What are zinc whiskers and how do they affect your choice of fixings?
Zinc whiskers are tiny metallic filaments that can form on surfaces coated with zinc and pose a risk of electrical malfunctions or short circuits in data centres. Understanding how zinc whiskers are formed, why they present a challenge in data centre environments, and which material finishes can help reduce the risk is important when selecting fixing and support systems. Walraven can support data centre projects with reliable solutions designed to meet the specific requirements of these critical environments.
How are zinc whiskers formed?
During zinc plating, zinc must bond firmly to the material’s surface. This process can create internal stresses in the coating. Galvanising, electroplating, temperature changes and mechanical loads can all cause these stresses. Over time, the stresses are released. This can lead to the formation of tiny crystalline zinc filaments.
Why are zinc whiskers a problem in data centres?
The presence of zinc whiskers in data centres poses a significant risk to the integrity and performance of electronic equipment. These microscopic filaments can detach from galvanised surfaces and, being electrically conductive, can cause problems ranging from minor interference to critical system failures such as short circuits that compromise the operation of servers, storage systems and communication networks.
Zinc whiskers may be small, but they can become problematic when:
- Air circulation systems in data centres maintain a constant airflow that can transport zinc whiskers from surfaces to critical areas of hardware.
- Equipment maintenance and inspection can generate vibrations or movements that displace the zinc whiskers into the air.
- Zinc whiskers do not degrade or disappear over time, so they can accumulate in sensitive areas, increasing the risk of faults.
What material finishes are best for data centres?
The highest risk of zinc whiskers comes from products with electroplated zinc coatings, so these should always be avoided. Alternative finishes that are unlikely to result in the growth of zinc whiskers include hot-dip galvanisation (HDG), Walraven’s BIS UltraProtect® 1000 (BUP 1000) products, and stainless steel.
Hot Dip Galvanised Fixings (HDG)
Hot-dip galvanised products are widely used in data centre projects. Although hot-dip galvanising involves dipping steel into molten zinc, it creates a thick, durable coating bonded to the steel, which is unlikely to result in the growth of zinc whiskers.
Walraven BIS UltraProtect® 1000 (BUP 1000) surface treatment
Walraven offers BUP 1000 as a standard finish (instead of HDG) on many fixings, including strut channel and pipe clamps. This is because it offers several benefits over a hot-dip galvanised finish. Walraven BIS UltraProtect® 1000 combines zinc, aluminium, and magnesium to provide a sturdy, durable product that is extremely stable and resistant to scratches and damage.
Walraven BIS UltraProtect® 1000 finish is:
- Unlikely to result in zinc whisker growth, as documented in our zinc whiskers declaration
- Offers advanced corrosion protection and durability (1000 hours salt spray test) compared to HDG (600 hours salt spray test)
- Has a more sustainable production process than hot-dip galvanised, using up to 55% less resources
Read more about the advantages of Walraven BIS UltraProtect® 1000 here, or if you have any specific questions about Walraven BIS UltraProtect® 1000, contact our team.
Stainless Steel
Stainless steel is the gold standard solution that offers maximum durability and will not be susceptible to zinc whisker formation, but it can be the more expensive option. Walraven offers a full range of stainless steel solutions if this is the route for your project.
Walraven can support you with data centre installations
In summary, Walraven offers high-quality and highly tested solutions designed to meet the demanding requirements of data centre environments. Our range includes modular systems that support fast and easy installation, complete fixing systems that deliver durability and reliability, and material options that are less susceptible to zinc whisker formation. Combined with expert technical support, we can help you select the most suitable solution for your project. If you have any questions, please get in touch with our technical team.
