RUVOLUM® Workshop | Armin Roduner

Corrosion Protection
Best Practice and Solutions for Aggressive
Environments
AGENDA

1. EXTERNAL / ENVIRONMENTAL
FACTORS
2. KEY FIGURES FOR LIFETIME
3. COMPARISON OF COATINGS
4. THEORETICAL EXPECTED
DESIGN LIFE
5. SOLUTIONS FOR
AGGRESSIVE ENVIRONMENT
6. CONCLUSION

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01
EXTERNAL / ENVIRONMENTAL FACTORS

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LIST OF EXTERNAL /
ENVIRONMENTAL FACTORS

Air (countryside)
Fresh water / under water
Polluted air (industrial zone)
Sea water / salt water
Chemicals (e.g. chloride)
Combinations

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02
KEY FIGURES FOR LIFETIME

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INTERNAL → PRODUCT
PROPERTIES

type of coating, Zinc (Zn100)

type of coating, Geobrugg SUPERCOATING (Zn95/Al05)
type of coating, Geobrugg ULTRACOATING (Zn95/Al4.5+
additive0.5)
coating mass per area [g/m2] or [μm]
coating thickness rate of degradation as a function of
environment
stainless steel

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03
COMPARISON OF COATINGS

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ZINC COATING (ZN100)

+ anodic coating (active coating)

+ passive and active protection
+ more than 100 years of
experience
+ very cost effective
- adherence problems with thick
coatings
- rough surface after corrosion
attack
- wears out very quickly in an
aggressive environment

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ALUMINIUM (AL100)

- Cathodic coating (passive coating)

- Only passive protection
+ Very smooth surface compared to
Zinc
Al Al
+ Good adherence
+ Improved corrosion resistance
- Very high production costs

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GEOBRUGG SUPERCOATING
95% ZINC / 5% ALUMINIUM
Combining the advantages of Zinc and Aluminium

Aluminium: Zn95Al05 Zn95Al05

Smooth and hard surface

good adherence
low corrosion rates
Zinc:
active protection
low costs
Also called Galfan, Bezinal, Crapal etc.
produced with double dip procedure
and end drawn
Why 5 % Alu and 95 % Zinc? % Zn
>> eutectic structure
% Al
(most homogenous Al-Zn alloy)

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COMPARISON ZN95/AL05 WITH
ZN100

Zn95/Al05 coated wire

150 g/m2

Zinc coated wire

200 g/m2

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COMPARISON ZN95/AL05 WITH
ZN100
Provides 3 - 4 times longer corrosion protection compared to
Zinc coated wires

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COMPARISON ZN95/AL05 WITH ZN100

e.g. marine
environment
(estimation)

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TECCO® AND SPIDER®

Compared to wire rope nets

The bigger the wire diameter…

→ the better the corrosion protection due to thicker coating!
→ the longer the lifetime!
→ the more resistance against shearing!

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IMPROVED CORROSION
PROTECTION
Wire rope clips

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IMPROVED CORROSION
PROTECTION
Old standard
electro galvanized:
Coating thickness: 6 – 8 µm
EN 13411-5 Type 1
Improved new standard
hot dip galvanized:
Coating thickness: > 53 µm
FF-C-450 Type 1 Class 1
(similar EN 13411-5 Type 2)
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04
THEORETICAL EXPECTED DESIGN LIFE

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Example of
corrosivity
categories
(EN ISO
14713-1)

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THEORETICAL EXPECTED
DESIGN LIFE

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05
SOLUTIONS FOR AGGRESSIVE
ENVIRONMENT

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PLASTIC COATINGS

Reduced lifetime when the plastic gets damaged during manufacturing, transportation
and installation. This is also stated like this in the CIRIA guideline C637 for soil nailing:

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PLASTIC COATINGS

Reduced lifetime when the plastic gets damaged during manufacturing, transportation
and installation. This is also stated like this in the CIRIA guideline C637 for soil nailing:

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SOLUTION FOR AGGRESSIVE
ENVIRONMENT: TECCO® STAINLESS
TECCO® G65/3 stainless steel

Available in sea water resistance quality 1.4462 ( AISI 318)

Tensile strength: min. 1’650 N/mm2

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SOLUTION FOR AGGRESSIVE
ENVIRONMENT: TECCO® STAINLESS
TECCO® SYSTEM3 - these parts are available in stainless:

• Wire rope diameter 12 mm

• Wire rope clip NG12
• Spike Plate P33/40 N
• Spike Plate P33/50 N
• Press claw Type 1
• Press claw Type 2

Spike plate in quality 1.4404

(AISI 316L), all other parts in
quality 1.4401 (AISI 316)
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SOLUTION FOR AGGRESSIVE
ENVIRONMENT: TECCO® STAINLESS
Soil Nails

Nails in stainless steel

quality are available.
Self drilling nails Titan 30/11
and 40/16 in quality 1.4462
Dywidag (Gewi) bars
diameters 20, 25, 28 and 32
mm, quality 1.4301 (304)
and 1.4436 (316)
Fibreglas nails

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SOLUTION FOR AGGRESSIVE
ENVIRONMENT: TECCO® STAINLESS
Isolators

To separate stainless steel

material from the zinc
coated steel.
Isolation of the nail from the
mesh and plate
Two sizes in black PA6
available

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SOLUTION FOR AGGRESSIVE
ENVIRONMENT: TECCO® STAINLESS
Available Documents

Data sheet G65/3

System Drawing
Appendix to manual

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SOLUTION FOR AGGRESSIVE
ENVIRONMENT: TECCO® STAINLESS
RUVOLUM® Calculation: TECCO® STAINLESS can be chosen!

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REFERENCE: PARTON BACK OF
ROCKS (UK)
Installed in 2009

TECCO® SYSTEM3 G65/3, nails, spike plates and press claws in

stainless steel 1.4401 (AISI 316)
Inspection done 29.07.2014
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REFERENCE: GOREHAMS CAVE,
GIBRALTAR (UK)
Installed spring 2015

TECCO® SYSTEM3 G65/3 in stainless steel 1.4462 (AISI 318)

all other parts in stainless steel 1.4401 (AISI 316)

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REFERENCE: GREAT WESTERN
BEACH (UK)
TECCO® SYSTEM3 G65/3 stainless steel 1.4462 (AISI 318)

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06
CONCLUSION

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THE CORROSION PROTECTION NEEDS TO
BE ADAPTED TO THE ENVIRONMENT.

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 GEOBRUGG SUPERCOATING (ZN95/AL05)
PROVIDES A 3 - 4 TIMES LONGER
CORROSION PROTECTION COMPARED TO
EQUIVALENT ZINC COATINGS.

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 THICKER WIRES ASSURE MORE COATING
THICKNESS AND THUS A LONGER LIFETIME
COMPARED TO THIN WIRES.

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STAINLESS STEEL IS AVAILABLE.

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 STAINLESS STEEL PROVIDES THE BEST
AVAILABLE CORROSION PROTECTION WITH
ABOUT 30% HIGHER PRICES FOR THE
TECCO SYSTEM.

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