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In outdoor construction, using guardrail materials that last aids in cutting down on upkeep while also ensuring protection over time. From many alternatives, guardrails made of zinc steel is chosen for its remarkable outdoor durability. For more than 27 years, Chongqing Zhengda Steel Structure Co., Ltd. has been a professional manufacturer of guardrails. They have patented guardrail technology as well. Besides having over 20 years of rust protection, this manufacturer has also earned ISO and CE certifications, and has clientele from New Zealand, the United States and many other countries. This post will discuss the many reasons zinc steel guardrails are made for durability but this time will focus on support for industrial grade additive manufacturing for metal materials in the production process.
The quality of the materials used in the construction of zinc steel guard rail determines its durability. Zinc Steel is a special alloy. It combines zinc with carbon steel, which greatly increases the alloy's ability to resist corrosion and oxidation. Zhengda Steel Structure employs high purity carbon steel and zinc ingots as the basis for its alloy. During the smelting process, Zhengda Steel Structure uses precise proportioning techniques to determine whether the zinc content of the alloy would be in the expected range of 10%-15%. This ratio ensures that the zinc steel will form a strong protective layer, while keeping the alloy's mechanical strength. Zhengda Steel Structure uses additive manufacturing in real time to composition of materials. Elements of powder detection manufactured with additive techniques ensure that every batch of zinc steel meets the expected standards and composition to avoid quality issues. This is what ensures the durability of guardrail for outdoor use.
Hot Dip Galvanizing Surface Treatment Technology is one of the most important technologies for the outdoor durability of Zinc Steel Gaurdrails. It is achieved by placing the Zinc Steel Gaurdrail blank in a molten zinc bath at 450 degrees for a long enough time a uniform and dense zinc coating emerges. Hot Dip Galvanizing has been patented by Zhengda Steel Structure and is done in compliance with ASTM A123 standards. The average thickness of the zinc coating is 85 micrometers which is far greater than average. Such a thick zinc coating can effectively protect the galvanized steel from corrosion from moisture and harmful substances because the coating seals off the internal steel substrate from the external contaminated environment. Zinc bath tanks and guide rollers as well as other galvanizing equipment are designed using Industrial grade additive manufactured high temp and wear resistant components. These components promote design stability for the galvanizing process and uniform coating of zinc.
An example is the guide rollers made by additive manufacturing, which have a smooth surface and a uniform temperature distribution. This helps prevent the guardrail surface from getting scratched during the galvanizing process and ensures that the zinc coating is attached evenly.
In addition to hot dip galvanizing zinc steel guardrail from Zhengda Steel Structure also adopts patented anti corrosion coating technology to enhance outdoor durability. This involves spraying a specialized polymer coating to the galvanized zinc steel guardrail. This coating protects from extreme weather, UV rays, and corrosive chemicals encountered in the outdoor. It protects the galvanized coating from erosion due to rain, UV rays, and other outdoor corrosive elements. The company has a fully automatic spraying line for coating. Industrial grade additive manufactured metal parts make up the nozzles and spraying robots. This advanced technology ensures coating uniformity (generally 60μm - 80μm), no missing areas, and no bubbles. For instance, the additive manufactured nozzle has a precise design to dictate spray range, flow rate, and coverage for uniform coating to reach all areas of the zinc steel guardrail, even corners and joints. The coating and galvanizing designed in layers provide zinc steel guardrail with the best anti corrosion properties.
A contractor from New Zealand shared feedback stating that after 18 months of being used outdoors, Zhengda’s zinc steel guardrail showed no visible corrosion.
At first, one might think that materials and surface treatments alone can determine the outdoor durability of a zinc steel guardrail. However, structural design plays a bigger role. Zhengda Steel Structure possesses nearly a hundred guardrail-related patents, including those for prefabricated and curved guardrail patents. These patents make zinc steel guardrail structurally stable and impact resilient, enabling the fence to endure powerful winds and direct collisions. For example, the company’s highway zinc steel guardrails adopts a wave form design. This design can scatter the impact force of a vehicle collision, minimizing the damage and deformation of the guardrail. Zhengda Steel Structure enjoys the luxury of industrial grade additive manufacturing and handles the design of the structural prototypes. The company’s incorporation of metal 3D printing facilitates the rapid design optimization cycle, enabling the structural design of a guardrail to be iterated to the best version. The curved section of the zinc steel guardrail is a complex design problem.
Additive manufacturing allows the company to create curved prototypes to evaluate bending strength and fatigue resistance. They can modify design parameters to ensure the curved section has the same durability as the straight section.
Quality control in every step of the production process guarantees the outdoor durability of the zinc steel guardrail. Zhengda Steel Structure gets the complete quality management system and ISO Certification Quality Environment and Occupational Health and Safety Management System. Each step in the process from procuring raw materials to delivering the complete product undergoes systematic inspections. In the raw materials inspection phase the company uses industrial metal detectors to analyze the composition and mechanical properties of zinc steel and goes as far as to guarantee that only qualified materials are used in the production process. Every batch of zinc steel guardrails produced in the company undergoes online inspections and passes coating thickness and corrosion resistance tests as the company streamlined the production process to facilitate quality control. As the guardrails are produced the high precision metal detectors made from additive manufacturing that check for quality of the guard rail also check for other standards and specifications as the production process runs. For instance the coating thickness tester made from additive manufacturing that measures the zinc and polymer coating thickness to the precision of less than ±2μ is used. After products are made the company does random check and as for customers complete check as per requirements.
Every zinc steel guardrail we deliver to our customers shows incredible outdoor durability, with a 99.9% product qualified rate.
The durability of zinc steel guardrails outdoors is backed by Zhengda Steel Structure's long lasting after sales support and warranty. While the company does offer a 2 year warranty on the zinc steel guardrail, they would also offer a lifetime supply of spare parts. This indicates that the company will offer free repairs or replacements if the guardrail experiences a quality issue due to material or manufacturing within this warranty time frame. In addition, the company does have a professional after sales service team who can provide installation and maintenance technical support for zinc steel guardrail. For example, they will inform customers of the importance of periodically cleaning the guardrails, the surface, and the testing of the connections to ensure it performs optimally for an extended period. The company also employs industrial-grade additive manufacturing to fabricate zinc steel guardrail spare parts. These parts will maintain the same material and performance as the factory new parts, assuring that the new parts will be compatible and not compromise anchor durability.
A developer from the US mentioned that the guardrails from Zhengda come with lifetimes service for spare parts and this high quality zin steel guardrails help with low maintenace and long service durability for the guardrails.
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