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Hot-Dip Galvanizing
AN OVERVIEW FOR ENGINEERS, ARCHITECTS, AND DETAILERS
By Philip G. Rahrig and John Krzywicki
H
igh quality galvanized The viscosity of liquid zinc at the vent and drain holes. Tubular or hollow
coatings are obtained galvanizing temperature plays a large fabrications must allow for cleaning so-
when steel assemblies are role in which assemblies can be galva- lutions and zinc to freely flow on both
designed to promote un- nized easily. The viscosity of molten the interior and exterior surfaces. To
restricted flow of cleaning zinc prevents it from entering gaps or accomplish this, vent and drain holes
solutions and molten zinc during the crevices less than 3/32”. Inside corners should be placed near the ends of steel
hot-dip galvanizing process. A basic on steel fabrications also present qual- articles to allow zinc to penetrate the
understanding of how steel is handled ity issues if not properly designed for interior, as well as drain from the inte-
in the galvanizing plant and what the galvanizing. In general, the number of rior upon withdrawal from the galva-
steel undergoes in the application of corners should be minimized. When nizing kettle.
the galvanized coating will aid steel applicable, corners should be cropped Recommended Details for Hot-Dip Galva-
detailers in preparing drawings that or enough space (3/32”) must be pro- nized Structures, produced by theAmerican
will produce the best possible galva- vided for the molten zinc to easily flow Galvanizers Association (AGA), is a use-
nized finish. in and out of tight spaces. When this ful reference and can be downloaded from
issue is overlooked, zinc will tend to www.galvanizeit.org/ref/details. It in-
Keep the following details in mind “pool” in these areas causing excessive- cludes working drawings containing the
when developing and reviewing ly thick coatings that may easily flake most commonly galvanized structures
structural details and shop draw- when subjected to rough handling. In and includes the necessary details re-
ings: addition, cleaning solutions are much quired for quality galvanizing. Another
Are the vent and drain holes of suf- less viscous than molten zinc and can useful reference is Designing with Hot-
ficient size and quantity? enter tight spaces that the zinc cannot. Dip Galvanized Steel, an AGA-produced
Dried residue from cleaning solutions CD-ROM.
Are the vent and drain holes locat- may remain trapped in the crevices af- After choosing hot-dip galvanizing as
ed properly? (One or more for drain ter galvanizing and may bleed onto the the corrosion prevention system for your
and one or more for venting.) surface if they come into contact with project, ASTM A123/A123M-02, Standard
Are corners of gussets, stiffeners, moisture. This will cause unsightly rust Specification for Zinc (Hot-dip Galvanized)
and bracing cropped to allow free staining on the surface of the steel. Coatings on Iron and Steel Products should
flow of zinc? Arguably the most important com- be the cornerstone of your project speci-
ponents of galvanized steel design are fication. ASTM A123 applies to structural
If the fabrication is comprised of
steel of two or more thicknesses,
is it designed to promote minimal
change in camber/straightness?
Are welds at overlapping surfaces
seal welded?
Does the fabricator know to remove
all weld flux and to use a weld mate-
rial of suitable chemistry to produce
good zinc coating?
Have I accounted for marking/
tracking of the parts through the
galvanizing process and on to the
job site?
Have I planned for tapping of nuts Identification marks or tags for each piece Cropped corners allow molten zinc to flow in
or threaded holes after galvaniz- need to be sturdy enough to survive the gal- and out of tight spaces, avoiding “pooling” in
ing? vanizing process. these areas causing excessively thick coat-
ings that may flake during rough handling.
be progressively dipped (aka “double-dip”) have a higher sus-
Is the steel going to receive an additional coating
ceptibility of warping (refer to ASTM A384, Standard Practice
on top of the galvanizing?
for Safeguarding Against Warpage and Distortion During Hot-
Inform the galvanizer that the steel is going to be coated after
Dip Galvanizing of Steel Assemblies, for additional informa-
galvanizing so they do not quench the material. After the article
tion). To eliminate concerns over warping, bracing— perma-
is removed from the kettle, it is often quenched to increase
nent or temporary— can be used to provide stability during the
the rate of cooling and/or to coat the steel with a passivation
thermal expansion and contraction cycle. Occasionally, when
layer to protect the galvanizing in transit and storage. This pas-
bracing is not used and warping and/or distortion occur, the
sivation layer may interfere with additional coating operations
part will return to its original shape during cool-down.
(refer to ASTM D6386, Standard Practice for Preparation of
molten zinc. Upon removal from the kettle, the once-molten
Is my fabrication going to fit in the galvanizing
zinc metal will solidify. As a result, the possibility exists for mov-
kettle?
ing parts such as drop-handles, shackles, shafts, and hinges
Throughout North America, a variety of sizes of hot-dip galvaniz-
to freeze together.
ing kettles is available, allowing a wide size-range of structural