatively, inclined shafts that extend to lengths
of up to 1000m long. Irrespective of the type of shaft used, environmental conditions

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The Southern African Institute of Mining and Metallurgy
8th International Corrosion Conference
R.E. Wilmot

encountered are usually highly corrosive and become more corrosive the deeper one
proceeds. These conditions are due to the presence of corrosive waters, high levels of
humidity, corrosive fumes and gases, and corrosive and abrasive ores.
In addition, thriving corrosion cells develop due to the accumulation of debris at catch
points and crevices including internal surfaces of various hollow steel components.

Vertical Mine Shafts

Winder House
Headgear

Downcast Upcast

Conveyances Ventilation shaft

Shaft steel

Reef
Haulages
1000-1500 m
Max 3160 m Ore passes
Stations

Loading stations
(shaft bottom)

Corrosion Profile: Vertical

Shafts Surface

~ 500 m

1000-
1000-1500 m
Max. 3160 m

~300 m
Relative
Corrosion Shaft Bottom
Rate 2 4 6 8 10 12 14 16 18

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The Southern African Institute of Mining and Metallurgy
8th International Corrosion Conference
R.E. Wilmot

Once a shaft and its related equipment are commissioned, extraction of ore becomes the
measurement criteria, with maintenance downtimes becoming an unwanted distraction
from this primary objective. Maintenance is restricted to about 8 hours per week and
mandatory safety inspections are normally included in the time. It is for these reasons
that the materials of construction must meet the demands of longevity and maintenance
free life.

Analysis of Mine Water

pH range 2.8 to 9.0

Chlorides + Sulphate range 100 to 2000 p.p.m.

HDG will tolerate

pH levels 6.0 to 12.5

Chloride levels 1000p.p.m. in hard water > 100 p.p.m.
calcium carbonate

Calcium salt deposits protect zinc surfaces

Zinc rarely susceptible to pitting corrosion

PERFORMANCE OF HOT DIP GALVANIZED STEEL

The original paper highlighted the “good to excellent” (Ref No.1) performance of hot
dip galvanizing, used since the late 1970s. The use of hot dip galvanized steel has
gained greater acceptance due its unique properties when used in conjunction with
carbon steel. Hot dip galvanizing is not simply another coating, but rather a material of
construction, that provides corrosion control by means of a stable ”barrier protection”,
combined with “cathodic protection” and at the same time superior bonding resulting
from the metallurgical reaction between the carbon steel and molten zinc. Enhanced
abrasion resistance is likewise improved by the same metallurgical reaction, which
results in the formation of a series of hard zinc/iron alloy substrate layers, which are in
fact harder than the parent steel that is being protected. A further benefit of this material
of construction, usually overlooked when predicting service life, is that the corrosion
resistant properties of the zinc iron alloys are up to 30% greater than that of pure zinc in
most environments. (Reference Porter “Corrosion Resistance of Zinc and Zinc Alloys”
62).

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The Southern African Institute of Mining and Metallurgy
8th International Corrosion Conference
R.E. Wilmot

The successful development of the use of hot dip galvanized steel for shaft steelwork
has taken place over a period of 20 to 30 years. A great deal has been achieved by the
galvanizing industry in this period to reach the point where this material can now be
confidently selected and used for major new mining projects. Some of the ‘milestones’
and achievements along the way have been:
• Controlling or avoiding distortion during galvanizing of large steel members
with critical tolerances, e.g. guides, buntons and station supports, by design and
modifications to the galvanizing process itself.
• Coordination with steel suppliers to ensure the optimal grade and composition of
steel to yield zinc coating thicknesses that minimise potential coating brittleness,
while still providing adequate corrosion protection.
• Developing the supply of hot dip galvanized fasteners to promote the availability
of all required sizes, types, strengths and shapes of fasteners.
• Developing a suitable specification for high strength bolts, and practical
guidelines for the tensioning of these bolts to ensure optimal grip and to
minimise relaxation affects.
• Assisting in the development of suitable duplex coatings for specific
applications and severe corrosive conditions.
• Improving various aspects of the supply chain that often negated the efficient
use of hot dip galvanized steel, e.g. using portable zinc spray units for site
repairs, tracking of components at all stages of the galvanizing process and
project execution, assisting users and fabricators at the project design and
planning stages, optimising transport and off-loading arrangements and
undertaking full assembly ‘mock-ups’ prior to installation in the shafts.

By including the galvanizer as a member of the project team from the design and
specifying stage through to final erection, apparent limitations to the use of the process
have and can be overcome. This is evident in the highly successful completion of
several major mining projects in recent years. The implementation of efficient
teamwork and good communication in the supply of a corrosion protection service to
complex multidiscipline, yet highly interrelated, projects have produced the required
results. As is the case for hot dip galvanized steel, any alternative material has to
provide a ‘package’ of properties to satisfy all safety, production, supply chain and
project management requirements.

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The Southern African Institute of Mining and Metallurgy
8th International Corrosion Conference
R.E. Wilmot

Equipping a Mine Shaft

3000m Depth x 10 m Diameter
• Streamlined & joint bunton supports 2800 Tons
• Shaft guides 2000 Tons
• Station structural steel 850 Tons
• Pump columns & piping 600 Tons
• Heat exchangers & ventilation ducting 350 Tons
• Miscellaneous steel work 100 Tons

TOTAL of STEEL to Equip a 3000m Shaft 6700 Tons

A CASE STUDY – Moab Khotsong Mine (Vaal Reefs No. 11 Shaft)

The original paper included a case study of Moab Khotsong Gold Mine, situated in the
Klerksdorp area. Included in this paper is a return follow up visit to the same shaft in
order to monitor progress on the continued effectiveness of the corrosion protection
system.

A brief description of this shaft is of particular interest as it personifies the use of hot
dip galvanized steel as a material of construction in an aggressive corrosive mining
environment.

Statistics of No.11 Shaft Moab Khotsong Mine

Shaft sinking started in 1992 and progressed at a rate of 4 meters per 24 hours. The
shaft, as it is today, is 10.6meters in diameter and 3160 meters in depth or a total
volume of 275000 cubic meters. It is currently one of the deepest “single drop” shafts in
the world serving 12 levels on the way down. Using the above shaft-sinking rate of 4
meters per 24 hours, it took approximately 790 actual working days of 24 hours per day
(2.2years actual working time) to complete. The three level personnel conveyance
“cage” takes approximately 4 minutes to travel from the surface to the lowest level,
reaching a top speed of 19meters per sec (68.4 Kms per hour). Each winder cost R120
million (US$14million) is computer controlled and will automatically bring the shaft
cage to rest within 10mm of the selected level. The shaft houses five sets of hoists, for
the conveyance of personnel, as well as ore hauling skips.

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The Southern African Institute of Mining and Metallurgy
8th International Corrosion Conference
R.E. Wilmot

Steel Prepared on Surface

Shaft Guides Additional Protection of

the Fasteners (Sealed)

Hot dip galvanized steel work waiting to be transported underground (1992)

Follow up Visits January 2003 and September 2006

Moab Khotsong No.11 shaft is now fully operational and being subjected to the full
service conditions as well as 10 years of a highly corrosive mining environment.

Site visits in January 2003 and again in September 2006 were undertaken to examine
the hot dip galvanized shaft steelwork, consisting of shaft guides, buntons and various
other steel structures, after a period of 9 to 10 years in actual service conditions. The
following photographs illustrate our findings, from which it can be seen that the hot dip
galvanized coating is performing exceptionally well. Coating thicknesses were found to
be in the order of 150 to 180µm. At certain isolated spots, the zinc coating had been
mechanically damaged, causing the coating to chip and exposing the zinc iron layer. In
these isolated spots no corrosion creep was evident while a portion of zinc iron alloy (25
to 35µm) was still providing protection to the steel structure. Slight rust staining
indicates that the zinc iron alloy is active and continues to provide corrosion protection.
The benefit of zinc is that corrosion creep is prevented due to cathodic protection, or the
fact that zinc will sacrifice itself to protect the carbon steel. (Zinc the “anode” is electro-
negative to carbon steel being the “cathode”).

The next three photographs were taken during the visit in 2003 and demonstrate the
ability of zinc to prevent corrosion creep by cathodic protection.

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The Southern African Institute of Mining and Metallurgy
8th International Corrosion Conference
R.E. Wilmot

Zero Corrosion Creep Zn thickness of

Undamaged
Area (284µm)

Mechanical Damage on Shaft Guide

Zn thickness within the

Damaged Area (37µm)

During September 2006, my Association colleague, Terry Smith, returned to the mine
and recorded the following photographs during the course of a routine shaft inspection.
One is able to achieve a glimpse at the environment found within a typical deep mining
shaft. Note the extent of the debris and poultice development that has taken place on the
shaft steelwork. This together with the continual wet environment, containing various
corrosive elements, contributes to the development of “ideal” corrosive conditions.

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The Southern African Institute of Mining and Metallurgy
8th International Corrosion Conference
R.E. Wilmot

Examination of a Shaft
Guide

Removal of the encrusted

poultices and measuring the
underlying hot dip
galvanized protective
coating reveals a coating
thickness of 430µm

Another Shaft Guide

This measurement taken on

the side giving 181µm of hot
dip galvanized coating

Examination of a Shaft Bunton

The underlying hot dip

galvanized coating measured
256µm.

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The Southern African Institute of Mining and Metallurgy
8th International Corrosion Conference
R.E. Wilmot

CONCLUSION

South African gold mines require between 15 to 20 years to explore, plan, and develop,
and large financial resources before a gram of gold is produced. Leading up to the day
when the first gold is produced, large facilities and equipment are installed, upon which
the mine will be dependent for its entire life. Such equipment must therefore provide
long-term maintenance free service. After many years of research and actual experience,
most of the gold and platinum mines in South Africa have now opted for hot dip
galvanizing and when necessary, duplex corrosion protection systems. At the last update
some 40 South African mines, of various descriptions, are specifying hot dip
galvanizing, and when required duplex coatings, for their corrosion protection system.
This represents a conservative estimate of 250000 tons of hot dip galvanized steel.

Hot Dip Galvanizing in Mines

Summary
• Assess the degree of corrosion
• Recommend galvanizing and duplex coatings
selectively
• Heavy duty coatings essential
• When galvanizing is not the solution say so and
suggest alternatives.

It has been proven that hot dip galvanizing remains in the forefront of corrosion
protection systems for not only the mining industry, but for many other industries as
well as domestic requirements. Hot dip galvanizing may be one of the oldest, but it
remains the most economical and viable protection system available today.

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The Southern African Institute of Mining and Metallurgy
8th International Corrosion Conference
R.E. Wilmot

Acknowledgements:

Anglo Gold and the Shaft Engineer at Moab Khotsong

References:

“Practical Guidelines for Corrosion Protection in the Mining & Metallurgical

Industry” by R.H.C. Andrew published by NACE International.

“Corrosion Resistance of Zinc and Zinc Alloys” page 62 by Frank Porter.

Hot Dip Galvanizers Association Southern Africa

Author biography:

R.H.C. Andrew – Mining Engineering Consultant

Bob Andrew holds a BSc in Chemical Engineering from the University of
Witwatersrand, Johannesburg, and an MSc in Corrosion Science from the University of
Manchester Institute of Science and Technology, England.

He has practiced as a corrosion consultant for the last 30 years, much of this time in the
gold and platinum mining industry. He has authored a book on corrosion protection in
the mining and metallurgical industry that was published in 1993 by NACE
International.

He is a retired Professional Engineer, a retired Fellow of the SA Institute for Mining

and Metallurgy and has been a member of NACE and the Corrosion Institute of South
Africa.

W.G.S. Barnett – Consultant to HDGASA

Walter G S Barnett has been actively involved in the hot dip galvanizing industry for
many years. As managing director of a galvanizing company in Johannesburg he was
responsible for the hot dip galvanizing of some thirty thousand tonnes of steel annually.

In 1990 he was appointed Executive Director of the Hot Dip Galvanizers Association
Southern Africa, which has since developed into a highly active center for the provision
of technical information and advice to specifiers, end users and galvanizers.

He is a corrosion consultant specialising in both organic and inorganic coatings.

Amongst his successful past achievements he considers the introduction of hot dip
galvanizing and duplex systems into the mining industry, for corrosive underground
applications, to be one of the most significant.

He has, for many years, been closely involved with the Corrosion Institute of Southern
Africa, where he is a Past President and honorary Life Member. In 1988 he received
the Institute’s Gold Medal award in recognition of meritorious service to the corrosion
industry and the advancement of corrosion science and technology.

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The Southern African Institute of Mining and Metallurgy
8th International Corrosion Conference
R.E. Wilmot

In 2000, Walter was awarded Honorary Life Membership of the Hot Dip Galvanizers
Association Southern Africa, and in this same year a trophy, the WGS Barnett Trophy,
was developed and presented to the winner of the Industrelek Hot Dip Galvanizing
Awards. This is a floating trophy and is presented each year.

At the EGGA Assembly 2002 in Porto, Portugal, Walter was presented with the pin
award in recognition of his contribution to the industry.

Walter is the author of numerous technical papers published in South Africa and
Internationally.

R.E. Wilmot – Executive Director HDGASA

Robert (Bob) Wilmot will present the joint paper at the conference. He has a Higher
National Diploma in mechanical engineering, a member of the South African Institution
of Mechanical Engineers, registered Professional Technologist (Engineering) and a
member of the South African Corrosion Institute.

Bob’s professional career started in 1969 when he was appointed as the works engineer
for a leading American company operating in South Africa. After a time as Production
Engineer, Works Manager and finally Managing Director, he was involved in the
growth and development of the company in South Africa. Part of the company’s
development lead to the construction and commissioning of a hot dip galvanizing plant,
and his interest in hot dip galvanizing technology. This interest in corrosion science and
hot dip galvanizing as a corrosion protection system continued and resulted in him
being appointed as Project Engineer with total responsibility for the construction and
commissioning of a modern, fully automatic, tube and pipe hot dip galvanizing plant for
another large South African company.

In April 2002, he joined the Hot Dip Galvanizers Association of Southern Africa as a
Technical Consultant. In January 2003 was appointed as Executive Director of the
Association, succeeding Walter Barnett, who is planning semi retirement, but will
remain on at the Association as Technical Consultant.

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