SEBGL - ST4
GUIDELINES
ON
LONG FIRST MAINTENANCE PERIOD
CORROSION PROTECTION SYSTEMS
FOR STRUCTURAL STEELWORK
A COST COMPARISON
Structural Engineering Branch, ArchSD
Guidelines on Long First Maintenance Period Corrosion
Protection Systems
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STRUCTURAL ENGINEERING BRANCH
ARCHITECTURAL SERVICES DEPARTMENT
January 2009 (Revised)
Structural Engineering Branch, ArchSD
Guidelines on Long First Maintenance Period Corrosion
Protection Systems
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Content
Content Page
1.
Introduction .
2.
Classification of Environment ... 3
3.
Life of Coating . 4
4.
Choices for Long First Maintenance Systems .. 5
5.
Cost Comparison between Type C or D painting System and Hot-Dip Galvanizing
Systems (including Type F Painting System)
6.
Recommendation .10
7.
References 11
Appendix Detailed Cost Comparison for Steel Sections of Blast-Cleaning Followed by
Type C or D Painting System and Hot-Dip Galvanizing Followed by Type F
Painting System
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Protection Systems
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1.
Introduction
The protection of structural steelwork against corrosion can be achieved by many
methods.
The selection of a protective system, however, involves qualitative
judgement on the relative importance of many factors that can vary widely according
to the type of structure, its function, its general location, its immediate environment,
and the required life to first maintenance. Cost, needless to say, also plays an
important part in the selection. BS EN ISO 12944 and BS EN ISO 14713 (partially
superseding BS 5493: 1977) has provided guidelines on the choices. The ArchSD
General Specification for Building 2007 (the G.SS. for Building (2007)) Table 15.7
also suggests some systems for selection. In the selection of a protective system, the
specifier should consider the environments of the steel structure and the
durability required of the painting system for the first major maintenance of the
painting.
2.
Classification of Environment
According to BS EN ISO 12944-2, atmospheric environments are classified as six
atmospheric-corrosivity categories (Table 1):
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Guidelines on Long First Maintenance Period Corrosion
Protection Systems
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Table 1 Classification of Corrosivity Category
Corrosivity
Degree of
category
corrosivity
Examples of typical environments
Exterior
Interior
Heated buildings with
C1
C2
C3
C4
C5-I
C5-M
very low
low
medium
high
very high
(industrial)
----
clean atmosphere, e.g.
Atmospheres with low
offices, schools
Unheated buildings where
level of pollution.
condensation may occur,
Mostly rural areas
Urban and industrial
e.g. depots, sports halls
Production rooms with
atmospheres, moderate
high humidity and some
sulfur dioxide
air pollution, e.g. food-
pollution. Coastal areas
processing plants,
with low salinity
Industrial areas and
laundries
Chemical plants,
coastal areas with
swimming pools, coastal
moderate salinity
ship and boatyards
Buildings or areas with
Industrial areas with
high humidity and
aggressive atmosphere
almost permanent
condensation and with
high pollution
Buildings or areas with
very high
Coastal and offshore
almost permanent
(marine)
areas with high salinity
condensation and with
high pollution
(Source: Adapted from BS EN ISO12944 2 and BS EN ISO 14713)
3.
Life of Coating
According to BS EN ISO 12944 and BS EN ISO 14713ISO 12944, the life or
durability of coating is considered as the time which can elapse before the first
major or general maintenance of the coating becomes necessary, or is more
commonly known as the Life to First Maintenance. Experience shows that Type A
painting to Table 15.7 of the G.S. for Building (2007), the life of the painting can
achieve about 2 to 3 years in the environment of Hong Kong, whereas it will be about
5 years for Type B painting.
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Protection Systems
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For Type C, D painting systems to Table 15.7 of the for Building (2007) and hot-dip
galvanizing without painting system, Type C, D painting systems and hot-dip
galvanizing with or without painting (Type F) are expected to have a long period of
first maintenance period for about 10 to 15 years even for C3 or C4 environment in
Hong Kong.Corus (2004) predicted the Life to First Maintenance based on their own
practical experience and the corrosion rates given in BS EN ISO 12944 and BS EN
ISO 14713, and their prediction is shown in Table 2:
Table 2 Anticipated Life of First Maintenance
with Different Corrosion Protection Systems
Corrosion Protection Systems
Type C Painting System
Type D Painting System
Hot-dip
galvanizing
Corrosivity category
C3
C4
C3
C4
(min C3
Life to First Maintenance
20 years
15 years
25 years
15-20 years
40 years
85m) without painting
C4
30 years
system
( BS EN ISO 1461 specifies the standard hot-dip galvanized coating to be 85m
for steel 6mm thick or more, and that thinner steel has thinner coatings.)
However, it is considered that the prediction by Corus (2004) is generally on the
high side, and our experience notes that Type C, D painting systems and hot-dip
galvanizing with or without Type F painting system are expected to have a first
maintenance period for about 10 to 15 years for C3 or C4 environment in Hong Kong.
According to BS EN ISO 12944 and BS EN ISO 14713, the life or durability of
coating is considered as the time which can elapse before the first major or general
maintenance of the coating becomes necessary, or is more commonly known as the
Life to First Maintenance. Experience shows that Type A painting to Table 15.7 of
the GS for Building (2007), the life of the painting can achieve about 2 to 3 years in
the environment of Hong Kong, whereas it will be about 5 years for Type B painting.
And our experience notes that Type C, D painting systems and hot-dip galvanizing
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Protection Systems
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with or without Type F painting system are expected to have a first maintenance
period for about 15 years for C3 or C4 environment in Hong Kong.
4.
Choices for Long First Maintenance Systems
4.1
For the Long First Maintenance Systems (i.e. 10-about 15 years), if in accordance
with the G.S. for Building (2007), the choice in effect is between blast-cleaning
followed by Type C (or D) painting systems and hot-dip galvanizing (with or
withoutor Type F orand G painting systems). The factors that have to be taken into
account for a choice include :-
4.2
(a)
cCost.
(b)
eEaste of control for quality.
(c)
pPerformance.
From experience of the past ArchSD projects, the hot-dip galvanizing is generally
easier to be used as long as the galvanizer is a well-established one; the difficult areas
are only at fasteners and welded joints. Though hot-dip galvanized bolts and nuts are
now readily available in Hong Kong, electro-plated fasteners are sometimes
mistakenly used. It should be noted that electroplated bolts can corrode quickly within
a few years. Therefore, hot-dip galvanized fasteners should always be used for long
first maintenance protective system. PSE should brief the site staff to check the
fasteners delivered to site.
4.3
Type C or D painting systems in Table 15.7 of the GS for Building (2007) are in line
with the painting systems A3.11, A4.14 or A4.15 of BS EN ISO 12944, which can
achieve 10 toabout 15 years first maintenance period for C3 or C4 environment.
These systems are also in line with recommendation of the superseded BS 5493 in
that systems SK3 and SL6 were suggested to provide for exterior exposed polluted
inland.
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Guidelines on Long First Maintenance Period Corrosion
Protection Systems
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4.4
However, Type C (or D) painting systems, since it requires labour for blast cleaning
and painting, demands more supervision and more control on workmanship. Further
discussion on the choice of the corrosion protection system for different first
maintenance can be found in SEB Guidelines ST3: Notes on Protective Coating of
Steel Structures Against Corrosion.
4.5
The following sectionparagraph will compare the cost between blast-cleaning
followed by Type C or to D painting systems and hot-dip galvanizing (with or
withoutincluding Type F painting system).
5.
Cost Comparison between Type C toor D Painting Systems and Hot-Dip
Galvanizing Systems (including Type F Painting System)
5.1
In 1994, this set of Guidelines was first issued to compare the cost of providing
corrosion protection between the then Type C painting system (now Type C and D
painting systems) and hot-dip galvanizing (including Type F painting system). At
that time, extensive surveys of the paint manufacturers and/or suppliers had been
conducted to obtain the then market price for the above corrosion protection systems.
It was found that the cost blast-cleaning followed by Types C or D painting system
was $120/m2, whilst the cost of galvanizing was $4/kg plus the cost of Type F
painting system at $32/m2. With such data, the Guidelines in 1994 concluded that
hot-dip galvanizing (including Type F painting system) became more cost-effective
solution for steel sections with surface area greater than 33m2 per tonne.
5.1
Painting Systems
Type C to D painting systems in Table 15.7 of the G.S. for Building (2007) are in line
with the painting systems A3.11, A4.14 or A4.15 of BS EN ISO 12944, which can
achieve 10 to 15 years first maintenance period for C3 or C4 environment. These
systems are also in line with recommendation of partially superseded BS 5493 in
that systems SK3 and SL6 were suggested to provide for exterior exposed polluted
inland.
5.22
Unit Cost of Painting
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Protection Systems
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In 1994, this Guidelines was first issued to compare the cost of providing corrosion
protection between the then Type C painting system (now Type C to D painting
systems) and hot-dip galvanizing (including Type F painting system). At that time,
extensive surveys of the paint manufacturers and/or suppliers had been conducted to
obtain the then market price for the above corrosion protection systems. It was found
that the cost of Types C to D painting system was $120/m2, whilst the cost of
galvanizing was $4/kg plus the cost of Type F painting system at $32/m2. With such
data, the Guidelines in 1994 concluded that hot-dip galvanizing (including Type F
painting system became more cost-effective solution for steel sections with surface
area greater than 33m2 per tonne.
5.2.2 For the purpose of this revision, this Guidelinesset of Guidelines has conducted
another survey in November 2008 on the current market price for the above items.
Four suppliers and/or contractors have been consulted, and the current prices for
blast-cleaning followed by Type C or D painting system are as follows:
Grit blasting to Sa 2
$36.5/m
Cost of paint (including wastage)
$84.0/m
Labour
$35.0/m
Allow for 15% profit
$14.5/m
___________
Total $170/m
5.33
Cost of Hot-Dip Galvanizing
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Protection Systems
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The market price for hot-dip galvanizing to BS EN ISO 1461 is $3.0/kg
($3000/tonne).
5.44
Cost of Painting to Galvanized Steel
Type F painting system surface involves applying British Rail T-Wash to the
galvanized surface followed by two coats of finishing paint with a dry film thickness
of 80 m. The market price of such painting system is:
Cost :
T-Wash + Painting
$38.5/m
Labour
$35.0/m
Profit
$6.5/m
___________
Total $80/m
5.55
Comparison of Cost of Protection for Long Life
5.5.1 The cost of comparison between blast-cleaning followed by Type C orto D painting
systems and hot-dip galvanizing (including Type F painting system) is attached in
Appendix. The results are summarised in Figures 1.
Surface Area = 18
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Protection Systems
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Figure 1 Cost Comparison between Painting and
Hot-Dip Galvanizing
5.5.2 Figures 1 shows that the cost of protection differs depending on the surface area per
unit tonne of section. For heavy section, i.e. less surface areas per tonne, less painting
will be required thus the painting cost is less. On the other handHowever, , the cost
of galvanizing is relatively constant irrespective the less surface area.
Two break-even points can therefore be found at surface area of 18m/tonne and 33
m/tonne. The two breakeven points indicate that:
(i)
for section where the surface area is more than 18 m/tonne, blastcleaning followed by Type C or D painting system is more cost
effective than hot-dip galvanizing (without any painting system); and
(ii)
for section where the surface area is more than 33 m/tonne, It is found
that blast-cleaning followed by Type C or D painting system is more
cost effective than hot-dip galvanizing (including Type F painting
system). in general except for light section where the surface area is
more than 33 m/tonne.
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Protection Systems
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5.5.3 The following examples for UC, UB, channel, angle, CHS, SHS and RHS are chosen
for comparison. They have been chosen as representatives for light-, medium- and
heavy-weight members of ..each section.
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Protection Systems
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For example :Area (m)/tonne)
Painting-
Galvanizing Gal+
Painting
-
Gal. +
/Tonne
ing
nize
UC
($ Per tonne of Section)
152 x 152 x 37 kg/m
24.70
4199
3000
4976
254x254x89 kg/m
16.90
2873
3000
4352
305x305x158 kg/m
11.60
1972
3000
3928
Pating
UB
($ Per tonne of Section)
203 x 133 x 3025 kg/m
36.400.80
61885236
3000
5912464
356 x 127 x 39 kg/m
30.20
5134
3000
5416
457 x 152 x 82 kg/m
18.40
3128
3000
4472
152 x 152 x 37 kg/m
24.70
4199
3000
4976
254x254x89 kg/m
16.90
2873
3000
4352
305x305x158 kg/m
11.60
1972
3000
3928
102 x 51 x 10.42 kg/m
36.30
6171
3000
5904
127 x 64 x 14.90 kg/m
32.00
5440
3000
5760
152 x 89 x 23.84 kg/m
26.00
4420
3000
5080
65 x 65 x 4 mm
67.36
11451
3000
8389
1200 x 1200 x 108 mm
34.3627.62
58414695
3000
57845209
225 x 225 x 15 mm
18.15
3085
3000
4452
UC
Channels
Angles
CHS
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26.9x3.2mm
88.9x3.2 mm 32.40
35.5
5508
6035
3000
3000
5592
5840
88.9x3.2 mm
193.7x5.0 mm 20.6
32.40
3502
5508
3000
3000
4648
5592
12.8
2176
3000
4024
90x90x3.6kg/m
36.30
6171
3000
5904
140x140x5.0 kg/m
26.00
4420
3000
5080
300x300x6.3 kg/m
20.40
3468
3000
4632
100x50x3.0mm
43.50
7395
3000
6480
200x100x5.0 mm
26.00
4420
3000
5080
450x250x8.0mm
16.20
2754
3000
4296
457x8.0mm
SHS
RHS
6.
Recommendations
6.1
For 10-about 115 years first maintenance period, it is recommended that :-
Use hot-dip galvanize if surface area 18m per tonne of Section.
(a).
If no painting to the finished galvanized surfaces is required and
without too much touch up to welded areas is required, use hot-dip galvanizing
if surface area 18m per tonne of section.
(b). If aesthetic is an important consideration and that painting is required, use Type
C or D painting system if surface area Use blast-cleaning followed by Type C
painting or equivalent if surface area < 33 m per tonne of sSection, and
hot-dip galvanizing +followed by Type F painting system when surface area >
33 m per tonne of section.
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Protection Systems
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If no painting to the finished galvanized surfaces is required, use hot-dip
galvanizing if surface area 18m per tonne of section.
6.2
With this rule, most structural framework using universal beams and columns is to be
protected by painting, and hot-dip galvanizing is for lightweight framework or lattice
girders assembled by angles or channels or where additional painting is not required
to the finished galvanized surfaces. For longer period of protection (e.g. 20 years or
more), hot-dip galvanizing to more than 140 micron or sprayed zinc will be required;
on this BS EN ISO 12944 and BS EN ISO 14713 provides more information.
6.3
However, the above rule is not rigid and consideration should be given to the
particular situation of each project, e.g. type of structure, function, general and
immediate environment and the staff requirement for supervision.
In the earlier section, it has been stated that the hot-dip galvanizing is generally
easier to be used as long as the galvanizer is a well-established one; the difficult areas
are only at fasteners and welded joints. Hence, if the cost of hot-dip galvanizing is
marginally (say 10%) higher than the cost of blast-cleaning followed by Type C or D
panting system, PSE may prefer to choose hot-dip galvanizing instead. PSE should
also make judgement on the combination of the sections used with different m2/tonne,
eg. in the case of trusses with combination of I-beams, angles and channels.
7.
References
British Standard Institution (1977), Code of Practice for Protective Coating of Iron
and Steel Structures Against Corrosion (London: BSI).
British Standard Institution (1998), BS EN ISO 12944-1: Paints and Varnishes Corrosion Protection of Steel Structures by Protective Paint Systems - Part 1: Part 1:
General Introduction (London:, BSI).
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Protection Systems
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British Standard Institution (1998), BS EN ISO 12944-2: Paints and Varnishes Corrosion Protection of Steel Structures by Protective Paint Systems - Part 2:
Classification of Environments (London:, BSI).
British Standard Institution (1998), BS EN ISO 12944-3: Paints and Varnishes Corrosion Protection of Steel Structures by Protective Paint Systems - Part 3: Design
Considerations (London:, BSI).
British Standard Institution (1998), BS EN ISO 12944-4: Paints and Varnishes Corrosion Protection of Steel Structures by Protective Paint Systems - Part 4: Types
of Surface and Surface Preparation (London:, BSI).
British Standard Institution (2007), BS EN ISO 12944-5: Paints and Varnishes Corrosion Protection of Steel Structures by Protective Paint Systems - Part 5:
Protective Paint Systems (London:, BSI).
British Standard Institution (1998), BS EN ISO 12944-6: Paints and Varnishes Corrosion Protection of Steel Structures by Protective Paint Systems - Part 6:
Laboratory Performance Test Methods (London:, BSI).
British Standard Institution (1998), BS EN ISO 12944-7: Paints and Varnishes Corrosion Protection of Steel Structures by Protective Paint Systems - Part 7:
Execution and Supervision of Paintwork (London:, BSI).
British Standard Institution (1998), BS EN ISO 12944-8: Paints and Varnishes Corrosion Protection of Steel Structures by Protective Paint Systems - Part 8:
Development of Specifications for New Work and Maintenance (London:, BSI).
British Standard Institution (1999), BS EN ISO 1461: Hot Dip Galvanized Coatings
on Fabricated Iron and Steel Articles Specification (London: BSI).
Corus (2004), A Corrosion Protection Guide for Steelwork Exposed to Atmospheric
Environments (Scunthorpe: Corus Construction & Industrial) (Available:
http://www.corusconstruction.com, Accessed: 2 January 2009).
British Standard Institution (1999), BS EN ISO 14713: Protection Against Corrosion
of Iron and Steel in Structures Zinc and Aluminium Coatings - Guidelines (London:
BSI).
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Appendix
Detailed Cost Comparison for Steel Sections of Blast-Cleaning Followed by Type C
or D Painting System and Hot-Dip Galvanizing Followed by Type F Painting System
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UC
Section
mm
356
634
356
551
356
467
356
393
356
340
356
287
356
235
356
202
356
177
356
153
356
129
305
283
305
240
305
198
305
158
305
137
305
118
305
97
254
167
254
132
254
107
254
89
254
73
203
86
203
71
203
60
203
52
203
46
152
37
152
30
152
23
x 406 x
x 406 x
x 406 x
x 406 x
x 406 x
x 406 x
x 406 x
x 368 x
x 368 x
x 368 x
x 368 x
x 305 x
x 305 x
x 305 x
x 305 x
x 305 x
x 305 x
x 305 x
x 254 x
x 254 x
x 254 x
x 254 x
x 254 x
x 203 x
x 203 x
x 203 x
x 203 x
x 203 x
x 152 x
x 152 x
x 152 x
Notes:
Surface
Area /tonne
(m2 /ton)
Cost Comparison of Different Protection ($ / ton of section)
Painting
Galvanize only
Gal+Painting
3.98
HK$676.60
HK$3,000.0
HK$3,318.40
4.49
HK$763.30
HK$3,000.0
HK$3,359.20
5.19
HK$882.30
HK$3,000.0
HK$3,415.20
6.05
HK$1,028.50
HK$3,000.0
HK$3,484.00
6.90
HK$1,173.00
HK$3,000.0
HK$3,552.00
8.05
HK$1,368.50
HK$3,000.0
HK$3,644.00
9.69
HK$1,647.30
HK$3,000.0
HK$3,775.20
10.80
HK$1,836.00
HK$3,000.0
HK$3,864.00
12.30
HK$2,091.00
HK$3,000.0
HK$3,984.00
14.10
HK$2,397.00
HK$3,000.0
HK$4,128.00
16.60
HK$2,822.00
HK$3,000.0
HK$4,328.00
6.86
HK$1,166.20
HK$3,000.0
HK$3,548.80
7.94
HK$1,349.80
HK$3,000.0
HK$3,635.20
9.46
HK$1,608.20
HK$3,000.0
HK$3,756.80
11.60
HK$1,972.00
HK$3,000.0
HK$3,928.00
13.30
HK$2,261.00
HK$3,000.0
HK$4,064.00
15.30
HK$2,601.00
HK$3,000.0
HK$4,224.00
18.50
HK$3,145.00
HK$3,000.0
HK$4,480.00
9.45
HK$1,606.50
HK$3,000.0
HK$3,756.00
11.70
HK$1,989.00
HK$3,000.0
HK$3,936.00
14.20
HK$2,414.00
HK$3,000.0
HK$4,136.00
16.90
HK$2,873.00
HK$3,000.0
HK$4,352.00
20.40
HK$3,468.00
HK$3,000.0
HK$4,632.00
14.40
HK$2,448.00
HK$3,000.0
HK$4,152.00
17.20
HK$2,924.00
HK$3,000.0
HK$4,376.00
20.10
HK$3,417.00
HK$3,000.0
HK$4,608.00
23.00
HK$3,910.00
HK$3,000.0
HK$4,840.00
25.80
HK$4,386.00
HK$3,000.0
HK$5,064.00
24.70
HK$4,199.00
HK$3,000.0
HK$4,976.00
30.00
HK$5,100.00
HK$3,000.0
HK$5,400.00
38.70
HK$6,579.00
HK$3,000.0
HK$6,096.00
HK$1,077.07
HK$2,286.50
HK$2,014.74
HK$2,470.10
HK$3,417.00
HK$5,292.67
HK$3,506.86
HK$4,076.00
HK$3,948.11
HK$4,162.40
HK$4,608.00
HK$5,490.67
Cost of blast-cleaning followed by Type C or D painting system is always less than 110% of the cost
of hot-dip galvanizing followed by Type F painting system,..
Structural Engineering Branch, ArchSD
Guidelines on Long First Maintenance Period Corrosion
Protection Systems
Issue No./Revision No. : 1/1
Page 19 of 28 19 - 19 -Page
19 of 28
File code : ST-4.doc
CTW/MKL/IL/
Issue/Revision Date : January 2009
Structural Engineering Branch, ArchSD
Guidelines on Long First Maintenance Period Corrosion
Protection Systems
Issue No./Revision No. : 1/1
Page 20 of 28 19 - 20 -Page
20 of 28
File code : ST-4.doc
CTW/MKL/IL/
Issue/Revision Date : January 2009
UB
Section
mm
914
388
914
343
914
289
914
253
914
224
914
201
838
226
838
194
838
176
762
197
762
173
762
147
762
134
686
170
686
152
686
140
686
125
610
238
610
179
610
149
610
140
610
125
610
113
610
101
533
122
533
109
533
101
533
92
533
82
457
98
457
89
457
82
457
74
x 419 x
x 419 x
x 305 x
x 305 x
x 305 x
x 305 x
x 292 x
x 292 x
x 292 x
x 267 x
x 267 x
x 267 x
x 267 x
x 254 x
x 254 x
x 254 x
x 254 x
x 305 x
x 305 x
x 305 x
x 229 x
x 229 x
x 229 x
x 229 x
x 210 x
x 210 x
x 210 x
x 210 x
x 210 x
x 191 x
x 191 x
x 191 x
x 191 x
Surface
Area /tonne
(m2 /ton)
Cost Comparison of Different Protection ($ / ton of section)
Painting
Galvanize only
Gal+Painting
8.87
HK$1,507.90
HK$3,000.0
HK$3,709.60
9.95
HK$1,691.50
HK$3,000.0
HK$3,796.00
10.40
HK$1,768.00
HK$3,000.0
HK$3,832.00
11.80
HK$2,006.00
HK$3,000.0
HK$3,944.00
13.30
HK$2,261.00
HK$3,000.0
HK$4,064.00
14.70
HK$2,499.00
HK$3,000.0
HK$4,176.00
12.40
HK$2,108.00
HK$3,000.0
HK$3,992.00
14.40
HK$2,448.00
HK$3,000.0
HK$4,152.00
15.80
HK$2,686.00
HK$3,000.0
HK$4,264.00
13.00
HK$2,210.00
HK$3,000.0
HK$4,040.00
14.60
HK$2,482.00
HK$3,000.0
HK$4,168.00
17.10
HK$2,907.00
HK$3,000.0
HK$4,368.00
18.70
HK$3,179.00
HK$3,000.0
HK$4,496.00
13.80
HK$2,346.00
HK$3,000.0
HK$4,104.00
15.40
HK$2,618.00
HK$3,000.0
HK$4,232.00
16.60
HK$2,822.00
HK$3,000.0
HK$4,328.00
18.50
HK$3,145.00
HK$3,000.0
HK$4,480.00
10.30
HK$1,751.00
HK$3,000.0
HK$3,824.00
13.50
HK$2,295.00
HK$3,000.0
HK$4,080.00
16.00
HK$2,720.00
HK$3,000.0
HK$4,280.00
15.10
HK$2,567.00
HK$3,000.0
HK$4,208.00
16.70
HK$2,839.00
HK$3,000.0
HK$4,336.00
18.40
HK$3,128.00
HK$3,000.0
HK$4,472.00
20.50
HK$3,485.00
HK$3,000.0
HK$4,640.00
15.50
HK$2,635.00
HK$3,000.0
HK$4,240.00
17.20
HK$2,924.00
HK$3,000.0
HK$4,376.00
18.50
HK$3,145.00
HK$3,000.0
HK$4,480.00
20.20
HK$3,434.00
HK$3,000.0
HK$4,616.00
22.50
HK$3,825.00
HK$3,000.0
HK$4,800.00
16.90
HK$2,873.00
HK$3,000.0
HK$4,352.00
18.50
HK$3,145.00
HK$3,000.0
HK$4,480.00
20.10
HK$3,417.00
HK$3,000.0
HK$4,608.00
22.10
HK$3,757.00
HK$3,000.0
HK$4,768.00
Structural Engineering Branch, ArchSD
Guidelines on Long First Maintenance Period Corrosion
Protection Systems
Issue No./Revision No. : 1/1
HK$1,955.57
HK$2,414.00
HK$2,694.50
HK$2,732.75
HK$2,255.33
HK$3,004.75
HK$3,192.60
HK$3,464.60
Page 21 of 28 19 - 21 -Page
21 of 28
HK$3,920.27
HK$4,136.00
HK$4,268.00
HK$4,286.00
HK$4,061.33
HK$4,414.00
HK$4,502.40
HK$4,630.40
File code : ST-4.doc
CTW/MKL/IL/
Issue/Revision Date : January 2009
457
67
457
82
457
74
457
67
457
60
457
52
x 191 x
x 152 x
x 152 x
x 152 x
x 152 x
x 152 x
24.30
HK$4,131.00
HK$3,000.0
HK$4,944.00
18.40
HK$3,128.00
HK$3,000.0
HK$4,472.00
20.30
HK$3,451.00
HK$3,000.0
HK$4,624.00
22.30
HK$3,791.00
HK$3,000.0
HK$4,784.00
24.90
HK$4,233.00
HK$3,000.0
HK$4,992.00
28.20
HK$4,794.00
HK$3,000.0
HK$5,256.00
Cost of painting
HK$3,879.40
HK$4,825.60
> 110% of Cost of gal + painting
Structural Engineering Branch, ArchSD
Guidelines on Long First Maintenance Period Corrosion
Protection Systems
Issue No./Revision No. : 1/1
Page 22 of 28 19 - 22 -Page
22 of 28
File code : ST-4.doc
CTW/MKL/IL/
Issue/Revision Date : January 2009
UB (contd)
Section
Cost Comparison of Different Protection ($ / ton of section)
(m2 /ton)
mm
406
74
406
67
406
60
406
54
406
46
406
39
356
67
356
57
356
51
356
45
356
39
356
33
305
54
305
46
305
40
305
48
305
42
305
37
305
33
305
28
305
25
254
43
254
37
254
31
254
28
254
25
254
22
203
30
203
25
203
23
178
19
152
Surface
Area /tonne
x 178 x
x 178 x
x 178 x
x 178 x
x 140 x
x 140 x
x 171 x
x 171 x
x 171 x
x 171 x
x 127 x
x 127 x
x 165 x
x 165 x
x 165 x
x 127 x
x 127 x
x 127 x
x 102 x
x 102 x
x 102 x
x 146 x
x 146 x
x 146 x
x 102 x
x 102 x
x 102 x
x 133 x
x 133 x
x 102 x
x 102 x
x 89 x 16
Painting
Galvanize
only
Gal+Painting
20.30
HK$3,451.00
HK$3,000.0
HK$4,624.00
22.30
HK$3,791.00
HK$3,000.0
HK$4,784.00
24.80
HK$4,216.00
HK$4,029.00 HK$3,000.0
27.40
HK$4,658.00
HK$3,000.0
HK$5,192.00
29.20
HK$4,964.00
HK$3,000.0
HK$5,336.00
34.20
HK$5,814.00
HK$5,389.00 HK$3,000.0
20.60
HK$3,502.00
HK$3,000.0
HK$4,648.00
24.10
HK$4,097.00
HK$3,000.0
HK$4,928.00
26.70
HK$4,539.00
HK$4,734.50 HK$3,000.0
30.10
HK$5,117.00
HK$3,000.0
HK$5,408.00
30.20
HK$5,134.00
HK$3,000.0
HK$5,416.00
35.40
HK$6,018.00
HK$3,000.0
HK$5,832.00
23.30
HK$3,961.00
HK$3,000.0
HK$4,864.00
27.10
HK$4,607.00
HK$4,601.33 HK$3,000.0
30.80
HK$5,236.00
HK$3,000.0
HK$5,464.00
22.70
HK$3,859.00
HK$3,000.0
HK$4,816.00
25.80
HK$4,386.00
HK$4,391.67 HK$3,000.0
29.00
HK$4,930.00
HK$3,000.0
HK$5,320.00
30.80
HK$5,236.00
HK$3,000.0
HK$5,464.00
35.40
HK$6,018.00
HK$6,018.00 HK$3,000.0
40.00
HK$6,800.00
HK$3,000.0
HK$6,200.00
25.10
HK$4,267.00
HK$3,000.0
HK$5,008.00
29.00
HK$4,930.00
HK$5,003.67 HK$3,000.0
34.20
HK$5,814.00
HK$3,000.0
HK$5,736.00
31.90
HK$5,423.00
HK$3,000.0
HK$5,552.00
35.60
HK$6,052.00
HK$6,120.00 HK$3,000.0
40.50
HK$6,885.00
HK$3,000.0
HK$6,240.00
30.80
HK$5,236.00
HK$3,000.0
HK$5,464.00
36.40
HK$6,188.00
HK$5,712.00 HK$3,000.0
34.20
HK$5,814.00
HK$3,000.0
HK$5,736.00
38.80
HK$6,596.00
HK$3,000.0
HK$6,104.00
39.80
HK$6,766.00
HK$3,000.0
HK$6,184.00
Structural Engineering Branch, ArchSD
Guidelines on Long First Maintenance Period Corrosion
Protection Systems
Issue No./Revision No. : 1/1
Page 23 of 28 19 - 23 -Page
23 of 28
HK$4,984.00
HK$4,896.00
HK$5,736.00
HK$5,536.00
HK$5,136.00
HK$5,228.00
HK$5,168.00
HK$5,165.33
HK$5,064.00
HK$5,066.67
HK$5,832.00
HK$5,832.00
HK$5,320.00
HK$5,354.67
HK$5,848.00
HK$5,880.00
HK$5,912.00
HK$5,688.00
File code : ST-4.doc
CTW/MKL/IL/
Issue/Revision Date : January 2009
127
203
30
203
25
203
23
178
19
152
127
x 76 x 13
x 133 x
x 133 x
x 102 x
x 102 x
x 89 x 16
x 76 x 13
41.30
HK$7,021.00
HK$3,000.0
HK$6,304.00
30.80
HK$5,236.00
HK$3,000.0
HK$5,464.00
36.40
HK$6,188.00
HK$5,712.00 HK$3,000.0
34.20
HK$5,814.00
HK$3,000.0
HK$5,736.00
38.80
HK$6,596.00
HK$3,000.0
HK$6,104.00
39.80
41.30
HK$6,766.00
HK$7,021.00
HK$3,000.0
HK$3,000.0
HK$6,184.00
HK$6,304.00
Cost of painting
HK$5,912.00
HK$5,688.00
> 110% of Cost of gal + painting
UC
Section
mm
356
634
356
551
356
467
356
393
356
340
356
287
356
235
356
202
356
177
356
153
356
129
305
283
305
240
305
198
305
x 406 x
x 406 x
x 406 x
x 406 x
x 406 x
x 406 x
x 406 x
x 368 x
x 368 x
x 368 x
x 368 x
x 305 x
x 305 x
x 305 x
x 305 x
Surface
Area /tonne
(m2 /ton)
Cost Comparison of Different Protection ($ / ton of section)
Painting
Galvanize only
Gal+Painting
3.98
HK$676.60
HK$3,000.0
HK$3,318.40
4.49
HK$763.30
HK$3,000.0
HK$3,359.20
5.19
HK$882.30
HK$3,000.0
HK$3,415.20
6.05
HK$1,028.50
HK$3,000.0
HK$3,484.00
6.90
HK$1,173.00
HK$3,000.0
HK$3,552.00
8.05
HK$1,368.50
HK$3,000.0
HK$3,644.00
9.69
HK$1,647.30
HK$3,000.0
HK$3,775.20
10.80
HK$1,836.00
HK$3,000.0
HK$3,864.00
12.30
HK$2,091.00
HK$3,000.0
HK$3,984.00
14.10
HK$2,397.00
HK$3,000.0
HK$4,128.00
16.60
HK$2,822.00
HK$3,000.0
HK$4,328.00
6.86
HK$1,166.20
HK$3,000.0
HK$3,548.80
7.94
HK$1,349.80
HK$3,000.0
HK$3,635.20
9.46
HK$1,608.20
HK$3,000.0
HK$3,756.80
11.60
HK$1,972.00
HK$3,000.0
HK$3,928.00
Structural Engineering Branch, ArchSD
Guidelines on Long First Maintenance Period Corrosion
Protection Systems
Issue No./Revision No. : 1/1
HK$1,077.07
HK$2,286.50
HK$2,014.74
Page 24 of 28 19 - 24 -Page
24 of 28
HK$3,506.86
HK$4,076.00
HK$3,948.11
File code : ST-4.doc
CTW/MKL/IL/
Issue/Revision Date : January 2009
158
305
137
305
118
305
97
254
167
254
132
254
107
254
89
254
73
203
86
203
71
203
60
203
52
203
46
152
37
152
30
152
23
x 305 x
x 305 x
x 305 x
x 254 x
x 254 x
x 254 x
x 254 x
x 254 x
x 203 x
x 203 x
x 203 x
x 203 x
x 203 x
x 152 x
x 152 x
x 152 x
13.30
HK$2,261.00
HK$3,000.0
HK$4,064.00
15.30
HK$2,601.00
HK$3,000.0
HK$4,224.00
18.50
HK$3,145.00
HK$3,000.0
HK$4,480.00
9.45
HK$1,606.50
HK$3,000.0
HK$3,756.00
11.70
HK$1,989.00
HK$3,000.0
HK$3,936.00
14.20
HK$2,414.00
HK$3,000.0
HK$4,136.00
16.90
HK$2,873.00
HK$3,000.0
HK$4,352.00
20.40
HK$3,468.00
HK$3,000.0
HK$4,632.00
14.40
HK$2,448.00
HK$3,000.0
HK$4,152.00
17.20
HK$2,924.00
HK$3,000.0
HK$4,376.00
20.10
HK$3,417.00
HK$3,000.0
HK$4,608.00
23.00
HK$3,910.00
HK$3,000.0
HK$4,840.00
25.80
HK$4,386.00
HK$3,000.0
HK$5,064.00
24.70
HK$4,199.00
HK$3,000.0
HK$4,976.00
30.00
HK$5,100.00
HK$3,000.0
HK$5,400.00
38.70
HK$6,579.00
HK$3,000.0
HK$6,096.00
HK$2,470.10
HK$3,417.00
HK$5,292.67
HK$4,162.40
HK$4,608.00
HK$5,490.67
Remarks: Cost of painting is always less than the cost of gal + painting in this case, and therefore use painting
as corrosion protection system for UC sections is recommended.
Structural Engineering Branch, ArchSD
Guidelines on Long First Maintenance Period Corrosion
Protection Systems
Issue No./Revision No. : 1/1
Page 25 of 28 19 - 25 -Page
25 of 28
File code : ST-4.doc
CTW/MKL/IL/
Issue/Revision Date : January 2009
Channel
Surface Area
/tonne
(m2 /ton)
Painting
Galvanize only
Gal+Painting
432x102
18.60
HK$3,162.00
HK$3,000.0
HK$4,488.00
381x102
20.30
HK$3,451.00
HK$3,000.0
HK$4,624.00
305x102
20.90
HK$3,553.00
HK$3,000.0
HK$4,672.00
305x89
22.10
HK$3,757.00
HK$3,000.0
HK$4,768.00
254x89
23.00
HK$3,910.00
HK$3,000.0
HK$4,840.00
254x76
27.40
HK$4,658.00
HK$3,000.0
HK$5,192.00
229x89
23.50
HK$3,995.00
HK$3,000.0
HK$4,880.00
229x76
27.80
HK$4,726.00
HK$3,000.0
HK$5,224.00
203x89
24.20
HK$4,114.00
HK$3,000.0
HK$4,936.00
203x76
28.30
HK$4,811.00
HK$3,000.0
HK$5,264.00
178x89
25.00
HK$4,250.00
HK$3,000.0
HK$5,000.00
178x76
30.00
HK$5,100.00
HK$3,000.0
HK$5,400.00
152x89
26.00
HK$4,420.00
HK$3,000.0
HK$5,080.00
152x76
32.20
HK$5,474.00
HK$3,000.0
HK$5,576.00
127x64
32.00
HK$5,440.00
HK$3,000.0
HK$5,560.00
102x51
36.30
HK$6,171.00
HK$3,000.0
HK$5,904.00
76x38
42.10
HK$7,157.00
HK$3,000.0
HK$6,368.00
Section
mm
Cost Comparison of Different Protection ($ / ton of section)
Angle
Section
mm
400x400x21
350x350x18
300x300x18
240x240x15
225x225x15
200x200x15
165x165x10
120x120x10
115x115x8
100x100x8
90x90x6
80x80x6
65x65x4
60x60x4
50x50x4
Surface Area
/tonne
(m2 /ton)
11.25
14.86
14.06
18.05
18.15
18.26
26.83
27.62
34.07
34.36
45.00
45.45
67.36
67.42
68.97
Cost of painting
Cost Comparison of Different Protection ($ / ton of section)
Painting
HK$1,912.50
HK$2,526.20
HK$2,390.20
HK$3,068.50
HK$3,085.50
HK$3,104.20
HK$4,561.10
HK$4,695.40
HK$5,791.90
HK$5,841.20
HK$7,650.00
HK$7,726.50
HK$11,451.20
HK$11,461.40
HK$11,724.90
Galvanize only
HK$3,000.0
HK$3,000.0
HK$3,000.0
HK$3,000.0
HK$3,000.0
HK$3,000.0
HK$3,000.0
HK$3,000.0
HK$3,000.0
HK$3,000.0
HK$3,000.0
HK$3,000.0
HK$3,000.0
HK$3,000.0
HK$3,000.0
Gal+Painting
HK$3,900.00
HK$4,188.80
HK$4,124.80
HK$4,444.00
HK$4,452.00
HK$4,460.80
HK$5,146.40
HK$5,209.60
HK$5,725.60
HK$5,748.80
HK$6,600.00
HK$6,636.00
HK$8,388.80
HK$8,393.60
HK$8,517.60
> 110% of Cost of gal + painting
Structural Engineering Branch, ArchSD
Guidelines on Long First Maintenance Period Corrosion
Protection Systems
Issue No./Revision No. : 1/1
Page 26 of 28 19 - 26 -Page
26 of 28
File code : ST-4.doc
CTW/MKL/IL/
Issue/Revision Date : January 2009
CHS
Surface
Area /tonne
(m2 /ton)
Section
mm
508x8.0
457.0x8.0
406.4x6.3
323.9x6.3
273.0x5.0
244.5x12
219.1x5.0
193.7x5.0
168.3x5.0
139.7x5.0
114.3x3.2
88.9x3.2
76.1x3.2
60.3x3.2
18.3x3.2
42.4x3.2
26.9x3.2
12.7
12.8
16.2
16.2
20.4
8.76
20.5
20.6
20.6
20.7
32.1
32.4
32.6
32.9
33.6
33.8
35.5
Cost Comparison of Different Protection ($ / ton of section)
Painting
HK$2,159.00
HK$2,176.00
HK$2,754.00
HK$2,754.00
HK$3,468.00
HK$1,489.20
HK$3,485.00
HK$3,502.00
HK$3,502.00
HK$3,519.00
HK$5,457.00
HK$5,508.00
HK$5,542.00
HK$5,593.00
HK$5,712.00
HK$5,746.00
HK$6,035.00
Galvanize only
HK$3,000.0
HK$3,000.0
HK$3,000.0
HK$3,000.0
HK$3,000.0
HK$3,000.0
HK$3,000.0
HK$3,000.0
HK$3,000.0
HK$3,000.0
HK$3,000.0
HK$3,000.0
HK$3,000.0
HK$3,000.0
HK$3,000.0
HK$3,000.0
HK$3,000.0
Gal+Painting
HK$4,016.00
HK$4,024.00
HK$4,296.00
HK$4,296.00
HK$4,632.00
HK$3,700.80
HK$4,640.00
HK$4,648.00
HK$4,648.00
HK$4,656.00
HK$5,568.00
HK$5,592.00
HK$5,608.00
HK$5,632.00
HK$5,688.00
HK$5,704.00
HK$5,840.00
SHS
Surface
Area /tonne
(m2 /ton)
Section
mm
400x400x10.0
350x350x8.0
300x300x6.3
250x250x6.3
200x200x5.0
180x180x6.3
160x160x5.0
150x150x5.0
140x140x5.0
120x120x5.0
100x100x4.0
90x90x3.6
80x80x3.0
70x70x3.0
60x60x3.0
50x50x3.0
40x40x3.0
12.9
16.2
20.4
20.5
25.9
20.7
26
26
26.00
26.20
32.80
36.3
36.5
36.6
43.9
44.1
44.6
Cost of painting
Cost Comparison of Different Protection ($ / ton of section)
Painting
HK$2,193.00
HK$2,754.00
HK$3,468.00
HK$3,485.00
HK$4,403.00
HK$3,519.00
HK$4,420.00
HK$4,420.00
HK$4,420.00
HK$4,454.00
HK$5,576.00
HK$6,171.00
HK$6,205.00
HK$6,222.00
HK$7,463.00
HK$7,497.00
HK$7,582.00
Galvanize only
Gal+Painting
HK$3,000.0
HK$3,000.0
HK$3,000.0
HK$3,000.0
HK$3,000.0
HK$3,000.0
HK$3,000.0
HK$3,000.0
HK$3,000.0
HK$3,000.0
HK$3,000.0
HK$3,000.0
HK$3,000.0
HK$3,000.0
HK$3,000.0
HK$3,000.0
HK$3,000.0
HK$4,032.00
HK$4,296.00
HK$4,632.00
HK$4,640.00
HK$5,072.00
HK$4,656.00
HK$5,080.00
HK$5,080.00
HK$5,080.00
HK$5,096.00
HK$5,624.00
HK$5,904.00
HK$5,920.00
HK$5,928.00
HK$6,512.00
HK$6,528.00
HK$6,568.00
> 110% of Cost of gal + painting
Structural Engineering Branch, ArchSD
Guidelines on Long First Maintenance Period Corrosion
Protection Systems
Issue No./Revision No. : 1/1
Page 27 of 28 19 - 27 -Page
27 of 28
File code : ST-4.doc
CTW/MKL/IL/
Issue/Revision Date : January 2009
RHS
Section
mm
500x300x8.0
450x250x8.0
400x200x8.0
300x200x6.3
300x100x8.0
250x150x5.0
250x100x10
200x150x8.0
200x120x5.0
200x100x5.0
160x80x4.0
150x100x5.0
120x80x5.0
120x60x3.6
100x60x3.6
100x50x3.0
90x50x3.6
80x40x3.2
60x40x3.0
Surface
Area /tonne
(m2 /ton)
16.1
16.2
16.2
20.5
16.3
25.9
13.2
16.4
26
26
32.6
26.2
26.3
36.2
36.5
43.5
41.3
44.1
42.1
Cost of painting
Cost Comparison of Different Protection ($ / ton of section)
Painting
HK$2,737.00
HK$2,754.00
HK$2,754.00
HK$3,485.00
HK$2,771.00
HK$4,403.00
HK$2,244.00
HK$2,788.00
HK$4,420.00
HK$4,420.00
HK$5,542.00
HK$4,454.00
HK$4,471.00
HK$6,154.00
HK$6,205.00
HK$7,395.00
HK$7,021.00
HK$7,497.00
HK$7,157.00
Galvanize only
HK$3,000.0
HK$3,000.0
HK$3,000.0
HK$3,000.0
HK$3,000.0
HK$3,000.0
HK$3,000.0
HK$3,000.0
HK$3,000.0
HK$3,000.0
HK$3,000.0
HK$3,000.0
HK$3,000.0
HK$3,000.0
HK$3,000.0
HK$3,000.0
HK$3,000.0
HK$3,000.0
HK$3,000.0
Gal+Painting
HK$4,288.00
HK$4,296.00
HK$4,296.00
HK$4,640.00
HK$4,304.00
HK$5,072.00
HK$4,056.00
HK$4,312.00
HK$5,080.00
HK$5,080.00
HK$5,608.00
HK$5,096.00
HK$5,104.00
HK$5,896.00
HK$5,920.00
HK$6,480.00
HK$6,304.00
HK$6,528.00
HK$6,368.00
> 110% of Cost of gal + painting
Structural Engineering Branch, ArchSD
Guidelines on Long First Maintenance Period Corrosion
Protection Systems
Issue No./Revision No. : 1/1
Page 28 of 28 19 - 28 -Page
28 of 28
File code : ST-4.doc
CTW/MKL/IL/
Issue/Revision Date : January 2009
