DEPARTMENT OF QUANTITY SURVEYING

FACULTY OF ARCHITECTURE, PLANNING AND SURVEYING

UNIVERSITI TEKNOLOGI MARA PERAK
SEMESTER MARCH - JULY 2023

PROTECTION FOR STEEL STRUCTURES (ALUMINUM COATING)

COURSE CONSTRUCTION TECHNOLOGY IV

COURSE CODE DQS252

SEMESTER 4

DATE OF WEEK 13
SUBMISSION

LECTURER DR.NORHAFIZAH BINTI YUSOP

GROUP MEMBERS AINA NASUHA BINTI NAZARUDIN (2021619214)

AINAA MAISARAH BINTI KARIP (2021616596)
AINA WAFIYAA BINTI ABDUL WAHAB (2021894242)
NURIN FARAH ALIA BINTI MOHD RIZA (2021861142)
NURASYIQIN BINTI AHMAD SUKAMTO (2021631178)
 TABLE OF CONTENT

BIL PARTICULARS PAGE

NUMBERS

1 ACKNOWLEDGEMENT 3

2. REPORT ORGANISATION 4

3. INTRODUCTION 4-5

4. FINDING / DEPTH OF DISCUSSION & FLOW OF IDEAS

1. METHODS OF CONSTRUCTION OR METHODS OF

6 -13
INSTALLATION
2. PURPOSES OF CONSTRUCTION OR INSTALLATION
3. ADVANTAGES OF THE METHOD OR SYSTEM
4. DISADVANTAGES OF THE METHOD OR SYSTEM

5. CONCLUSION 14 - 15

6. REFERENCES 16

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 ACKNOWLEDGEMENT

Alhamdulillah, First and foremost, we would like to thank Allah for allowing us to
complete the assignment given to us by our Construction Technology instructor. Despite
the fact that every member of the group contributed resources, this mission was
accomplished.Minor issues that arose throughout the project's duration.Thankfully, all of
them.We were able to adjust appropriately and prudently due to the fact that the
problems were resolvable.

We would like to thank Madam Norhafizah Bt. Yusop, our lecturer in Technology
Construction, for always teaching and guiding us in comprehending what we needed to
know while studying this subject and producing a quality work project. Without her
guidance, we would not have been able to complete our assignments successfully. She
consistently encouraged and modeled how to complete this assignment so that we could
produce quality research results.

Next, I'd like to thank my teammates who have always worked well together, even
in challenging circumstances, in order to complete a large project using all available
resources and responsibilities. We anticipate that all of these funds will aid us and our
organization's efforts. Many thanks to everyone who contributed to the completion of our
group endeavor. They consistently offer suggestions and feedback on our initiatives,
which enables us to advance. Thank you to the owner of the plan for consenting to be
interviewed in order to assist us in gathering information for this task.

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 REPORT ORGANISATION

This report contains further explanations and information about aluminum coating
protection for steel structure. In order to protect steel constructions from rust, damage
caused by the environment, and any other potential causes of destruction, a coating
must be applied to the steel. One type of coating that can be used is one that is
composed of aluminum. This report started with the introduction of aluminum coating
and will be continued with the construction method of aluminum coating. This report also
includes the purpose of installation and advantages as well as the disadvantages of the
method used to protect the steel structure.

INTRODUCTION

Metal panels keep the inside of a structure safe from rain, wind, and snow. They
also provide a strong, flexible covering for structure that can be used to control
temperature and sound in a variety of ways. But there are limits to every object, and
steel is exposed to rust. Luckily, there are proven methods to protect steel so that it can
keep working at its best for as long as possible.

A coating, such as one made of aluminum, must be applied on steel in order to

protect steel structures from rust, environmental damage, and other potential sources of
destruction. This is known as providing protection for steel structures. The aluminum
coating prevents the steel from rusting when exposed to elements such as air, water, or
chemicals that promote oxidation. This prevents rust from beginning and stops it from
progressing. It provides steel structures with a robust and protective covering, allowing
them to survive longer, better maintain their shape, and function more effectively. This
makes them last longer and reduces the costs associated with their maintenance.
Aluminum coating, when applied to steel surfaces, offers a number of benefits, including
galvanic protection, good resistance to corrosion, and the capacity to heal itself if it
becomes damaged. As a result of these advantages, aluminum coating is an efficient
form of protection that finds widespread application across many types of industries,
including the industrial sector in addition to construction, transportation, and
infrastructure.

Moreover, steel protection is often used in places with a lot of corrosion to make
structures stronger and last longer. Steel can be kept safe in many different ways. A

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usual way to protect steel is to coat it with aluminum. It is better than high-alloy steel
because it is less expensive but has the same durability and power. Aluminized steel has
a small layer of aluminum oxide on the outside, followed by a layer made of aluminum,
silicon, and steel, and then a core of steel. Aluminized steel can be made in a number of
ways, including by cladding, hot dipping, electrolytic coating, metallizing, and calorizing.
Aluminized steel is very resistant to corrosion. At temperatures below 800 °C (1,470 °F),
it still has the same qualities as the basic material.

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 PROTECTION FOR STEEL STRUCTURES (ALUMINIUM COATING)

3.1 METHODS OF CONSTRUCTION OR METHODS OF INSTALLATION

Direct current is transmitted through the electrolytic solution through the

aluminum layer of the anode, with the aluminum item serving as the anode (positive
electrode). By releasing hydrogen on the cathode (negative electrode) and oxygen on
the aluminum anode's surface, the current has contributed to the buildup of aluminum
oxide. Although they are technically possible, pulsed and alternating current are rarely
used. Various solutions can require voltages between 1 to 300 V DC, with the majority
requiring between 15 and 21 V. Higher voltages are frequently needed for thick coatings
made in sulfuric and organic acids. The anodizing current varies according to the
aluminum anode's surface area and commonly falls between 30 and 300 A/m2.

In order to gradually dissolve the aluminum oxide during aluminum anodization

(also known as eloxal or electrolytic oxidation of aluminum), the process is typically
carried out in an acidic solution like sulfuric acid or chromic acid. To create a cap with
nanopores that range in size from 10-150 nm, the acid's activity and the rate of oxidation
are balanced. These openings enable the electrolyte solution and current to reach the
aluminum substrate and increase the coating's thickness past what is achieved through
auto passivation. The pigment can be absorbed via these holes, however in order for the
color to be preserved, a sealer must be applied after. Usually, a fresh nickel acetate
sealer is applied after the color. The underlying oxide can continue to resist corrosion
even in the presence of substantial corrosion since the dye is simply a surface layer.

To enable the production of a constant oxide layer, conditions like electrolyte

content, acidity, solution temperature, and current must be managed. Harder, thicker
films typically result from using more concentrated solutions at lower temperatures with
higher voltages and currents. Film thicknesses can range from as little as 0.5
micrometers for brilliant ornamental work to as much as 150 micrometers for
architectural applications.

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3.2 PURPOSES OF CONSTRUCTION OR INSTALLATION

The methods and supplies employed to protect steel components against a variety
of potential risks and hazards are referred to as protection for steel structures. To
improve the robustness, safety, and functionality of the steel components, coatings,
treatments, or physical barriers must be applied.

There are a lot of purposes in installation of this protection for steel structures.
Firstly is to provide fire protection. Steel is a robust and long-lasting material, but it is
sensitive to high temperatures, which can compromise the strength of its structural
components. As a result, providing fire resistance is one of the main goals of protection
for steel structures. Steel constructions are coated with fire-resistant coatings, sprays, or
insulation to slow the spread of fire and keep the steel from heating up to dangerous
levels.

Other than that, corrosion protection. This is because when steel is exposed to
moisture, chemicals, and environmental factors, it is vulnerable to corrosion. Protective
coatings are used to build a wall between the steel surface and corrosive chemicals,
such as paints, sealants, or galvanization. This aids in extending the steel structure's
useful life and preserving its structural integrity over time. For the impact resistance,
steel constructions could require defense against conceivable impact or collision
situations. In order to guard against damage from vehicle motion, falling items, and other
impacts, protective barriers such as bollards and crash barriers may be installed.

Steel constructions may need to be protected from particular environmental elements

in some areas. For instance, safeguards like windbreaks or wind-resistant design
components may be introduced to maintain the structural stability of the steel elements
in coastal areas or places where there are strong winds. In some cases, Steel buildings
may need to be protected against theft or vandalism. To prevent unauthorized entry or
structural damage, additional security measures might be put in place such as fences,
surveillance cameras, or anti-climbing equipment.

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 For the aesthetic enhancement, Steel structure safety precautions may also be
aesthetically pleasing. To improve the visual attractiveness of the building, make it more
aesthetically pleasing, or line it with the surroundings, architectural cladding or
decorative finishes might be used. Overall, the design of steel structure protection strives
to assure the steel components' safety, lifespan, usefulness, and aesthetic appeal while
avoiding any dangers and hazards that might endanger their integrity.

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3.3 ADVANTAGES AND DISADVANTAGES OF THE METHOD

ADVANTAGES DISADVANTAGES

This coating technique for aluminum is Aluminum is one of the metals with the
strong and resistant to the effects of lowest hardness, it cannot be used in any
harmful substances. They are not evident applications that involve a significant
or conspicuous because weld joints, amount of pressure
grinding, and polishing markings cover
them.

Anodized materials are resistant to Aluminum has very thin layers prevent pit
sunlight, making them perfect for outdoor corrosion, which would otherwise occur
use. For individuals who want to preserve when exposed to salts, which are harmful
the texture and appearance of the original to most other metals
structure, there are translucent kinds and
colors available for customers to choose
from.

Aluminum can also be powder coated in Aluminized steel will oxidize and corrosion
addition to being anodized. Powder will occur if the aluminum coating is
coating, like painting, uses dry powder damaged and the steel is exposed
rather than liquid components. because it is very resistant to corrosion.

Anodizing coating does not peel off, The difficulty of the task at hand The
therefore it will not fade or break as it problem with it is that even a small
becomes a part of the steel structure. scratch can cause it to corrode very
quickly.

Anodized materials are strong and Anodizing method has a number of

long-lasting, they have been shown to be limitations, one of which is that it
suitable for usage in high-traffic areas. necessitates the utilization of particular
Also, pieces with an anodized aluminum types of aluminum. As a direct
coating are 100% recyclable. consequence of this, not all varieties of
aluminum can do the same thing.

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Using this method makes it easier to Anodising method cannot be done on
achieve a smooth, clean surface and less aluminum due to its low-grade metal
likely that it will chalk, which is very because the process requires the base
helpful when working on building projects. metal, which is prone to color fluctuations.
This makes anodising unsuitable for
usage on low-grade metal.

Powder coating is often significantly less The total cost of the construction will be
expensive than anodizing because it affected in a certain way. Due to the
requires less effort and can be environment and the condition of the
accomplished by the majority of people structure, anodising aluminum has some
with little to no expertise. flaws, especially on steel.

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Some of the flaws are as follows:

FIGURE 1 : PITTING CORROSION

The term "pitting corrosion" refers to a type of surface corrosion that occurs on
aluminum metal and is marked by the appearance of small holes (pits) on the surface. In
most cases, these pits do not have an effect on the product's overall strength. It is more
of an aesthetic problem, although it can result in failure if the outward appearance is
extremely important.

The presence of chloride anions is what causes pitting corrosion, which typically
takes place in areas of the world where there is a high concentration of salt in the air. To
a certain extent as well, pitting corrosion can be caused by sulfate salts. When alkaline
and acidic salts are present, pitting corrosion is noted to be in its most severe form.

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 It is necessary for the potential of the alloy to be higher than that of the electrolyte
(salt solution) for pitting corrosion to take place. The development of pitting corrosion is
often preceded by the presence of surface imperfections at grain boundaries and
second-phase particles.

FIGURE 2 : STRESS CORROSION CRACKING

SCC stands for stress corrosion cracking, which is a form of intergranular

corrosion that can lead to the complete failure of aluminum components. This type of
corrosion is referred to from this point forwards as SCC.

In order for this corrosion to take place, there are three conditions that need to be
met. The first of these is an alloy that is prone to corrosion. SCC is more likely to occur in
certain types of aluminum alloys than in others. Alloys with a high yield strength are
more likely to experience stress corrosion cracking than alloys with a lower yield
strength.

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 The second need is that the atmosphere where the service is being performed
must be humid or damp. The presence of tensile tension in the material constitutes the
third requirement that must be met. This tensile stress is to blame for the crack
appearing in the metal in the first place and for its subsequent spread throughout the
material.

There are two distinct kinds of procedures that use SCC. The first type of cracking
is called intergranular stress corrosion cracking (IGSCC), and it occurs when a crack
spreads along the grain boundary. The second type of cracking is known as
transgranular stress corrosion cracking (TGSCC), which occurs when the crack moves
through the grain bodies rather than along the boundaries.

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4.0 CONCLUSION

In conclusion, coating steel structures with aluminum is a strong and reliable way
to protect them from corrosion and other damage caused by the environment. Aluminum
coating is a strong barrier that protects steel surfaces from water, chemicals, and other
things in the air that can start or speed up the rusting process.

There are many benefits to covering with aluminum. Its ability to resist corrosion
protection steel structures for a long time, making them stronger and giving them a
longer working life. Aluminum coatings can fix small damage and flaws on their own, so
they keep their integrity over time. Also, the aluminum coating's galvanic protection
works as a sacrificial anode, giving up its own life to protect the steel underneath from
corrosion.

To put on an aluminum finish, one has to carefully prepare the surface and think
about the needs of the project. Cleaning, removing grease, and shaping the surface in
the right way make sure that the aluminum coating sticks well to the steel base.
Depending on the size and complexity of the steel structure, different ways to apply the
paint can be used, such as spraying, brushing, or dipping.

To figure out how well an aluminum coating works, it has to try its resistance to
corrosion, how long it lasts, and how well it holds up. To make sure the protective layer
keeps working, it's important to do regular upkeep like inspecting and fixing any coating
damage or wear and tear. Visual inspection and non-destructive tests are two kinds of
inspection methods that help find any signs of coating wear or corrosion starting.

Case studies and successful applications show that aluminum coating works well
to protect steel structures in a wide range of industries and uses. These examples show
that it is a very successful way to keep people safe.

In the end, aluminum coating gives steel structures a reliable and long-lasting
layer of protection against corrosion and other environmental factors. By preparing the
surface properly, coating it with aluminum in the right way, and making sure it gets
regular upkeep, the durability, structural integrity, and performance of steel structures

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can be greatly improved, saving money and extending their service life. Aluminum
coating is still a popular and effective way to protect steel structures in many industries,
due to its high resistance to corrosion, ability to heal itself, and galvanic protection.

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5.0 REFERENCES

Aluminum Anodizing | Industrial Metal Finishing. (n.d.). Anoplate. Retrieved July 7, 2023,

from https://www.anoplate.com/finishes/anodizing/

BorTec. (n.d.). Aluminium Coatings - Benefits & Disadvantages » BorTec. BorTec.

Retrieved July 7, 2023, from

https://bortec-group.com/glossary/aluminium-coatings/

Custom Manufacturing, Hardware, Rubber and Plastics guides on Thomasnet. (n.d.).

Thomasnet. Retrieved July 7, 2023, from https://www.thomasnet.com/articles/

GeoMiq. (n.d.)

https://geomiq.com/aluminium-anodising-process-and-benefits/https://www.phos.

co.uk/finishes/anodising

3. Process Defects - Anodizing Defects Catalog. (n.d.). Anodizing Defects Catalog.

Retrieved July 7, 2023, from http://www.defects.qualanod.net/9.html

Velling, A. (n.d.). What is Aluminum Corrosion? Fractory. Retrieved July 7, 2023, from

https://www.alu4all.com/what-is-the-difference-between-anodizing-aluminumand-

p%20owder-coated-aluminum/

Velling, A. (2020, May 20). Aluminum Corrosion | 13 Types Explained. Fractory.

Retrieved July 7, 2023, from https://fractory.com/aluminium-corrosion/

What is Anodizing? The Finish of Choice | AAC. (n.d.). Aluminum Anodizers Council.

Retrieved July 7, 2023, from https://www.anodizing.org/page/what-is-anodizing

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