JOHANNESBURG – South Africa’s industrial and public sectors are facing an urgent call to overhaul infrastructure maintenance strategies by accelerating the adoption of zinc-based corrosion protection. As the nation grapples with crumbling steel and concrete assets, the International Zinc Association (IZA) Africa has identified a significant drop in domestic zinc consumption as a primary red flag for the longevity of the country’s rail, mining, and coastal heritage.
The structural integrity of many high-value assets is currently in jeopardy due to what experts describe as a legacy of inadequate protection. Simon Norton, Director of IZA Africa, notes that the visible deterioration of concrete structures—marked by cracking and spalling—is often the result of internal steel rebar corrosion. To combat this, the IZA is advocating for a shift toward hot-dip galvanizing, particularly in the aggressive environments of deep-level mines and coastal zones where salt-laden air accelerates metal fatigue.
“Zinc remains one of the most powerful and versatile tools for rehabilitating steel and concrete infrastructure,” highlights Norton. “Where possible, deteriorated steel should be removed and hot-dip galvanised. If this is not achievable, zinc metal spray, zinc aluminium metal spray or high-quality zinc-rich paints can be applied to provide robust and long-term corrosion protection once the surfaces have been correctly prepared.”
The economic case for zinc is underscored by a staggering decline in its industrial use. Prior to 2011, South Africa consumed approximately 129,000 tons of refined zinc annually, a figure that has since plummeted to an average of just 60,000 tons over the last five years. This downward trend suggests a move away from long-term durability in favor of short-term cost-cutting—a strategy that Norton warns will lead to prohibitive maintenance costs and potential structural failures in the coming decade.
Beyond surface coatings, the technical application of zinc extends to critical civil engineering components like anchor systems and rail fasteners. In corrosive soils, the industry standard involves a “duplex” approach: hot-dip galvanizing the steel anchors before applying a tough bitumastic layer to ensure they survive aggressive underground conditions. This level of specification is seen as essential for the revitalisation of the national rail system and the safety of the mining sector’s hoisting infrastructure.
Looking ahead, the IZA believes that reversing the current infrastructure decay will require a dual approach of national policy reform and a rigorous educational drive within the engineering profession. With many large global consulting firms having exited the local market, smaller domestic firms now require extensive technical support to understand the lifecycle benefits of zinc. Norton emphasizes that for any project within 10km of the coast, the inclusion of galvanized rebar and fasteners should be viewed as a non-negotiable standard rather than an optional extra.
