Professional Documents
Culture Documents
Rob White
Representing Corr-Serve
Topics
02/08/2016
OXIDATION
Fe = Fe2+ + 2e
cathode
Anodic dissolution
anode
e-
steel
Flow of
electrons
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
100
rural inland, C2
80
60
40
industrial inland/urban
coastal, C4
20
polluted industrial/coastal,
C5
0
0
10 20 30 40
50 60
70 80
thickness, um
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
Topics/methodology
02/08/2016
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
02/08/2016
In-line
L-shape
U-shape
Monorail transport
02/08/2016
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
Wires
02/08/2016
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
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
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
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)
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
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
Zinc quality
Role of Al
Immersion and withdrawal
Skimming, drossing
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
8/2/2016
Contents
Introduction
Degreasing
Rinsing
Pickling
Fluxing
Passivation
Closing Comments
8/2/2016
Mixture based
on E1 has
good
wettability
and low
smoke
Modern fluxes
based upon
E2. Lowers
thermal
tension and
thus
possibility of
surface
cracks.
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
8/2/2016
8/2/2016
Operational range
(very low corrosion
rate) measured
buffer capacity, g/l
HCl
8/2/2016
ZnCl2
to
NH4Cl
ratio
8/2/2016
Flux regeneration
Flux Bath
ZnCl + NH Cl
2
Hydrogen peroxide
Ammonia
Reaction Tank
Sludge Thickener
Filter Press
8/2/2016
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)
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
55.65%
44.35%
45.80%
54.20%
Comment:
If the Iron is too high it will effect the accuracy of the SG reading.
Iron should not exceed 2.5gms/lt.
Calculation of density, SG =
Insert Actual ZnCl2, gms/lt. =
Insert Actual NH4Cl, gms/lt. =
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%
45.80%
54.20%
Drying
8/2/2016
Open drying
Controlled cooling
Quenching
Quench and passivation
Passivation
ZnO
Zn(OH)2
ZnCO3
8/2/2016
Passivation liability or
essential process
Atmosphere
Reacts with
Forms
Zn
ZnO
Zn(OH)2
Unstable
White Rust
ZnCO3
Stable
Protective
Barrier
10
8/2/2016
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)
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
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
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
Storage options
Keep dry
Store off ground
Stack with separation between articles
Store at an angle
Transport sheets covered
13
8/2/2016
Closing Comments
14
8/2/2016
Towers
General
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
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
4
5
6
7
8
9
10
11
Water Rinse
Water Rinse (Includes cascading)
Ambient
Ambient
12
13
14
15
16
NOTES:
Max.Temp. 45 to 50C
Max.Temp. 45 to 50C
Ambient
ZnCl2
gms/lt.
3NH4Cl
gms/lt.
15
8/2/2016
Chemical analyses
Training
16
8/2/2016
17
02/08/2016
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
02/08/2016
Influence of Al
avoiding oxidation
reduced wettability
risk of black spots
thickness reduction
10
60
300
1500
ppm Al
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
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
02/08/2016
Skimming
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
02/08/2016
02/08/2016
GALVANIZING QUALITY
Defects management
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.
CAUSES
Ash deposits
Flux
inclusions
and deposits
CONDITION
CAUSES
Dull grey or
mottled
coating
appearance
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.
02/08/2016
Galvanizing bath
composition
29
10
02/08/2016
Market aesthetics
Large multifaceted crystal
structure
Provides for a better
gloss on paint coating
However all coatings will
turn grey in time!
11
02/08/2016
12
02/08/2016
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
0 - 0.04
> 0.035
High especially
when P high
Sandelin
(low P)
4a
0.04
0.135
< 0.01
Moderate
increases with Si
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
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, %
14
02/08/2016
15
02/08/2016
16
02/08/2016
Element
Si
< 0.04
Si + 2.5P
<= 0.09
Si
0.15 - 0.2
General Comments
Issue
Developed market
Developing market
Comment
Cost
Ditto
Fabricator
Viewed as an important
chain in acceptance
Ditto
Steel Use
Coating
performance
Specifier often
persuaded by direct
comparisons
Markets
Market
Development
Communicati
on
Most methods of
communication can be
used. There are numerous
sources of data
Standards
Performance is often
company dependant
restricting overall
growth
Performance
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
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
Distribution of Ni
19
02/08/2016
20
02/08/2016
21
02/08/2016
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
24
02/08/2016
Zn Ti - General
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)
25
02/08/2016
Zn-Sn-Bi-Ni
Zn Pb
Zn Ni
Ni Sn Bi
200
Sn V Bi
100
V Ti
0.1
0.2
0.3
0.4
Zn Al
26
02/08/2016
CASTINGS
PROFILES
t6
70
80
t<6
60
70
Grade
Thickness
Microns (g/m2)
inches
< 1.6
< 1/16
45
45(320)
65
65(460)
1/8 - 3/16
85
85(600)
85
85(600)
6.4
1/4
100
100(705)
27
02/08/2016
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")
610
550
458
397
381
381
336
305
305
259
Appearance
Comments
Zn Pb (GOB/PW)
Zn Ni (TechnigalvaTM )
Zn Bi (GalvaFlowTM )
Zn Sn (development
alloy to GalvecoTM ,
BritePlusTM )
Zn-Sn-Bi-Al (Brite
PlusTM )
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
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.
2.
Closing remarks
29
ISO 1461
ASTM A 123
ASTM A 385
ISO 14713
ISO 12944
Distortion
Venting
1. Worldwide recommendations
di
02/08/2016
Topics/Methodolgy
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
ASTM A385
Steel selection
Use of different materials
Overlapping surfaces
Cutting, shearing, punching
Cold forming - distortion
02/08/2016
ISO 14713 Pt 1
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
02/08/2016
Distortion
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
Safety
Coating continuity
Immersion speed and internal stressing
Appearance
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