Those born before the early 90s are fully acquainted with the name BIM Ltd. In its time it was nothing short of an institution.
In its heyday in the 70s and 80s, BIM was a Marsa based factory in the business of steel fabrication services and production of galvanised furniture. Indeed, it could be safely assumed that few offices in Malta did not make use of some kind of BIM produced furniture.
Its factory in Marsa was a landmark, a reference point, particularly when giving directions within the locality. Over the years, its popularity waned, and the company subsequently faded into oblivion.
On the 7th of December 2018 BIM Limited rose from the ashes.
A fter years of having sunk into oblivion, the Baldacchino brothers – Adrian and Dennis, revived BIM and inaugurated a new state of the art galvanizing facility in Ħal Far. Access to this new facility was made possible through Malta Industrial parks. However, work needed to be done to the dilapidated 2000m2 area. All had to be gutted and rebuilt from scratch.
BIM’s rebirth was not just rebuilding the production facility from scratch. Adrian explained that in BIM’s zenith, galvanising was not quite up to the required scratch. Maltese customers requiring galvanising work mostly resorted to Sicilian providers. Galvanising work in Malta was dead, the business had to start as if it were a completely new project and with the immovable objective to show, and indeed provide, all customers with an impeccable service; an excellent end product, thus finally and rightfully granting BIM Ltd a reputation of quality.
The Baldacchino’s siblings’ background was on their side though. Having been brought up in the family business which provides the supply of building materials – waterproofing, membrane; and a plethora of steel products.
BIM’s new foundations could hardly have become more solid
The government, wholesalers, ironmongers and building contractors have been their long-standing customers for decades on end; BIM’s new foundations could hardly have become more solid.
The brothers invested in the implementation of the latest galvanizing technologies, complying with all European standards for safety, quality and efficiency.
The factory was set up with equipment purchased from the best manufacturers in the United Kingdom. Adrian explained that when choosing the equipment, environmentally friendly elements were chosen. This ensured that fossil fuel consumption in the factory is very low in comparison to the heating requirements involved. BIM have invested in Liquified Petroleum Gas (LPG) powered machinery and equipment, which is much more efficient – and much cleaner for heating – particularly when compared to the diesel consumed in the old Marsa operations. Adrian emphasis that this choice was the best solution when one considers that the facility is never switched off and the plant machines reach temperatures of up to 450 degrees, making BIM Ltd one of Malta’s top ten consumers of LPG.
Protecting Steel
Going forward, would there be other alternatives that one might look at? There are, such as epoxy –and painting; though one could argue that the value of their effects are far lower than those given by actual, factual, hot-dip galvanising.
Epoxy coating is costlier, susceptible to cracks, and vulnerable to being damaged during installation. If cracks occur – something which is relatively common – then epoxy is more likely to flake, Adrian explains. This would allow rust to seep beneath the cracks.
Galvanising is probably the only truly reliable anti-corrosion solution for steel products. It is more durable; being made of over 99% of pure zinc; and hence is far less susceptible to physical damage during installation or otherwise.
Galvanising … the only truly reliable anti-corrosion solution for steel products. It is far less susceptible to physical damage during installation or otherwise
And even if it were to allow any portion of the metal to become re-exposed through, for example, heavy battering during a heavy-handed, difficult installation, the exposed area is contained and seepage underneath the galvanisation cannot occur; it bonds at a molecular level with the underlying metal.
In terms of value for money – no other rust proofing efforts come close. The application cost of labour-intensive coatings such as painting has risen far more than the cost of factory applied Hot Dip Galvanizing. Even in cases where the initial cost is higher than alternative coatings, galvanizing is invariably more cost effective, due to lower maintenance costs during a longer service life. In fact, the life expectancy of Hot Dip Galvanized coatings is generally between 10 to 80 years – and this in some of the most corrosive urban and coastal environments.
The application of full protective coating can be applied in minutes however a comparable multicoat paint system may require up to a week. This too is why it has become a common occurrence in countries such as Germany, Italy, Belgium, Luxembourg, to name a few; for their beams, railings, staircases, and a wide array of steel structures to be galvanized. Indeed, unpainted galvanized steel structures are a common occurrence there.
Hot Dip Galvanising
Hot Dip Galvanizing generally has the lowest first cost when compared to other commonly specified protective coatings for steel; even to those wielding far smaller benefits.
The first step of the process is the immersion of the product in an acid solution to ensure a uniform cleaning of the steel surface. The product in question is set onto jigs and by means of a monorail is transported to one of the four pickling tanks.
Pickling is a preparatory process that involves a mixture of hydrochloric acid, a degreaser and an inhibitor. This highly important process generally takes between 45 to 75 minutes – depending on the type of steel that is undergoing the process. The mixture’s recipe has been honed through experience, consultation with experts and even from mistakes made in the early days.
Once the pickling process is completed, the acid is removed by means of a thorough water rinsing. The material is then dipped in the flux solution, which will assist to obtain a more solid and uniform coating of zinc to the steel structure. Inspection of organic coatings is necessary after surface preparation and each stage of coating application thereafter.
The minimum coating thicknesses are verified by means of internal, as well as by regular third-party inspections; through visual assessments and technical, non-destructive testing methods to determine coating thickness and BIM’s general quality standards.
Hot Dip Galvanising processes are covered by ISO 1461 certification. However, BIM Ltd are working towards obtaining the coveted ISO 9001 certification. The target is to obtain this certification in the coming year and currently the company has already started to operate under such directives, emulating requirements of this type of certification.
Equally important when it comes to certification is health and safety for the facility’s personnel who are all trained in steam handling, galvanising, firefighting, first aid and forklift handling. BIM Ltd’s plant manager was hand-picked from a sister company to move to BIM and be responsible for quality, operational efficiency and site safety. Furthermore, a Health and Safety Consultant regularly visits the factory to ensure that regulations are adhered to and that operational efficiency and safety is maintained.
photo: a factual example of the safety gains when galvanising steel to be embedded into concrete
There is a false impression that the steel that is inserted into concrete is not susceptible to rust
In a short span of time, just about two years, BIM have registered incredible growth. Their wide-ranging projects include high profile ones like the newly launched carpark at the Malta International Airport, to marine related industry projects through their working closely with some of Malta’s largest shipyards. Recently they have also embarked on a project with the Malta Film Studios who have invested in an expansion programme of the facility whereby new garages and stores are being built and all steel being galvanised. “A wise decision,” states Adrian, considering their exposed location in Rinella.
There is a false impression, Adrian reckons, that the steel that is inserted into concrete is not susceptible to rust. It might be time – particularly for sea front developments, for Government to introduce legislation demanding that high rise elements, or at least public projects, include galvanising, he adds.
As we wrap up this interview, Adrian’s message is clear. Galvanising is the way forward. It should be part of any construction process. Whilst the majority of architects are still of the opinion that galvanising steel embedded in concrete is not necessary, they cannot guarantee that in the next thirty years a building will not develop any spalling cracks. But if the steel is galvanised then a guarantee is secured. The cost burden to the overall project is practically negligible especially when one considers the huge competitive advantage automatically gained when one eventually decides to sell their property.
The behemoth that was once BIM is once again well and truly alive. A name with a long history has now reborn with a new mindset inherited from a well-established, privately owned organisation that is a success story in itself.
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