Professional Documents
Culture Documents
Galvanizing
What We Need to Know
Contributors
Fred Tinker
National Institute of Steel Detailing, Inc.
With Assistance From:
Christine McCulloch - Education Committee
National Institute of Steel Detailing, Inc.
Andrew Lesko - Calwest Galvanizing
Melissa Lindsley - American Galvanizers Association
Paul Parks - Infosight Corporation
Photos contributed by the American Galvanizers Association
First Printing: March 1, 2009
2009 National Institute of Steel Detailing and the American Galvanizers Association. The material provided herein has been developed to provide accurate
and authoritative information about after-fabrication hot-dip galvanized steel. This material provides information only and is not intended as a substitute for
competent professional examination and verication as to suitability and applicability. The information provided herein is not intended as a representation
or warranty on the part of the NISD or AGA. Anyone making use of this information assumes all liability arising from such use.
Hot-Dip
Galvanizing
Table of Contents
Introduction..........................................................5
Galvanizing History..............................................5
Handrail..........................................13
Surface Preparation..................................6
Degreasing..................................6
Pickling........................................6
Fluxing.........................................6
Galvanizing.............................................7
Inspection................................................7
Galvanized Coating Characteristics
Metallurgical bond...................................7
Coating Uniformity....................................7
Cathodic protection..................................8
Galvanized Coating Performance
Time to First Maintenance.........................8
Exposure to High Temperature....................8
Additional Galvanizing Information
Galvanizing vs. Painting: By the Numbers.....9
Painting Hot-Dip Galvanized Steel.............9
Sheet Steel/Continuous Galvanizing...........9
Design Considerations........................................10
Welding Procedure................................11
Flux & Slag Removal....................11
Stitch and Seal Welding .............12
Introduction
Hot-dip galvanized steel has been effectively used for
more than 150 years. The value of hot-dip galvanizing
stems from the relative corrosion resistance of
zinc, which, under most service conditions, is
considerably better than iron and steel. In addition
to forming a physical barrier against corrosion, zinc,
applied as a hot-dip galvanized coating, cathodically
protects exposed steel. Furthermore, galvanizing
for protection of iron and steel is favored because
of its low cost, the ease of application, and the
extended maintenance-free service it provides.
Galvanizing History
79 AD
1742
1772
Luigi Galvani, galvanizings namesake, discovers the electrochemical process that takes place
between metals during an experiment with frog legs.
1801
1829
1837
French engineer Stanislaus Tranquille Modeste Sorel took out a patent for the
early galvanizing process.
1850
British galvanizing industry is consuming 10,000 tons of zinc annually for the
production of galvanized steel.
1870
First galvanizing plant opened in the United States. Steel was hand-dipped in the
zinc bath.
Today
600,000+ tons of zinc is consumed in North America to produce hot-dip galvanized steel.
P.J. Malouin, a French chemist, presents to the Royal Academy of Sciences several
experiments involving the coating of iron by molten zinc.
Caustic
cleaning
Rinsing
Pickling
Rinsing
Flux
solution
Drying
Zinc
bath
Cooling and
inspection
Fluxing
Steel is immersed in liquid ux (a zinc ammonium
chloride solution) for two purposes. First, the ux will
remove any remaining iron oxides. Additionally, the
ux will create a protective lm to prevent oxidation
prior to dipping into the molten zinc bath (Yellow
Tank, Figure 1).
Surface Preparation
Degreasing
Degreasing
Pickling
Dilute solution (between 8% to 15%) of either
ambient hydrochloric or heated sulfuric acid removes
surface rust and mill scale to provide a chemically
clean metallic surface (Red Tank, Figure 1).
Pickling
Galvanizing
The steel article is immersed in a bath of molten zinc
heated to between 815-850F (435-455C). During
galvanizing, the zinc metallurgically bonds to the
steel, creating a series of abrasion-resistant zinc-iron
alloy layers, topped by a layer of pure zinc.
As the steel is withdrawn from the zinc bath, excess
zinc is removed by draining, vibrating, or for small
items, centrifuging. It is important to remove all
excess to ensure the part is suitable for its intended
use. The galvanized item is either cooled by air or
water, or dipped in a passivation solution to prevent
oxidation.
Inspection
The nal step in the galvanizing process is the
inspection of the surface condition and coating
thickness. The inspection of galvanizing is relatively
easy because zinc does not adhere to unclean steel.
Coating Uniformity
Cathodic Protection
Galvanized coatings also offer cathodic protection,
which simply means the zinc will sacrice itself to
protect the underlying base steel. Often steel pieces are
roughly handled during shipment and/or erection, which
can damage organic coatings. Galvanized steel can
withstand this rough handling, and if damaged, the steel
will still be cathodically protected by the surrounding
zinc (see Figure 3). The same principle is used to protect
outboard boat engines.
100
90
80
Key
70
Rural
60
Suburban
Temperate Marine
50
Tropical Marine
40
Industrial
30
20
10
0
1.0
1.5
2.0
2.5
3.0
3.5
4.0
*Time to first maintenance is defined as the time to 5% rusting of the substrate steel surface.
4.5
5.0
Temperature
Design Considerations
10
Welding Procedure
It is common practice to weld steel prior to
galvanizing, which ensures the entire structure is
coated with zinc. There are a few things to consider
when welding before galvanizing, including the
removal of contaminants and the viscosity of zinc.
Machine surfaces
on pitted steel
ted
Pit
&
d
Ol
Castings with
mild carbon steel
New
&C
lea
11
Good Weld
Seal Weld
For highest quality galvanizing and nal appearance,
smooth clean welds free of ux and slag are
required.
12
Sheared Edge
If these edges are exposed during the hot-dip
galvanizing process, the microcracks that formed
on the sheared edges may propagate into the steel.
These edges may need to be ground to remove any
microcracks formed during shearing.
In the picture above, the end plate design is such that the
holes are used for drainage but only in the orientation
shown. If turned 90 degrees the base plates will trap zinc
upon removal from the galvanizing bath. Contact your local
galvanizer for the proper way to vent pipes and tubes.
If steel is not adequately or properly vented, it may
become a danger to galvanizer personnel, as well
as allow explosive pressure to build, resulting in
irreparable damage to the steel.
13
Masking
It is possible to mask
sections of a part to
avoid the development of
the galvanized coating.
Examples where masking
is commonly used:
1. Field welded shear studs
2. Slip critical bolt surfaces
3. Field welded splice areas
Masking
All stiffeners and gusset plates should be cropped There are 4 categories of masking material:
(See Figure 12&14) to provide an opening with a
Acid-resistant, high temperature tapes
2
minimum of 0.3 in or 13/16 in. hole at the corners of
Water-based pastes and paint-on formulations
all stiffeners. (See Figure 13&15).
Resin-based, high temperature paints
High temperature greases
Masking using a material to produce intentionally
ungalvanized areas, typically used on surfaces to be welded,
on faying surfaces, or areas where the galvanized steel
coating is not necessary for uniform corrosion protection.
Marking
Figure 13: Hole
close to corner
Before
14
After
Barcode Tags
Barcode Tags
Metal barcode tags can also be used to identify materials.
These tags are resistant to caustic wash and acid pickling.
The tags will survive the molten zinc bath with minimal
damage, as they are durable in a wide temperature range
(-22F to 1400F (-30C to 760C)).
Additional information can be stored in the bar code
besides the piece mark, including job name and
number, grade of steel, weight of piece, name of
customer, etc.
Standard
Clearance
Hole Diameter (in.)
Oversized
Clearance
Hole Diameter (in.)
db < 1/2
db + 1/16
db + 2/16
1/4 (4/16)
5/16
3/8 (6/16)
1/2 (8/16)
9/16
5/8 (10/16)
db + 1/16
db + 3/16
5/8 (10/16)
11/16
13/16
3/4 (12/16)
13/16
15/16
7/8 (14/16)
15/16
1 1/16 (17/16)
db + 1/16
db + 4/16
1 (16/16)
1 1/16 (17/16)
1 1/4 (20/16)
db > 1 1/8
db + 1/16
db + 5/16
1 1/8 (18/16)
1 3/16 (19/16)
1 7/16 (23/16)
15
Temporary Bracing
Large diameter, thin-walled pipe and many long or
complex fabrications may require temporary bracing
to prevent possible distortion. The slow (3 ft/min)
immersion of steel items into the zinc bath creates an
uneven heating and cooling gradient.
Progressive Dipping
Lifting Aids
16
Appearance
When steel parts are removed from the molten zinc bath,
the hot-dip galvanized coating can appear bright and
shiny, spangled, matte gray, or a combination of these.
Regardless of the appearance, the corrosion protection
afforded is the same. After a few months of exposure
to the atmosphere, hot-dip galvanizing forms a protective
layer of zinc corrosion byproducts that will give all pieces
a uniform, matte gray appearance.
Shiny surface
Dull surface
Spangled surface
17
A 153/ A 153 M
A 384/ A 384 M
Practice For Safeguarding Against Warpage And Distortion During HotDip Galvanizing Of Steel Assemblies
Practice For Providing High-Quality Zinc Coatings (Hot-Dip)
Specification for Cold-Formed Welded and Seamless Carbon Steel
Structural Tubing in Rounds and Shapes
Specification for Hot-Formed Welded and Seamless Carbon Steel
Structural Tubing
Standard Specification for Carbon and Alloy Steel Nuts
Specification for High-Strength Low-Alloy Columbium-Vanadium Steels of
Structural Quality
Specification For Zinc-Coated (Galvanized) Steel Bars For Concrete
Reinforcement
Practice For Repair Of Damaged And Uncoated Areas Of Hot-Dip
Galvanized Coatings
Specifications for Steel Structural Shapes For Use in Building Framing
A 385
A 500
A 501
A 563
A 572
A 767/ A 767 M
A 780
A 992
B6
D 6386
E 376
Practice For Measuring Coating Thickness By Magnetic-Field Or EddyCurrent (Electromagnetic) Test Methods
18
19
ungalvanized areas?
Yes, but because masking or stop-off materials may
not be 100% effective, contact your galvanizer for
suggestions.
20
21
22
23
24
25
26
27