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02/08/2016

Rob White
Representing Corr-Serve

Workshops APGGC 2016

Topics

WORKSHOP 1 JIGGING FOR PROFIT


(LOADING BEAMS, SPECIAL DESIGNS, ETC)

WORKSHOP 2 IMPROVING ZINC EFFICIENCY


(PICK-UP, SURFACE QUALITY, ETC)

WORKSHOP 3 OPTIMISING FABRICATIONS


(DISTORTION, VENTING, ETC)

Some useful references

02/08/2016

Some opening comments

Do you understand why we galvanize?


Have you ever read ISO 9223, 9224, 12944?
Do you understand the competition?
Do you really understand costs/pricing?
Will work from Fabrication to Jigging to Kettle
management

BASIC CORROSION PROCESS


REDUCTION
O2 + H2O + 2e =
2OH-

OXIDATION
Fe = Fe2+ + 2e

cathode

Anodic dissolution
anode

e-

steel
Flow of
electrons

THE PROTECTION AFFORDED BY ZINC


Zn(OH)2
Zn5(OH)6(CO3)2

steel corrodes Fe

Fe2+

Zn dissolves Zn

Zn2+

Zn layer

steel substrate

REACTIONS AVAILABLE:
Zn(OH)2
ZnO +H2O (both slightly insoluble)
5Zn(OH)2 + 2CO2
Zn5(OH)6(CO3)2 + 2H2O (highly insoluble)
5Zn2+ + 2HCO3- + 8(OH) Zn5(OH)6(CO3)2 + 2H2O
Fe + water = rust
Fe + Zn + water
Fe + Zn(OH)2  (cathodic
protection + precipitation)

02/08/2016

Phase

% Fe

Eta

Eh, mV

Thickness,
um

Hardness
DPN

Composition

-760

8 - 15

70

Zn

Zeta

0.02
5.8 6.2

-600

7 - 25

179

Fe-Zn13

Delta

7 - 12

-550

30 - 40

244

Fe-Zn-

Gamma 21 - 28

-450

1-2

250

Fe-Zn2

Steel

-400

159

Fe

The Galvanized Coating:


Metallurgically bonded to base steel

Hard, tough and adherent coating

Relationship between coating thickness and life

service life, years

100

rural inland, C2

80
60

urban inland/mild coastal,


C3

40

industrial inland/urban
coastal, C4

20

polluted industrial/coastal,
C5

0
0

10 20 30 40

50 60

70 80

thickness, um

WORKSHOP 1 JIGGING FOR PROFIT (LOADING BEAMS, SPECIAL DESIGNS, ETC)


Key questions checklist
Efficiency basics:
1. Plant design
a. New shapes and plant evolution
b. Reduction of manpower
2. Materials handling
Typical jigging equipment
1.
2.
3.
4.

Wire
Chains
Systems
Practical

Safety
1. Basics
Venting
1. Simple rules
2. Holes sizes
Distortion
1. Design issues
2. Dipping buoyancy parts
Big Beams
Double dipping

02/08/2016

Jigging for Profit


Workshop 1
APGGC 2016
Rob White

Topics/methodology

Relevance of plant design


Some generalities
Will show some general photos and videos
Will do the ITT quizzes!
A word on bouyancy and heat exchangers
Some chain data
Big beams

First steps Feasibility Study


product mix (large, small)
product volume (enough to fill two shifts, 5
days a week)
shape of products (angles, tubes,
fabrications, etc.)
steels used (are the reactive?)
distance from users (steel fabricators)
competition (HDG and paint yards)

02/08/2016

First steps Plant


kettle size required
equipment required
treatment facilities (chemicals)
basic process layout preferred (materials
flow, operators, land type, land size)
building required (dimensions including
headroom, special areas (closed process
room)

Plant sizing
length, width, depth of articles
tank sizing - allow at least 100mm all round and
200mm addition for depth (will typically be
sightly more)
headroom requires 45 angle accommodation +
crane depth(s) + allowance for drainage height +
allowance for fume capture - (min 8m)
tanks required (minimum) 1 x degrease, 1 x
rinse, 3 x pickle, 2 x rinse, 1 x flux bath, drying
area, 2 x post treatment

Building and Yard sizing


working space is important
plant working area 2000 m2 (minimum)
yard area 2x
working under cover is always preferred for
final product cleaning and storage

02/08/2016

Typical plant layouts

In-line
L-shape
U-shape
Monorail transport

What does Materials Handling


have to achieve?
Movement of product through the plant transport
system

Movement of product into and out of the process


tanks entry and exit from the various stages
Safe plant operation no injury or product damage
Optimum productivity - correct loading and product positioning
Minimal product contact few contact marks

Basics of Materials Handling


Heavy Loads know the safe working loads
Forklifts
Boom cranes
Gantry cranes

Jigging understand jigging options


Hanging systems available
Optimum arrangement of articles
Correct dipping procedures

02/08/2016

Typical Jigging equipment


Wire
Chain hooks
Slings
Special systems

Chains G60 ASTM A 413


D Nominal
size, mm

Working
Load Limit,
kg 450C

133

5.5

252

7.1

420

8.7

637

10.3

889

13.5

1533

16.7

2345

19.8

3290

23

4445

26.5

5880

To determine Safe Maximum


Working Load use:

Breaking strength x 0.25 x 0.70

Wires

Use annealed wire minimum 3mm


1 wire if article can be lifted with one arm
2 wires if two arms
Have loading tables displayed
Always tie back wires

02/08/2016

Crane Hook Height

Length = x

45 Slope to
allow for
the
drainage of
excess
molten zinc

Crane Hook
Height above
Floor Level,
effectively
Bath Length
+ 900mm

Length = x
45
Floor Level

900mm
Molten Zinc

Positioning of the product to allow for adequate drainage

A word on wires and jigs

Always ensure that wires are not just bought low Si


wire preferred - http://www.bottaro.org/en/hot-dipgalvanizing-wire
Jigs should be designed to minimise pick-up, aid
draininage and ease jigging
Ti can be used to reduce Zn pick-up on jigging systems
Vibratory jigs assist with zinc draining

Safety aspects
All equipment chains, hooks, Special Jigs, flight bars,
cranes should have their safe working load logged
Use the correct Jigging Equipment
Venting to be visible and adequate
Safety equipment to be worn according to the
process step gloves and hard hat essential

02/08/2016

Venting rules of thumb


Holes should be 25% of diameter or cross
section
Holes should be diagonally opposite one
another per section
Holes should be away from weld areas
Jigging should allow for complete venting
and drainage
No vent holes NO PROCESSING
Vent holes SHOULD NOT be made by the
galvanizer

Jigging Core principles

Jig Loading
Load to the maximum capacity where possible
Try to get a 45angle minimum
Do not Jig from the ends
Try NOT to mix articles on a Jig
Jig to minimise distortion
Always ensure that there is 100mm clearance
between the sides of the tanks and the
articles on the Jig
Always have a full Jig waiting to be processed.

02/08/2016

Do Not Jig from both ends


(will maximise distortion)

25% from both


ends
or
30% from
bottom end

Mixed work

hollow
sections
or long
solids

light solids

Simple rules
Dipping speed SLOW
Light solids and hollow sections
Dipping speed HIGH
Solid heavy and plate sections (will minimise
distortion)

First entry to kettle on Jig


Longer heavier pieces

02/08/2016

Distortion

Minimizing distortion
Brace where possible
Jig correctly steepest angle possible (vertical?) and
sufficient support
Keep articles sufficiently spaced
Fast entry into kettle
Air cool (use thermal blankets if possible) to 150C
and the quench if possible

Big beams
Try to understand steel chemistry high Si values will yield
thick grey coatings
Minimize loading to get in and out of the kettle with
minimum time
Always hang as an I and not H
Ensure chained such that minimises marks and can get
good angle and support part way along the length
Use first in first out principle
If +/- 15mm can quench
If notice any bending on lifting ALWAYS air cool

VIDEO

02/08/2016

GALVANIZING

DESIGN

WELDING

MATERIAL

FABRICATION

POTENTIAL FOR LMAC

Productivity target
Sort the articles for the Jigs
Fill Jigs
Use special Jigs where appropriate
Always have one full Jig at the beginning of
the process
5 dips per hour
Always one full Jig in front of the kettle area
Kettle must be the plant constraint

02/08/2016

Conclusions
Plant design
know what the market needs and build accordingly
Layout can be personal but U and L shapes optimise
materials handling and operator use

Materials Handling
understand safe working loads principle
jig sensibly
understand dipping principles

10

WORKSHOP 2 IMPROVING ZINC EFFICIENCY (PICK-UP, SURFACE QUALITY, ETC)


Key questions checklist
Fluxing:
1. Needs to produce clean surfaces
a. Role of ammonium and zinc chlorides
b. Reactions on immersion presence of iron, iron salts, bath reactions
2. Key parameters
Zinc bath management
1.
2.
3.
4.

Zinc quality
Role of Al
Immersion and withdrawal
Skimming, drossing

The role of Alloys


1.
2.
3.
4.
5.
6.
7.
8.
9.

Zn Ni
Zn Bi
Zn Sn
Zn Mn
Zn Ti
Zn V Ti
Zn Sn V Ni
Zn Sn Bi Ni
Zn Al

Passivation
1. The reasons for white rust the need to passivate
2. Passivation options
3. Best practice

Zincessential for life

8/2/2016

Chemical Treatments for


General Galvanizing
Rob White
Corr-Serve

Contents

Introduction
Degreasing
Rinsing
Pickling
Fluxing
Passivation
Closing Comments

Fluxing requirements (1)


Key objective is to facilitate the metallurgical
reaction between molten zinc and the steel article
Provides surface protection and prevents reaction
with the molten zinc surface zinc oxide minimise
any Fe (in all forms) loading into the kettle
ZAC is available in two forms: the double salt and
triple salt. Triple salt is most commonly used.
Chemical formula of triple salt is ZnCl2 : 3NH4Cl
(1.0 : 1.18 by weight ratio). Is this the right thing
to do?

8/2/2016

Fluxing requirements (2)Lets get a


handle
Flux coating to prevent
flash rusting and keep
surface clean

Has to stop any bath


surface oxide reaction
Flux coating to provide final pickle at
high temperature
Flux to boil off and ensure intimate contact with
zinc
MOLTEN ZINC

Fluxing requirements (3)


The balance

Mixture based
on E1 has
good
wettability
and low
smoke

Modern fluxes
based upon
E2. Lowers
thermal
tension and
thus
possibility of
surface
cracks.

Fluxing requirements (4)


Whats happening
Liquid reactions
NH4Cl
ZnCl2.2H2O + HCl
ZnCl2 + 2H2O
Oxyacid + FeO
2NH4Cl + FeO

HCl + NH3
oxyacid
Zn(OH)2 + 2HCl first pickling (ZnCl2 hygroscopic)
FeCl2
H2O + 2NH3 + FeCl2

At temperature
2Al + 3H20
NH4Cl
6HCl + 2Al
Al2O3 + 6NH4Cl
2AlCl3 + 3H20
Zn + NH4Cl
2NH4Cl + ZnO
Fe Cl2 + Zn
3ZnCl2 + 2Al
Fe as particles

Al2O3 +H2
NH3 + HCl
secondary pickling
2AlCl2 + 3H2
2AlCl2
too much NH4Cl and it fumes and consumes
Al2O3 + 6HCl
thin film on Zn causes black spots
ZnCl2(NH)3 + H2 smoke
H2O + NH3 + ZnCl2:NH3 (OFTEN ZINC OXYCHLORIDE ASH)
Fe + ZnCl2
= dross - inhibited by high Al so little dross
2AlCl2 + 3Zn
more reaction with moisture
Fe in the coating and free dross

8/2/2016

Fluxing requirements (5) The


Operator
The Operator must check for
sufficient drainage and venting holes.
product must be a uniform dull grey colour, without
black mill scale and no water breaks.
product has not been allowed to develop flash rusting,
due to prolonged time left in the atmosphere before it
is fluxed.
product has been passed through the water rinse to
remove residue acid and free iron compounds.

Fluxing requirements (6) Operating


parameters
Immersion time 2 - 5 minutes
Requires liquid flow
Must be heated up to 70 C
Typically 1 to 2 kg/5litres water (200g to 400g per
litre).
Commonly used

Double salt ZnCl2:NH4Cl (56%:44% by weight) lower


fume, less consumption.
Triple salt ZnCl2:NH4Cl (46%:54% by weight)

Fluxing requirements (7) Practical


parameters
Experience shows that double salt better for larger pieces
Density SG = 1.22 to 1.25
thin sections 1.12 to 1.15
T&P/general work 1.15 to 1.22
heavy sections 1.22 to 1.25
pH Control
pH = 3.2 to 4.5 max.
Iron Chloride (FeCl2) <3g/ltr. (ideally <2g/ltr)
1g Fe 20g dross
Balance of zinc chloride (60% ZnCl2) & ammonium chloride (40% NH4Cl)
Temperature of +35C (pH lowers as T rises)
Optimum quality flux will allow max level of alum. of 0.007%. Practically 0,005%
max.

8/2/2016

Flux Quality (8) - reality


Concentration, g/l ZAC and Zn/NH3 balance
Zn
NH4+ in flux or NH3
Cl
Temperature
Acidity/Buffer capacity
Fe (dissolved)
Comes from the pickling process. Not
possible to remove all dissolved salts in rinse
stage

Flux temperature (9)


Low or ambient temperature pre-flux leads
to a dried flux distribution that is thin at the
top of the work and heavier at the bottom.
Hot pre-flux in general tends to even the
distribution.

Why measure density (10)?


ZAC measured by SG (or Baume)
Analyse cold solution please
Unfortunately SG affected by dissolved Fe and Zn/NH3
balance

8/2/2016

Acidity/Buffer capacity (11)


Objectives simple STOP CORROSION
Titrate with 0.5N sodium carbonate solution to pH4
(methyl orange end point) to estimate ability to
absorb acid

Operational range
(very low corrosion
rate) measured
buffer capacity, g/l
HCl

Role of dissolved Fe (12)


Reacts with Al on the bath surface reduces brightness
(even local black spots)
Increases dross and so Zn consumption up to 20% of dross
from Fe in flux)
Roughens the surface due to local dross production results
in poorer drainage
Makes use of alloys difficult
Target < 0.8 g/l !! (between 3 and 0.8 16kg/tonne Zn saved)
At the quoted 5 g/l doesnt make any real impression on
galvanizing quality!

8/2/2016

Flux balance (13)

Go for a slight XS of NH4Cl

Effect of ratio imbalance (14)


High ZnCl2 results in slow drying after
fluxing causing excessive splashing
during entry of steel into galvanizing
bath

High NH4Cl causes


excessive
galvanizing fumes

ZnCl2
to
NH4Cl
ratio

Low NH4Cl can cause


black spots on
galvanized coatings

Low ZnCl2 results in re-oxidation of the steel


surface during drying after fluxing, reducing the
fluxing efficiency and increased dross production
during galvanizing

Flux balance (15)

Ideally all the Cl converts to ZAC but never so the


Zn/NH3 balance shifts from 1:3 to either XS of ZnCl2 or
NHCl
When Fe removal used (always please) acidity can
increase and so more NH3 or Zn needed.

8/2/2016

Flux regeneration
Flux Bath
ZnCl + NH Cl
2

Hydrogen peroxide
Ammonia

Reaction Tank

Pure Flux Solution

Sludge Thickener

Filter Press

Sludge Storage Tank

Filter cakes for waste collection company

Advantages of flux treatment

Decrease in zinc pick-up from 9.5 to < 7 %


Higher production rate - increase of over 10 %
Lower production of zinc ash
Lower production of fume
Lower dross production from 8 t/2 wks to 2 t/6 wks
Higher quality product

8/2/2016

WORK SHEET FOR ESTABLISHING CORRECT BALANCE FOR FLUX


- Dated 24 March 2004

Report by: Bob Wilmot HDGASA


Density Conversions
Baum =
S.G. =

Baum to SG SG to Baum
28.000
28.065
1.240
1.239

NB For this calculation to be accurate, the iron content must be < 2,5 gms/lt.
Actual readings from the plant (INPUT DATA)

REQUIRED BALANCE - OBJECTIVE

Measured Zn
Measured Chlorides

88.4 gms/Lt
199 gms/Lt
Required SG = 1.24
Tank length (m) = 6
width (m) = 1.2
Depth (m) = 2.5
ZnCl2 (gms/Lit) = 184.27
NH4Cl (gms/Lit) = 155.60
Tank size (litres) 18000
Ratio ZnCl2/NH4Cl & reciprical= 1.1843
Requirements to Correct Tank Solution using Double Salts
ZnCl2 (Kgs) = 1642
2NH4Cl (Kgs) = 1150
NEW SG should now be 1.240

Calculated SG = 1.24
Ratio
54.22%
45.78%
0.8444

Total Flux (gms/Lit) = 495


275
220

55.65%
44.35%

Requirements with Triple Salts


Requirements with Triple Salts
Total
Flux
(gms/Lit)= = 561
Total
Flux
(gms/Lit)
ZnCl2
(gms/Lit)
ZnCl2
(gms/Lit)= = 257
NH4Cl
(gms/Lit)
NH4Cl
(gms/Lit)= = 304

45.80%
54.20%

Requirements with Double Salts


ZnCl2
(gms/Lit)= =
Total Flux
(gms/Lit)
ZnCl2
(gms/Lit)
NH4Cl
(gms/Lit)= =
NH4Cl (gms/Lit) =

Requirements to Correct Tank Solution using Triple Salts


ZnCl2 (Kgs) = 1306
3NH4Cl (Kgs) = 2671
NEW SG should now be 1.239
Calculation of density, SG = 1.169

Cross check calculation of flux solution for balance


Total Flux g/l = 567.601
Using Triple Salts
45.46%
Calculation
of ZnCl2
Calculated
SGg/l= = 258.005
Calculation
of NH4Cl
Total
Flux g/lg/l= = 309.596 54.54%
Calculation of ZnCl2 g/l =
Calculation
of
NH4Cl
g/l
=
Requirements with Double Salts

Comment:

Insert Actual ZnCl2, gms/lt. = 184.27


Insert Actual NH4Cl, gms/lt. = 155.60

If the Iron is too high it will effect the accuracy of the SG reading.
Iron should not exceed 2.5gms/lt.

Test Balance for SG


Calculation of density, SG = 1.240
Insert Actual ZnCl2, gms/lt. = 275
Insert Actual NH4Cl, gms/lt. = 220

Calculation of density, SG =
Insert Actual ZnCl2, gms/lt. =
Insert Actual NH4Cl, gms/lt. =

Measured Iron content in gms/lt. = 20.7

Far too high as it should be < 2.5 gms/lt.


The iron content will distort your SG reading.
Recorded SG reading was 1.209.
With an iron < 2.5gms/lt the SG would have been I.166
Measured pH of 3.41 @ 20.7s is low and should range between 3.5 and 4.5

Calculated SG = 1.24
Total Flux g/l = 567.601
Calculation of ZnCl2 g/l = 258.005 45.46%
Calculation of NH4Cl g/l = 309.596 54.54%
Requirements with Double Salts
Total Flux (gms/Lit) = 495
ZnCl2 (gms/Lit) = 275
NH4Cl (gms/Lit) = 220

55.65%
44.35%

Requirements with Triple Salts


Total Flux (gms/Lit) = 561
ZnCl2 (gms/Lit) = 257
NH4Cl (gms/Lit) = 304

45.80%
54.20%

Drying

Required to evaporate all water (not to pre-heat


articles)
Allow enough time for drying to occur
Keep article temperature below 80 C to avoid flux
breakdown (and black spots)
Using dryers at 100 C provides best finish
Do not store articles near treatment tanks where high
humidity can occur

8/2/2016

Observations of good flux colour

light grey watery colour indicates that the solution is


within specification.
reddish brown muddy colour indicates the presence
of iron as Ferric Hydroxide (Fe(OH)2). However
suspended Fe will show as brown.
greenish brown colour indicates the presence of
excess amounts of dissolved iron in the form of
Ferrous Chloride (FeCl2).

Iron management is essential


Dont worry about the rinses flash rusting will result
in some dissolved iron
However, a second rinse significantly reduces the Fe
drag out
Ferrous salts are reduced to metallic iron which
reacts with the zinc to produce dross (and so increase
the consumption of dross 15 parts Zn to 1 part Fe
depending upon the alloy formed!)
In-line Fe reduction is simple

End of process options

Open drying
Controlled cooling
Quenching
Quench and passivation
Passivation

THE CORROSION PROCESS OF A ZINC SURFACE


Zinc
metal

ZnO

Zn(OH)2

ZnCO3

Zincessential for life

8/2/2016

Passivation liability or
essential process

Atmosphere
Reacts with

Forms

Zn
ZnO

Zn(OH)2

Unstable

White Rust

ZnCO3
Stable
Protective
Barrier

Reasons for white rusting

10

8/2/2016

White rust formation

Use of dichromate
Simple control concentration only (up to 1%), 5 to 10
mg/m2 coating weight
Three factors affect passivation
[Na2Cr2O7] 0.12 to 0.15% with free Cr at 400 to 600 mg/l
pH between 5.0 and 6.5 use H2SO4 to control
Chloride less than 0.5% (5g/l)

Keep temperatures below 70/80 degrees

Chromates
Advantages

Ease of use
Effective
Low cost
Attractive appearance
Generally accepted

Disadvantages
Environmental aspects
Not tolerant of acid rain conditions
Not paintable

11

8/2/2016

Silicates
Advantages
Environmentally sound
Resistant to acid rain conditions
No prior treatments required if surface painted

Disadvantages
Surface not bright
Require careful monitoring and filtering

Phosphates
Advantages

Simple to use (and can control usage)


Can be spray applied
Resistant to acid rain conditions
No prior treatments required if surface painted

Disadvantages
Surface dark grey
Post rinse preferred

Others - chemicals
Silanes
Difficult to use and require filtering

Cr 3
Variable performance

Acrylics
Easy to use and require little treatment

mill oils and prelubes


Simple but limited protection

Others water displacers, solvents, etc.

12

8/2/2016

ILZRO tests
Tests done on 45 products in 2008
4 Cr 3+, remainder organic and organic Cr free
compounds
Three test carried out
ILZRO spray tests
Humidity tests
Wet storage test

Only 4 exceeded the performance of Cr6+


Inorganic silane
3um organic treatment
Two Cr 3+ treatments

Storage options

Keep dry
Store off ground
Stack with separation between articles
Store at an angle
Transport sheets covered

13

8/2/2016

Removal of white rust


Leave light staining it will go grey!
Stubborn deposits, with a stiff bristle (not steel wire)
brush:
Use 10% ammonia solution
Use 5% dichromate with 0.1% sulphuric acid
In both cases thoroughly rinse and allow to dry

Passivation questions to ask


What systems can be tolerated water based, oils,
solvent based, etc.
How wet will the surface be over time
What time of protection is required
What type of conditions will the articles be subjected to
prior to use (alternate wet/dry, temperature ranges,
etc.
Methods available for application of passivation
Methods available for removal of passivation

Closing Comments

Look after the basics


Monitor, monitor, monitor
Keep accurate records
Ensure personnel trained

14

8/2/2016

Understand the process

Degreasing affects pickling


Pickle conditions and drag-out determine rinse
compositions
Rinse compositions affect flux composition
Rinse composition and drag-out affects flux
treatment needs
Flux composition affects galvanizing
Post treatments may not be required

Typical consumption values


Consumption

Towers

General

Tube & Pipe

Zn

40 45 kg/tonne

55 65 kg/tonne

60 70 kg/tonne

Ash production

6 10 kg/tonne

6 10 kg/tonne

6 10 kg/tonne

Dross production

4 5 kg/tonne

4 5 kg/tonne

4 5 kg/tonne

Dust production

10 15 kg/tonne

TYPICAL (example) HOT DIP GALVANISING PLANT

Sheet GAL-QP-09 Annex A


Revision No.0 - 17th April 2001

DAILY CHEMICAL ANALYSIS LOG SHEET FOR GALVANISING PROCESS TANKS


DATE OF READINGS

TESTED BY:

Refer to QUALITY CONTROL MANUAL (GAL-QP-09 & 16) for test procedures and control of records.
TANK No.

TYPE OF CHEMICAL

CONCEN.
%

TEMP.
C

ION CONTENT
gms/liter

pH

SG

COMMENTS
Specification requirements

1
2
3

5% Alkaline Degreaser (Includes Skimmer)


5% Alkaline Degreaser (Includes Skimmer)
Water Rinse

4
5
6
7
8
9

16% - 8% HCl Pickling max 10% ion


16% - 8% HCl Pickling max 10% ion
16% - 8% HCl Pickling max 10% ion
16% - 8% HCl Pickling max 10% ion
16% - 8% HCl Pickling max 10% ion
16% - 8% HCl Pickling max 10% ion

10
11

Water Rinse
Water Rinse (Includes cascading)

Ambient
Ambient

12

ZnCl2+3NH4Cl Flux Iron 2.5gms/lt. Max.


Balance between ZnCl2 & 3NH4Cl
Mixture by chemical weights

pH =3.2 to 4.5, S.G. =1.22 to 1.24


Ideal balance ZnCl2 46% & 3NH4Cl 54%
Ideal ZnCl2 246gms/lt.& 3NH4Cl 290gms/lt.

13

Zinc Kettle 440C to 455C max.

14
15

Passivating1% Sodium Di-chromate


Water Quench Ambient

16
NOTES:

Max.Temp. 45 to 50C
Max.Temp. 45 to 50C
Ambient

ZnCl2
gms/lt.

3NH4Cl
gms/lt.

See separate analysis for Zinc (Al & Pb)

Pipe Passivating1% Sodium Di-chromate


1. Control specifications, refer to "FLOW CHART FOR THE GALVANISING PLANT", GALV-QM-01
2. Numbers and size of baths is determined by size of product to be processed and production requirements.

15

8/2/2016

Chemical analyses

Understand the relationships between the factors (SG


versus temperature, Baume degrees to density, etc.)
Understand masks (often iron values are masked and
require double checking)
Keep test solutions fresh
Understand Ionic Balances

Training

Operators should be well versed in galvanizing basics


Operators should be empowered to act when
parameters are not as specified
Operators should be regularly trained, especially on
new process techniques

IZA Operators Training Tool (1)

16

8/2/2016

IZA Operators Training Tool (2)

17

02/08/2016

Basic bath management to improve


Zn pick-up efficiency and appearance
Workshop 2 APGGC 2016
Rob White
Corr-Serve

BASIC KETTLE MANAGEMENT

Quality of the zinc


Temperature of the bath
Time of immersion
Rate of withdrawal
Spangle

Composition, %

Grade

Specification

Zn
(min)

Pb
(max)

Fe
(max)

Cd
(max)

Sn
(max)

Cu
(max)

Al
(max)

Total
non
zinc
(max)

Special High
Grade

ASTM B6

99.99

0.003

0.003

0.003

High Grade

ASTM B6

99.9

0.03

0.02

0.02

Prime
Western

ASTM B6

98

1.4

0.05

0.2

Z1

UNE-EN 1179

99.995

0.003

0.002

0.003

0.001

0.001

Z2

UNE-EN 1179

99.99

0.005

0.003

0.005

0.001

0.002

0.01

Z3

UNE-EN 1179

99.95

0.03

0.02

0.01

0.001

0.002

0.05

Z4

UNE-EN 1179

99.5

0.45

0.05

0.01

0.5

Z5

UNE-EN 1179

98.5

1.4

0.05

0.01

1.5

0.05

0.001

0.005

02/08/2016

Zinc Quality
Pb
- saturated in zinc melt (1.4%)
- assist with spangle formation
- lower surface tension (by as much as 30%) reducing drips, etc.
- assists with drossing (film of liquid Pb around dross particles
causes them to sink)
- protects base of kettle
Al
- lowers ash formation (protects against zinc surface oxidation
avoid the frosty bath!)
- easily consumed (+reacts with chlorides of flux if level too high)
- brightens coating (reduces intermetallic layers, increases zinc
wettability protects galvanized surface from oxidation)
- typically 0.4/0.8kg consumed per tonne steel
Fe
- produces dross

Aluminium(Al) additions to the bath


Al is primarily added to make the coating
shine
Additional benefit is that it reduces molten
zinc surface oxidation ( ash formation)
Optimum Al content is 0.005 0.007%
If << 0.005% Al the coating lacks
brightness.
If >> 0.007% ( especially > 0.015%) Al
there is a risk of coating bare areas (black
spots) because of reduced flux
effectiveness

02/08/2016

Influence of Al
avoiding oxidation
reduced wettability
risk of black spots

thickness reduction

10

60

300

1500

ppm Al

Bath temperature management


Effect of Temperature on Solubility of Iron and
Aluminum in Zinc

Surface appearance
Temperature of Zn
Bath fluidity
Molten metal surface tension
Bath cleanliness (absence of dross and surface oxidation
a role of Al). If bath is yellowish Al to low.
Withdrawal rate
Solidification (cooling) rate
Article orientation in kettle

02/08/2016

Bath temperature

Lower is better
- minimises ash and dross
- optimises (minimises) alloy layer growth
- optimises Zn consumption
- minimises kettle wear
Minimise temperature differentials
- minimises chances of floating dross and so impact
on coating quality
- creates uneven kettle wear

Time of immersion

Immerse work rapidly


reduces temperature gradients and so distortion
avoids differential immersion time and so coating
thickness
requires good drying

Minimise time
wait until boiling off stops

Chemical analysis of
the steel (Si & P)
Steel thickness
Surface roughness
Immersion time
Zinc Temperature
Speed of
withdrawal
Angle of
withdrawal
Alloy additions,
including-Al, Ni, Pb.

02/08/2016

Withdrawal rate
WITHDRAWAL
RATE

COATING WEIGHT

TOO HIGH
COATING
THICK AND
LUMPY
OPTIMUM
1.4m/min
TOO LOW
COATING TOO
THIN

IMMERSION TIME

Spangle

Large spangles require


- a smooth surface
- thin Zn layer
- uniform temperature drops
- sufficient time for the spangle to develop
(slow cooling)

Note six fold


geomtery of the
spangle

Note primary and


secondary growth
directions

With reduction in Pb levels, it may be required to


add Sb (up to 0.1%) to get a spangle.

02/08/2016

Skimming

Skim slowly just in front of the material


Skim slowly no waves
Use light paddle make it easy for the guy
Do not use NH4Cl bad practice.
A vibrator hoist will assist with liquid Zn removal

Drossing
Pasty grey alloy 25 Zn to 1 Fe
Reaction product of Zn with Fe so lower immersion
times, lower temperatures
Good dross should contain > 3% Fe
Good drossing practise involves

Reducing Dross

Use of an inhibitor in the pickle tank


Efficient rinsing of work
Maintaining the flux at a low iron content
Operating the bath at as low a temperature as
possible
Avoiding large changes in bath temperature
Minimise the processing of reactive steel

02/08/2016

Causes of floating dross

Reaction between molten zinc and iron


Thermal gradients in the galvanizing bath
Addition of aluminium as pure metal
Poor mixing of aluminium
Disturbance of bottom dross
Processing work to soon after drossing

Avoiding floating dross

Maintain a uniform bath temperature


Control additions of aluminium
Avoid disturbance of bottom dross
Allow sufficient time for settling after drossing
Maintain a low level of bottom dross
Allow floating dross to settle
Bubble nitrogen through the molten zinc

Some final practical aspects


Minimise use of remelt
- contains Fe, Pb, Sn
- can result in high dross production
- more viscous than virgin Zn
Dross properly
- dross weekly
- keeps viscosity down (& Zn consumption)
- avoid remelt
Ash production depends on
- temperature
- air flow
-bath composition
- surface area

02/08/2016

GALVANIZING QUALITY

Depends upon the factors mentioned


Have not even mentioned the factors such as
re. poor pre-treatment (Fe carry over from the flux, acid,
wet work pieces, etc.)
Chemistry of steel
Surface roughness/size of article

Galvanizing requires mastery of the basics (keep all


differentials to a minimum)

Zinc temperature operating


range
 Operating range 440 460oC but 445
455oC is preferable. 448 452oC
range is generally considered best
< 440oC. Risk of non-smooth coatings
because of low zinc fluidity

> 460oC . Risk of shorter kettle life due


rapid attack by molten zinc and more
dross formation
23

Defects management

Are they acceptable?


Are they process related?
Are they steel related?
Do they impact upon performance?

02/08/2016

CONDITION
Bare spots

General
roughness

Dross
protusions

CONDITION
Blisters /
Pimples
Lumpiness
and runs

CAUSES
Paint, grease or oil residues.
Scale or rust residues.
Residual welding slag.
Weld porosity or undercut.
Rolling defects in basis steel.
Embedded sand in castings.
Overdrying of preflux.
Excess aluminium in bath.
Articles in contact during hot dip
galvanizing.

Chemical analysis of the steel.


Surface condition of steel.
Overpickling.
Uneven cold working.
High galvanizing temperature
and/or long immersion time.

Entrapped dross particles.

GROUNDS FOR REJECTION?


Yes, except where bare spots
are small and suitable for
repair, according to ISO 1461

No, except by prior agreement.

No, unless dross contamination


is heavy.

CAUSES

GROUNDS FOR REJECTION?

Surface defects in steel.


Absorbed hydrogen.

Yes, but not due to poor hot dip


galvanizing, repair procedure
must be agreed upon.

Withdrawal speed too high.


Cold zinc temperature.
Delayed run-off from seams,
joints, bolt holes, etc.
Articles in contact during
withdrawal.

Only on basis of prior


agreement.

Ash deposits

Ash burnt on during dipping.


Ash picked up from top of bath
upon exit.

Yes, if in gross lumps, unless


removed and adequate coating
present under deposits.

Flux
inclusions
and deposits

Flux burnt on during dipping.


Surface residues on steel.
Flux picked up from top of bath.

Yes, unless removed and


adequate coating present under
deposits.

CONDITION

CAUSES

Dull grey or
mottled
coating
appearance

Reactive steel due certain levels of Not if due to steel composition or


silicon and/or phosphorus. Severe condition, or limited to occasional
cold working of steel.
areas.
Slow cooling after galvanizing.

GROUNDS FOR REJECTION?

Rust stains

Weeping stains, from seams and No, but inadequate welding may
folds.
be reason for rejection.
Deposits of ground steel filings or No.
storage on or near rusty material.

Wet storage
stain (white
rust)

Confinement of closely-packed
articles under damp conditions.
Packing of articles while damp.

No, unless present prior to first


shipment, and coating thickness
not to ISO 1461.
Customer to exercise caution
during transportation and
storage.

02/08/2016

Galvanizers should ensure that


their customers understand
galvanizing inspection

Galvanizing bath
composition

29

Why the interest in alloys?

Changes in steel production


Use of silicon killed steels
Need to reduce coating weights (viscosity and
catalysis reduction)
Need to improve aesthetics (viscosity and catalysis
reduction)
Need to reduce Pb in kettle

10

02/08/2016

North America survey on Pb

Market aesthetics
Large multifaceted crystal
structure
Provides for a better
gloss on paint coating
However all coatings will
turn grey in time!

Sandelin Effect thick coating (Si)

11

02/08/2016

Sandelin Effect peeling (P)

Sandelin Effect tree bark (P)

12

02/08/2016

Refer to: Galvanizing reactive steels a guide for galvanizers and


specifiers, ILZRO (1998)

How to limit Zn pick-up

13

02/08/2016

Steel
reactivity

Coating appearance

0 - 0.035 0
0.025

Normal
occasionally low

Few defects

2 Semi -sandelin

0 - 0.04

0.025 0.035

Normal

Localised defects due to


outbursts of zeta layer

0 - 0.04

> 0.035

High especially
when P high

Tree bark tendancy to


flake

Sandelin
(low P)

4a

0.04
0.135

< 0.01

Moderate
increases with Si

Normal with few defects

Sandelin
(high P)

4b

0.04
0.135

> 0.01

High

Few defects

Hyper
Sandelin (low P)

5a

0.135
0.35

< 0.03

High

May appear normal with


few defects

Hyper
Sandelin (high P)

5b

0.135
0.35

> 0.03

High

Tendancy to flake

> 0.35

> 0.0

High

Tendancy to flake

CLASS

Si, %

Normal
sandelin

Non classical
sandelin

Extreme Hyper
Sandelin

P, %

Class 1: Normal reactivity

Normal coating structure


Alloy layer thickness 50 85 um
Total coating thickness 65 120 um
Occasionally problems with THIN coatings

Class 2: Semi Sandelin


Normal coating structure
but often shows
outbursts of reactive
coating
Total coating thickness
can be up to 500 um

14

02/08/2016

Class 3: Non classical Sandelin

Coatings very thick with no unalloyed layer,


many defects, poor appearance and easily
damaged
Coating thickness 150 300 um with areas up
to 1000um!

Class 4a: Classical Sandelin (low P)

Usual sandelin structure but relatively thin.


Few defects.
Coating thickness 100 180 um

Class 4b: Classical Sandelin (higher P)

Usual sandelin structure


Coating thickness 180 500 um

15

02/08/2016

Class 5: Hyper Sandelins

Coating normally has unalloyed zinc layer


present. Prone to defects or peeling
Coating thickness 120 200 um

Class 6: Extreme Hyper Sandelins

Coating normally has littleor no outer zinc


layer present. Prone to defects or peeling
Coating thickness 200+ um

16

02/08/2016

The old story is still true though


Galvanized coatings with these
steels will generally be
aesthetically pleasing, have
acceptable adhesion and be
free of alloy outbursts.
The higher the Si the thicker
the coating
In steels with Si between 0.15
and 0.20 the presence of P
should not show alloy outbursting

Element

Si

< 0.04

Si + 2.5P

<= 0.09

Si

0.15 - 0.2

General Comments

Technology is improving but industry still sells on


tonnage basis
Need to sell on service performance (what the
customer wants) but industry still sells on price
Regions in different stages of development

Issue

Developed market

Developing market

Comment

Cost

There is always a need for


convincing data

Ditto

Whilst often contentious and regional,


comparison costs are always persuasive

Fabricator

Viewed as an important
chain in acceptance

Ditto

The fact that surveys have been carried out


indicates that this area is key to market
development

Steel Use

Cultural. See the


challenge as increasing
the percentage of steel
galvanized

Cultural but also


depends upon
availability. The
challenge is to increase
the use of steel

Where alternative materials are used, the


drives of the steel industry should be
supported

Coating
performance

Data is available but


dispersed

Specifier often
persuaded by direct
comparisons

The plethora of information is often


indigestible by the market. Clarity and
simplicity is required

Markets

Sophisticated, user more


interested in soft issues

Cost, performance and


availability are key
issues

Where possible, the experience in the


developed markets must be leveraged

Market
Development

Large Associations have


capacity

New Associations rely


upon information from
others

A common industry portal is required

Communicati
on

Most methods of
communication can be
used. There are numerous
sources of data

Direct personal contact


required. Access to
international data
difficult

Although subjective, it appears as if the


internet and seminars address the extremes

Standards

Consensus agreed upon


standards. Aesthetics still
an issue

Performance is often
company dependant
restricting overall
growth

The harmonisation of standards will address


part of the issue

Performance

Service issues paramount

Delivery (and price) is


the key to success

Partnering as a business principle should be


encouraged

17

02/08/2016

ALLOYS

Zn Ni
Zn Bi
Zn Sn
Zn Mn
Zn Ti
Zn V Ti
Zn Sn V Ni
Zn Sn Bi Ni
Zn Al

Alloys can
Assist with Sandelin Effects
- control reactivity
- minimal thickness variations
Improve surface condition
- smoothness
- appearance (spangle, brightness)
- minimise defects
- better for painting
Assist with Pb removal

Role of alloys - summary


Influence
Influence
des lments
of alloying
d'addition
elementssur
(overview)
les proprits
Elements
ZINC
Tension
superficielle
(450
C) dynes/cm
780
Surface
tension
(450
C)
Viscosit
(450 (450
C) poise
0,035
Viscosity
C)
Mouillabilit
Wettability
Solubilit
dans in
Zn liquide
(%) C)
Solubility
liquid(450
ZnC)(450
Solubility
solid(%)Zn
Solubilit
dans in
Zn solide
Melting temperature
Temprature
de fusion
419,5
Dross formation
Mattes
Ash formation
Cendres
Gloss
Brillance
Spangle
Fleurage
Zn-consumption
Consommation
de Zinc

Pb

Bi

Sn

Fe

1,1

100

0,02 - 0,03

Ni

Cu

Al

0,06

15

0,04

2,85

18

02/08/2016

Zn Ni (1) - General

Specifically for Si range 0.05 to 0.12%


Reduces coating thickness to 0.25% Si
Normal melt range is 0.03 0.05% Ni
Added as master alloy (2% Ni) or powder
Improves coating ductility
Gives good lustre to coating
Better coating adherence (bending, etc.)
Can result in high dross (floating and settled) production
(possibly more due to reducing solubility of Fe in the melt)
when Ni > 0.06%

Zn Ni (3) Sandelin effects

Distribution of Ni

19

02/08/2016

However, if less coating thickness produced with ZnNi


then overall the dross production should be less!

Zn Ni (2) coating effects


Controls growth of alloy layer
Reduces bath viscosity and assists drainage and so
reduces outer layer thickness
Produces a whitish lustre

20

02/08/2016

Zn Ni (4) Practical Issues


Maintain bath Ni contents in the range specified.
Make small Ni additions frequently to minimise
variations in concentration
Ensure that Ni is fully dissolved.
Keep bath temperature as constant as possible.
Lower temperature prior to drossing (445)
Can reduce Zn consumption by over 15%
Will not be effective where steel P > 0.04%

21

02/08/2016

Typical example of application for Zn Ni

Zn Ni (5) - Costs

22

02/08/2016

$2200
$2750
$3300
$3850
$4400

Zn Bi - General
Selection based upon ability to reduce surface tension of
zinc
- better drainage (10 x more effective than Pb - 0.13% Bi
has same effect as Pb at max solubility)
Bright coating with angular spangle
Decrease in dross production (11%)
Working concentration 0.1% Bi
Has no effect on reactive steels
Has good synergies with Ni

23

02/08/2016

Zn Sn - General
Has been used at 0.2% in the past where it creates bigger
whiter spangles
Reduces coating thickness
Appears to restrict steel reactivity (although conc needed is
high up to 5%)
Produces large spangles
Has good synergies with Ni (reduces Sn needed by 50%)
Has good synergies with Al (Al 0.035% can reduce requirement
for Sn to 0.45%) and this alloy appears effective with reactive
steels
Offers the opportunity to look at Pb free as has similar
properties to Pb re. dross
Appears to reduce dross and ash production
Excessive Sn can impair kettle life

Zn Mn - General

Really only experimental at present


Appears to reduce the Sandelin Peak but not
effective at higher Si levels
Indications are that 1% + may be needed
Likely to be part of an alloy mix

24

02/08/2016

Zn Ti - General

Really only experimental at present


Appears to reduce the Sandelin Peak but not
effective at higher Si levels
Indications are that low levels (<0.01%) may be
needed
Likely to be part of an alloy mix

Zn V Ti - General
Coatings are smooth and bright but without spangle
Coatings appear yellowish (although not if Al >
0.003%)
Initial indications are that 0.04% V 0.05% Ti are
effective (using PW) up to 1% Si in steel
Zn pick-up reduced by 37%
Coating thickness can be reduced by 50%
Ash production up by 50% - compatibility problems
with conventional fluxes thought to be the reason
Microstructure is similar to normal coating

Zn-Sn-V-(Ni)

Coatings tend to be shiny with large spangles


No accelerated kettle attack (compared to Zn-Pb)
Zn pick-up reduced by around 50%
Effective on steels with SE to 0.5%

25

02/08/2016

Zn-Sn-Bi-Ni

The coating thickness can increase slightly in the normal


range. However, this can be controlled by reducing the
temperature to 440
Coating is bright with large spangles
For reactive steels the coating thickness drastically reduced.
Dross generation can be reduced by 50%
Little or no floating dross
Ash production is reduced slightly
Provide the option for Pb free galvanizing
Requires bath additions of Sn 1.8% and Bi 0,5% with Ni 0.05%

Average coating thickness, um

Alloy additions impact on Sandelin effect

Zn Pb
Zn Ni

Ni Sn Bi

200
Sn V Bi
100
V Ti

0.1

0.2

0.3

0.4

Silicon equivalent (Si + 2.5P), wt%

Zn Al

Al can cause problems with fluxing so new techniques


are required
Current technologies include
- MicrozincTM (3% Al)
- GalfanTM (5%Al)

26

02/08/2016

Galvanizing and the standards


ASTM A123
- bath chemistry (impurities<2% by mass)
- coating thickness minimum specified
- adhesion test
ISO 1461
- bath chemistry (impurites < 1.5% by mass other than
Fe and Sn)
- coating thickness minimum specified

Requirements of ISO 1461

CASTINGS

PROFILES

MINIMUM COATING THICKNESS ON ARTICLES


THAT ARE NOT CENTRIFUGED
Local
Category and
Mean coating
thickness m
coating
thickness (t)
thickness
mm
m
70
85
t6
3t<6
55
70
1.5 t < 3
45
55
t < 1.5
35
45

t6

70

80

t<6

60

70

Minimum Average Coating


Thickness Grade,
asMinimum
per ASTM
A123
Coating
Average Coating
Article Thickness
Structural
shapes
mm

Grade

Thickness
Microns (g/m2)

inches

< 1.6

< 1/16

45

45(320)

1.6 - < 3.2

1/16 - < 1/8

65

65(460)

3.2 - < 4.8

1/8 - 3/16

85

85(600)

4.8 - < 6.4

>3/16 - < 1/4

85

85(600)

6.4

1/4

100

100(705)

27

02/08/2016

Minimum Average Coating Thickness Grade,


as per ASTM A153
Class of
material

Class A
Class B
B-1
B-2
B-3
Class C

Class D

Description

Castings
Rolled, pressed and forged
articles
t 4.76mm (3/16"), l <
381mm (15")
t < 4.76mm (3/16"), l <
381mm (15")
any t, l < 381mm (15")
fasteners, d > 9.52 (3/8")
washers, t = 4.76mm
(3/16") - 6.35 (1/4")
fasteners, d 9.52 (3/8")
washers, t < 4.76mm
(3/16")

Minimum weight of zinc coating (g/m2)


of surface
Any individual
Average of
specimens tested1 specimen
610
550

610

550

458
397
381

381
336
305

305

259

1. Number of articles sampled to be taken as similar to that


for ISO 1461

Summary of alloy performance


Alloy

Appearance

Comments

Zn Pb (GOB/PW)

Base standard. Good


even coating with spangle

On normal steels coating


acceptable.

Zn Ni (TechnigalvaTM )

Bright, white with good


spangle

Only effective up to 0.25%


Si

Zn Bi (GalvaFlowTM )

Bright coating with angular


spangle

No affect (on its own) with


reactive steels

Zn Sn (development
alloy to GalvecoTM ,
BritePlusTM )

Whitish coating with large


spangles

Effective on all steels but


high concetrations needed
to counter reactive steels

Zn-Sn-Bi-Al (Brite
PlusTM )

Bright coating with large


spangles

Effective on all steels and


complies with ASTM 123

Bright coating with large


spangles

Effective on all steels but


need to be aware of
standards restrictions

Zn-Sn-Bi-Ni

(GalvecoTM )

Summary by element
flux

reactivity

fluidity

spangle

brightness

reduces

increases

dross

Effect
Element

Al
Pb
Ni

Sn

increases

increases

V Ti
Bi

28

02/08/2016

HDG Alloys/Processes - Tradenames


Type

Trade name

Company

Zn Al Pb Sn Mg

PolyGalva

Groupe PolyGalva

Zn Al Ni

Supergalva

Mitsui

Zn Ni1

Technigalva
Direct Alloy Process

Nyrstar
Teck

Zn Ni V1

Ecozinc

Groupe Ecozinc

Zn Bi1,2

GalvaFlow

Xstrata

Zn Bi Sn Al1,2

BritePlus

Teck

Zn Sn Bi Ni1

Galveco

Nyrstar

Zn Bi Sn V1
Zn V

Ti1

Teck/Nyrstar
Decraloy and others

Teck

1.

Can be used with SHG or PW-Zn with added Al

2.

Can be used with Zn Ni baths

So why use alloys?

Improved coating quality drainange, etc.


Control steel reactivity (Al, Ni, Sn, V, Ti)
Reduce coating thickness (Al, Bi, Pb, Sn)
Improve plant efficiency?! (especially mixed alloy use)
Need to control maximum additions!?
Maybe provides opportunity for plant selfmanagement?!

Closing remarks

HDG requires mastery of the basics


The Si and P effects are more complex than originally
thought
Bath Alloys offer some opportunities to minimise
steel reactivity and improve coating appearance
However, all bath alloys require careful control and
plant testing to check producer claims

29

WORKSHOP 3 OPTIMISING FABRICATIONS (DISTORTION, VENTING, ETC)


Key questions checklist
Basic checklists
1. Role of design - communications
2. Steel suitability
3. Welding
Standards
1.
2.
3.
4.
5.

ISO 1461
ASTM A 123
ASTM A 385
ISO 14713
ISO 12944

Distortion
Venting
1. Worldwide recommendations
di

02/08/2016

Fabrication requirements for


galvanizing
Workshop 3 APGGC 2016
Rob White

Topics/Methodolgy

Galv quizz what do you know


Basic checklists
Standards ISO 1461, 14713, ASTM 123, 385
Distortion - general
Venting guidance specifically
Photos and discussions

What do you know?


Overlaps, gaps, and holes must be designed at least ___ in size for
the zinc in the galvanizing process to penetrate and fully coat the
steel surface.
a. 2.0mm b. 0.8mm c. 6.0mm d. 12.5mm
What will happen at joints of steel sections that differ considerably in
thickness during hot-dip galvanizing?
What repair methods are permissible?
a. Zinc-rich paint, zinc-based solder, and zinc flame spray
metallizing
b. Zinc-based solder, zinc electroplating, and zinc-rich paint
c. Zinc-rich paint, zinc-flame spray metallizing, and cathodic
protection
d. Zinc-based solder, zinc-flame spray metallizing, and zinc
electroplating

02/08/2016

Basic checklists
Standards 1461, 123, 14713, 385, 12944
Liaison Between Design Engineer, Fabricator, and Galvanizer
(ISO 1461 Annexure A)
Steel suitable for galvanizing and suitably marked
Combining Different Materials and/or Surfaces
Designs comply with ISO 14713 Pt2/ASTM A 385 size and
shape, overlapping surfaces, distortion, castings, threaded
parts, moving parts.
Welding complies with AWS D1.1/ISO 8501 (table 1)
Venting and draining is possible
Lifting for galvanizing

Simple notes to fabricator

Cutting holes try to drill


Remover sharp edges and corners
Remove paint, wax, oils and slag

ASTM A385

Steel selection
Use of different materials
Overlapping surfaces
Cutting, shearing, punching
Cold forming - distortion

02/08/2016

ISO 14713 Pt 1

ISO 14713 Pt 2 Annexure A

S te p 3
* S e le c t a n IS O 1 2 9 4 4 c om plia nt s ys te m

E N IS O 1 2 9 4 4 -5: 19 9 8
T a b le A 9 : P a in t s ys te m s c o rro siv ity c a te g o r ie s C 2 to C 5 -I an d C 5 -M
S u b s tra te : H o t-d ip -g a lv a n iz e d s te e l)
Th e p a in t s ys te m s g ive n i n th e fo llo w in g ta b le a re o n ly e xa m p le s ,. O th e r p a in t s ys te m s h a vin g th e s a m e p e rfo rm a n c e
a re p o s s ib le .
If th e s e e xa m p le s a re u s e d , it s h a ll b e e n s u re d th a t th e p a in t s ys te m s c h o s e n co m p ly w ith th e in d ic a te d d u ra b ility w h e n e xe c u tio n o f th e p a in t w o rk ta k e s

P a in t
Syst em
No

P r i m i ng c o a t ( s)

B ind er 5)

N umb er o f
co at s

S9 .0 1
S9 .0 2

PV C

S9 .0 3
S9 .0 4
S9 .0 5
S9 .0 6

AY

T o p c o a t ( s) ) i nc l ud i ng
i nt e r m e d i at e c o a t ( s ) )

NDFT

3)

B ind er 5)

40

80

80

PV C

40

T o t al N D F T 3 )
L

80

80

12 0

80

16 0

16 0

240

80

80

80

80

80

16 0

80

16 0

240

S9 .0 9

80

80

40

80

12 0

S9 .11

S9 .12

S9 .13

80
80

EP
or
4)
PU R

80

80

B ind e r s f o r p r iming c o a t ( s )

2 -3

16 0

240

3 -4

1- p ack

2 - p ack

PV C

= Po lyvinyl chlo r id e

AY

= A cr ylic

EP

= Ep o xy

PU R

= Po lyur et hane

C3
H

C 5- I

C4
H

C 5- M
H

16 0
240
320
B i nd e r s f o r t o p c o a t ( s)

P a i n t s ( l iq ui d )
N o o f co mp o nent s

80
12 0

S9 .0 7

EP
or
PU R

C2

1
AY

E x p e c t e d d u r ab i l i t y 2 ) 6 )
( s e e 5 . 5 a n d I S O 12 9 4 4 - 1)

P a i nt s y s t e m

NDFT 3 )

S9 .0 8

S9 .10

1)
2)
3)
4)
5)
6)

N um b er o f
co at s

P a i nt s ( l i q u i d )
N o . o f co mp o nent s

W at er
b o r ne
p o ssib le

1- p ack
PV C

= Po lyvinyl chlo r id e

AY

= A cr ylic

EP

= Ep o xy

PU R

= Po lyur et hane

2 - p ack

W at er
b o r ne
p o ssib le

x
x

x
x
x

Th e m e c h a n ic a l o r c h e m i ca l s u rfa c e p re p a ra ti o n re rq u ire d is d e s c rib e d in IS O 1 2 9 4 4 -4 .


Th e d u ra b ility is in th is c a s e re la te d to th e p a in t s ys te m a d h e s io n to th e h o t-d ip -g a lva n ize d s u rfa c e .
N D FT = N o m in a l D ry Film Th ic k n e s s . S e e 5 .4 fo r fu rth e r d e ta ils .
If c o lo u r a n d g lo s s re te n tio n is re q u ire d , it is re c o m m e n d e d th a t th e la s t c o a t s h o u ld b e b a s e d o n a l ip h a tic P U R .
Fo r e xp la n a tio n o f a b b re via tio n s , s e e fo o t o f ta b le
L ig h t g re y s h a d in g in d ica te s th a t th e p a in t s ys te m s c o n c e rn e d w o u ld n o t n o rm a l ly b e u s e d fo r th e s e c o rro s ivity c a te g o rie s .
Th e y a re n o t lis te d in ta b le A.2 a n d /o r A.3 .

02/08/2016

Distortion

Insertion in molten zinc


will reduce the yield
strength of most steels by
around 30/40% temporarily

VIDEO
Beam distortion
bracing

Distortion in beams 2

Distortion
Design and fabricate sections of uniform steel thickness.
Use symmetrical designs where possible, and avoid asymmetrical designs where
cleats or plates are welded to one side only of a beam or RHS section.
Avoid designs which require fabrications with a large surface area of thin plate to be
double-dip galvanized.
During fabrication use balanced or staggered welding techniques to avoid uneven
locked-in stresses.
If cutting a plate to size, ensure all sides are cut using the same technique. Guillotine
is the preferred cutting technique.
Ensure that the structural design of the item is sufficient to support its own weight
at 50% of the steel specified yield strength. Consider temporary bracing if potential to
yield exists.
Ensure that venting and draining holes are adequate. This will allow the item to be
immersed and withdrawn from the molten zinc as quickly as possible.
During fabrication, accurately perform parts to avoid force or restraint during
welding.
Consider (or consult your galvanizer) the hanging requirements for the hot dip
galvanizing process. This will ensure the fabrication is adequately supported
throughout the process.
Lift and lower the jig during immersion to minimise immersion by assisting melting
of solidified zinc

02/08/2016

Venting reasons for

Safety
Coating continuity
Immersion speed and internal stressing
Appearance

Venting - size of holes

Venting size of holes

02/08/2016

Developing design
recommendations for Kjoints
Vents and position of holes for
analysis

02/08/2016

Conclusions
No difference is detected in test results for
geometries with and without vent holes. This
lack of influence was also observed in the finite
element simulation. The welds with the chord
are close to the holes, acting as reinforcement.
Therefore, the local buckling in the brace does
not occur at the location of the hole.
The most common failure mode in the tested
joints was local buckling of the brace member
that is far enough from the hole to avoid any
influence of it.
It is possible to develop design guidance on the
size and location of galvanizing holes for tubular
lattice girders and similar structures.

Venting
General comment would still be 25% of dia/width for a
CHS

02/08/2016

Finally

Photos and videos


DISCUSSIONS

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