Metallic zinc is a non-renewable resource that is a critical input to galvanizing operations, which, in turn, is critical to building long-lasting steel structures that are crucial to our global infrastructure. The InterCoat ChemGuard portfolio, particularly the newest invention in that portfolio (ChemGuard-AG -> just starting a limited commercial phase), offers galvanizers the ability to produce galvanized material as G30 (0.30 oz of Zn) and outperform the corrosion protection on galvanized materials as high as G235 (2.35 oz of Zn). In such a scenario, ChemGuard can reduce the volume of metallic zinc required by more than 85% - creating a product that is far more sustainable, aiding to create better longevity for a limited supply of a valuable resource.
Every ton of zinc ingots, a critical raw material in the galvanizing process, creates approximately 2.6 tons of CO2 emissions. If zinc's ability to resist corrosion can be inexpensively improved, galvanized steels can be produced with less zinc, releasing less CO2, and be more efficient and less costly. Past methods of enhanced corrosion protection have added cost and increased metallic additives, using approaches such as amalgams of aluminum and magnesium.
InterCoat ChemGuard AG is a waterborne dried-in-place coating that bonds at a molecular level (covalently) with the galvanized zinc coating and enhances its corrosion resistance by impressive multiple (refer to illustrations for accelerated testing). When InterCoat ChemGuard is applied and reacted with thin layers of galvanized coating, it significantly slows the rate of corrosion/sacrifice so that it lasts longer and protects better.
The returns CG can offer, in terms of sustainability, go beyond the straight-forward reduction of metallic zinc. By engineering built in lubricity packages, downstream operators can process the steel "as-is", coated with ChemGuard ( "dry" – no additional lubricants). By providing built-in lubricity packages for roll-forming, stamping, and other down-stream processes - there is less need to add petroleum-based lubricants to the product.
A change in galvanizing strategy, by utilizing InterCoat ChemGuard, offers comprehensive corrosion protection while supporting a reduced carbon footprint and can save considerable production costs for adopters. Currently, galvanizers support a wide-array of galvanized coating weights (G30, G40, G60, G90, G120, G165, G190, G235) and, traditionally, the higher the coating weight the lower the line efficiency (lines are slowed to accommodate for thicker layers of metallic Zn). The adoption of a product like InterCoat ChemGuard allows for higher metallic coating weights to be eliminated while offering equivalent or better corrosion protection - without an impact to production throughput or efficiencies.
InterCoat ChemGuard has the ability to create improved longevity for our non-renewable resources without sacrificing the performance of a technological staple upon which our global infrastructure relies. Additionally, it can do so without creating increased costs to adopters, both at the manufacturing and end-user level.