QUALITY SYSTEM PROCEDURE Page 1 of 5

TITLE : HOT-DIP GALVANIZING PROCEDURE.

PROCEDURE NO : II/PR/LM6000/02

REVISION : 00 DATE: 15.06.2007.

PREPARED BY CHECKED BY

S.TAMIZH SELVAN, R. BALAMURUGAN,

ENGINEER – QUALITY. MANAGER - QUALITY
 II/PR/LM6000/02 REV.00 DATE 15.06.2007

HOT-DIP GALVANIZING PROCEDURE PAGE 2 OF 5

REVISION STATUS

REV DATE CHANGE

 II/PR/LM6000/02 REV.00 DATE 15.06.2007

HOT-DIP GALVANIZING PROCEDURE PAGE 3 OF 5

PROCEDURE FOR GALVANIZING & STEEL

1. SCOPE:
This procedure deals with the galvanizing procedure of hot-dip galvanizing
of iron & steel.

2. REFERENCE : ASTM A123-2001; ASTM A153; ASTM A143; ASTM B6;

SSPC SP1 & SP11

3. PROCEDURE :

3.1 Preparation of Metal surface for Galvanizing.

3.1.1 Cleaning: Removing of Contamination like oil, grease or paint over the
surface to be galvanized. Cleaning carried out by dipping the work in
degreasing bath and should be raised and lowered in order to allow
degreasing solution to enter inaccessible areas. Then immediately after
degreasing the work should be rinsed in hot water (60 0C) followed by
finding rinsing in cold running water.

3.1.2 Pickling: Removal of scale, patches and burnt-on on the surface to be

galvanized by dipping the work in pickling bath (Diluted hydrochloric acid
or sulphuric acid) with suitable inhibitor.

3.1.3 Rinsing: After pickling the work should be thoroughly rinsed in running
water.

3.1.4 Fluxing: Work is dipped in a strong solution of zinc ammonium chloride.

Note: Pre fluxed & dried work should be galvanized without delay i.e.
within an hour of fluxing

3.2 Galvanizing:

3.2.1 Galvanizing bath: Galvanizing bath should contain not less than an
average of 98.0% zinc by weight. The zinc used in the bath should
conform to Specification B6 (Slab zinc). Temperature of the bath is so
critical to have consistency in product quality & to economically use zinc.
Rate of immersion is as rapid as possible to reduce amount of dross & to
have uniformity of coating.

3.3 Water Quenching: To remove flux residues, work is quenched in water.

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3.4 Centrifuging: Small articles are handled in baskets. They are centrifuged to
remove excess of zinc immediately after galvanizing while the coating is still
in the molten condition. Threads on articles which are unsuited for
centrifuging shall be cleaned with a rotating wire brush immediately after
galvanizing before the coating sets.

3.5 Post-treatment: To avoid formation of ‘white rust’ or ‘wet storage stain’ on

freshly galvanized surfaces post treatment like chromating is carried-out
which will retard ‘white rust’ attack temporarily.

3.6 Stacking :To avoid flaking of coating articles are stacked immediately after
quenching to allow the articles to dry before any further handling.

4. Testing and inspection:

4.1 Visual Appearance: Coating shall be adherent, smooth, reasonably bright,

continuous & free from imperfections such as flux ash and dross insulation
bare & black spots, pimples, lumpiness & runs, rust stains, bulky white
deposits & blisters. No traces of solidified drop or sharp edges acceptable.

4.2 Coating thickness: Any one of the following method is used to determine the
coating thickness:

4.2.1 Magnetic Thickness Measurement: Using magnetic thickness gauge

the thickness of the coating is measured in accordance with Practice
E 376. A minimum of five readings shall be taken at each location near
the ends and in the middle of each piece being tested. For large
products, the minimum of five readings in a location shall be taken
peripherally about 4 in. (100 mm) from each end and in the approximate
center of the member.

4.2.2 Stripping Method: The average weight of zinc coating may be

determined by stripping test pieces from the sample at location
approximately 4 in. (100mm) from each end and third from the
approximate center of the member. The weight of coating is measured
and should conform to the standard. Weight of coating per square foot of
actual surface shall average not less than 3 ounces and no individual
specimen shall show less than 2.5 ounces.

4.2.3 Weighing before and after galvanizing: The average weight of the zinc
coating is determined by weighing the article before and after
galvanizing.
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4.3 Adhesion Test: The test is conducted on coated surface by cutting or prying
with the point of a stout knife, applied with considerable pressure in a manner
tending to remove a portion of the coating.

4.4 Embrittlement Test: The test is conducted in accordance with practice A 143

6. Repair of Galvanized surfaces:

All Galvanizing surfaces that require welding, cutting, drilling or other preparation
and any galvanized surface that has been damaged shall be repaired with an
approved coating repair system. Before application of repair coating surfaces
shall be prepared in accordance with SSPC SP1, followed by SSPC SP11.

7. Records:

Sample Galvanizing test report form as in Annex A

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 ANNEXURE - A

GALVANIZING - SUPPLIER NAME & ADDRESS

T.C. NO. : DATE :

TO YOUR PURCHASE ORDER No.

M/s. INDIRA INDUSTRIES
NO 6, SIPCOT INDUSTRIAL COMPLEX PROJECT :
RANIPET – 632 403

TEST CERTIFICATE
1. Reference Standard ASTM A123 - 2001

2. Name of the Zinc Used & Percentage

3. Component Description & Quantity

4. Test sample size

5. Magnetic Gauge reading

6. Stripe test result

7. Knife test

8. Visual Inspection

9. Others

Chemist : for

Date :