Zinc Surfaces A Guide to Alloys, Finishes, Fabrication, and Maintenance in Architecture and Art

THE LEADING RESOURCE FOR ARCHITECTS, DESIGNERS, AND ARTISTS WORKING WITH ZINC

Zinc Surfaces: A Guide to Alloys, Finishes, Fabrication and Maintenance in Architecture and Art combines the latest guidance and information about zinc surfaces into a single and comprehensive resource for architects and artists everywhere.

The fifth book in the author’s authoritative Architectural Metals Series, Zinc Surfaces offers a highly visual, full-color guide to ensure architects and design professionals have the information they need to properly maintain and fabricate zinc surfaces. Numerous case studies illuminate and highlight the theoretical principles contained within.

Full of concrete strategies and practical advice, Zinc Surfaces provides readers with complete information on topics including:

• The use of zinc in architecture
• The history of zinc’s use in design
• How to choose the right alloy for your purposes
• Surface and chemical finishes
• Corrosion resistance of various alloys

This book is perfect for architecture professionals, metal fabricators and developers, architecture students and instructors, and designers and artists working with metals.

L. WILLIAM ZAHNER is President and CEO of A. Zahner Company, Inc. and Zahner Metal Conservation. He is an internationally recognized expert on the design and use of architectural metals, and the author of this series of books, including Stainless Steel Surfaces; Aluminum Surfaces; Steel Surfaces; and Copper, Brass, and Bronze Surfaces, all published by Wiley.

Preface xiii

CHAPTER 1 Introduction to Zinc 1

Element 30 Zn – Spelter 1

The Zinc Atom 9

History 11

Zinc Mineral Forms 17

Zinc in Art 18

Zinc as an Architectural Metal 24

Health and Hygiene 28

The Enigmatic Metal 31

CHAPTER 2 Zinc Alloys 33

Introduction 33

Alloying Descriptions 34

Ingot Alloys 36

Zinc Alloys – Rolled Forms 39

Zinc Alloys Used in Architecture 41

Wrought Zinc Alloys 44

Architectural Rolled Zinc 47

Forged and Extruded Zinc Alloys 53

Cast Zinc Alloys 55

Slush Casting 56

Zinc Die Casting 58

Gravity Cast Alloys 59

Kirksite 62

CHAPTER 3 Finishes 63

Introduction 63

Appearance among Metals 65

Mill Finishes 68

Natural Zinc Color 68

Mechanical Finishes 71

Mechanically Rolled Textures 72

Preweathered Zinc Surface 73

Clear Coating with Pigmentation 77

Blackened Zinc 77

Custom Patina Finish 79

Dark Variegated Patinas on Zinc 80

Zinc Oxide Patinas 87

Zinc Iridescent Patina 93

Galvanized Zinc Surfaces 93

Galvanized Steel Structural Shapes 99

Darkening Galvanized Steel 100

Zinc Phosphate Coatings on Galvanized Steel 101

Zinc Fabric 102

Other Methods of Applying Zinc to Steel 103

Zinc Anodizing 104

CHAPTER 4 Expectations 105

Introduction 105

Natural Finish on Thin Sheet Material 107

Natural Finish on Thick Plate Material 109

Natural Finish on Cast Surface 110

Preweathered Finish 113

Preweathered with Added Pigmentation 119

Expectations – Preweathered Surface 120

Blackened Zinc 121

Color Matching 122

Custom Patinas 124

Flatness and Visual Distortion 131

Creep 135

Galvanized Surface 138

Darkened Galvanized Steel 142

CHAPTER 5 Available Forms 145

Introduction 145

Wrought Forms of Zinc 148

Plate 152

Sheet and Coil 153

Zinc Foil 158

Extrusion 158

Tube and Pipe 159

Wire 160

Rod 160

Wire Mesh 160

Expanded Metal 160

Perforated Zinc 162

Textured Zinc Sheet 163

Zinc Ornamentation 165

Cast 166

Slush Cast 167

Die Cast 167

Sand Cast 169

Zinc Powder 171

CHAPTER 6 Fabrication 173

Working with Zinc 173

Storage and Handling 174

Cutting Zinc 177

Shearing and Blanking 177

Saw Cutting 177

Laser 178

Plasma 179

Waterjet 179

Punching / Perforating /Bumping 180

Forming and Bending 184

Grain Direction and Anisotropy 185

Temperature Effect on Forming 187

Brake Forming 187

V-Cutting 191

Roll Forming 191

Superplastic Forming 192

Forging 193

Extrusion 194

Machining 194

Soldering 195

Welding 197

Fusion Stud Welding 199

Resistant Welding of Zinc 201

Expansion / Contraction 202

Bolting and Fastening 204

Thermal Spray 206

Hot-Dipped Galvanizing 206

Casting 208

Die Casting 210

Slush Casting 211

Permanent Mold Casting 212

Sand Casting 212

Plaster Mold Casting 212

Spin Casting 212

CHAPTER 7 Corrosion 215

Introduction 215

Zinc as a Protective Coating 216

Galvanized Steel 218

Zinc Alloy Coatings on Steel 219

Zinc Powder in Paint Coatings 220

Sherardizing 221

Thermal Spray 221

Zinc Anodes 222

Battery 222

When Zinc Does Not Protect Steel 224

Zinc Corrosion 225

Interior Exposures 227

Exterior Exposures 228

Sheltered Exterior Surfaces 230

Uniform Corrosion 235

Underside Corrosion 236

Wet Storage Stain 237

Galvanic Corrosion 239

Determining Factors for Galvanic Corrosion 242

Difference in Electro-Potential 243

Geometric Relationship 243

Distance 244

Electrolyte Effects 244

Temperature Effects 245

Pitting Corrosion 246

Intergranular Corrosion 248

Stress Corrosion Cracking 248

Zinc Artifacts and Statues 249

Deicing Salts 251

Chlorides 252

Fertilizer 253

Saponification 254

Corrosive Substances in Proximity 254

CHAPTER 8 Maintaining the Zinc Surface 257

Introduction 257

Zinc Surfaces 258

Why a Maintenance Procedure 260

Develop a Maintenance Strategy 260

Restoring the Preweathered Appearance 264

Effects of Different Environments 266

Physical Cleanliness 267

Chemical Cleanliness 278

Mechanical Cleanliness 292

Galvanized Steel Surfaces 296

APPENDIX A Brand Names 301

APPENDIX B Select Specifications for Zinc 303

References 1

Index 1

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