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1. Hot dip galvanising is often the best and often the most cost effective method of protecting steel from corrosion. Under certain combinations of circumstances, steel can crack in galvanisation by the process known as Liquid Metal Assisted Cracking LMAC.

2. This document will give risk values for the factors which lead to cracking, and risk values for the type of structure. Steel members will fall into categories of minimal risk (no action), low risk (some inspection), medium risk (high levels of inspection) and high risk (not suitable for galvanising).

3. Engineers will then have the choice of changing the member to reduce the risk category, or accepting the extra inspection (and remedial work) or finding alternate means of protection.

4. The commentary explains the contributing factors.

5. The risk points are calculated as follows: (note no P <0)

  a. Yield stress P = (ys - 300)/25  
  b. Carbon equivalent P = (CE-.4) x 50  
  c. Relative thickness of co joint steel P = (Tmax/Tmin) - 1

(does not include end plates on free ends of )

  d. Fillet weld throat P = leg length mm/10
  e. Butt weld thickness P = weld depth mm/10  

f. Steel components

  hot rolled IHL|C < 20mm P = 0
  Hot rolled IHL|C > 20mm P = 1
  hot rolled O tube P = 1
  hot rolled ℤ box P = 2
  cold rolled IHL|C P = 2
  cold rolled O tube P = 3
  cold rolled 𔭰 box P = 4

welded up beams

P = 4
  g. Total member depth: IHL|C

P = 2 x depth m


O𔭰 tube box P = 3 x depth m

  h. Internal redundancy (if a truss)

     triangulated truss

P = (total number of inter nodal members -3)/3

     verendeel truss

P = (total number of inter nodal members - 4)/4

  i. Relative depth of components (if a truss)

P = 4 x (deepest component/total truss depth)

  j. Holes:

Drilled P = 0

Punched P = 3

Flame cut P = 4

Punched or flame cut, reamed P = 1

Square cornered P = 4

  k.Type of structure:

Regular warehouse/workshop P = 0

Medium rise P = 1
High rise P = 4

Hospital/school P = 4

Public meeting/assembly point P = 4
Fatigue loads P = 4

Public road or rail bridge P = 6.

  l. Effect of failure:

Catastrophic P = 4

Out of plane members prevent collapse P = 0

In between P = 2



6. Need for inspection after galvanising

Score Action to be taken

0 - 6

No special requirements

6 - 12

100% visual inspection near joints

12 - 18

10% MPI, 100% MPI of all joint types where a failure has occurred. Query suitability for galvanising.

18 +

100% MPI within D/2 of joints, welds. Query suitability for galvanising.

7. Responsibility: the designer of the steel is responsible for the risk assessment, the inspection and any remedial work.

8. Programme: the programme is available on CD Rom from BCSA or REIDsteel, cost: ú25.  Order Form>>

* IHL|C: I beams, H beams, L angles, | flats, C channels