WHAT IS INNOGALTM ?
- INNO vative GAL vanizing - wide range of value added wire byproducts
- Alloy of Zinc-Aluminum at 95% Zn and 5% AI
- Presence of aluminum in the INNOGALTM coating leads to an adherent aluminum oxide layer formed on the surface
- This protective aluminum oxide layer slow down the active reaction of the zinc in the alloy and increases the life of INNOGALTM considerably
- Additional corrosion protection by the Fe/Zn/Al layer (formed on the steel when aluminum diffuses into steel) after Zn/Al is fully corroded
Aluminum Zinc
(Zinc 95%/ Aluminum 5%)
Steel Wire
DOUBLE DIPPING PROCESS
- Properly annealed, cleaned and fluxed steel acquires a galvanized coating in the first bath
- Transforms into aluminum-iron-zinc in second molten INNOGALTM bath to achieve coating composed of 95% zinc and 5% aluminum eutectic alloy
THE SPECIFICATIONS
BS EN 10244 - 2 : 2009
Steel wire and wire products
Non-ferrous metallic coatings on steel wire
ADVANTAGES OF THE PROCESS
- Corrosion resistance up to FOUR times that of galvanized wire
- Can be extensively redrawn and subjected to severe wire forming operations (Superior ductility)
- A cost effective alternative to higher prices anti-corrosion materials and coating
- Environmental friendly
- 14 dedicated INNOGALTM lines to meet volume demands and fluctuating requirements
Illustration of
Zinc galvanized and INNOGALTM wire coating
- Zinc galvanized wire is formed by Fe + Zn layer and an outer layer of pure Zinc.
- INNOGALTM is formed by a layer of Fe+Al+Zn acting as sacrificial coating.
- Outer layer composed of fine, alternating layers consist of Zn and Al in the form of lamellae.
Corrosion of Welding Points
Zinc Galvanized Steel Wire
ZnO
Fe
Zn
FeZn
- Welding points are exposed to the air as the coating is melted during the welding process
- As a result red rust appear
Fe
Al2O3
Zn95 + Al5
FeAl3
- With the layer of sacrificial protection or cathodic protection (FeAl3 ), welding points are protected from rusting.
Test Comparing Regular Galvanized Fence
with INNOGALTM Welded Fence
Regular Galvanized
543
265
Coating Weight, g/m²
Salt Spray Test (NaCl): Number of hours to 5% red rust
360
768
Hours per g/m²
0.66
2.9
KESTERNICH Test (SO2): Number of cycles to 5% red rust
15
24
Cycles per g/m²
0.027
0.09
Pre-galvanized Welded Fence vs
Hot dip galvanized Welded Fence
Manufactured by advanced fully automated machine
Consistent coating mass
Less handling
Cost effective
Achieved better results in NaCl and SO2 test
Shorter lead time
Hot Dip Galvanizing
Mesh deliver to outsourced hot dip galvanizer
Inconsistent coating mass
More handling
Costly
Did not perform well in NaCl and SO2 test
Longer lead time