Document No: PIPPL/SP&C/IOCL/TCMPL/002

PASSIVE INFRA PROJECTS PVT LTD

Revision No: 00, Dated : 19-03-2022

Galvanizing Procedure

CONTENTS
1. Galvanizing Process

2. Hot Dip Galvanized Coating

3. Hot Dip Galvanized Benefit

4. Coating Defect

5. Repairing Galvanized

6. Zinc Rich Paint

7. Designing Articles/ Fabrication on Galvanizing

8. Effects of Silicon On Coating

9. Inspection Coating and Continuity

10. Standards Related to Hot Dip Galvanizing

 Document No: PIPPL/SP&C/IOCL/TCMPL/002
Revision No: 00, Dated : 19-03-2022
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Galvanizing Procedure

GALVANIZING FLOW CHART

Preparing/Classified

Caustic Soda (NaOH)

For fresh & clean steel or re-
galvanized (Grit Blasting, Concentrate Controlled at 8—10%
Special Treatment on Request
Degreasin
at Extra– Charge) g Temp: 50-70 C

Risin
g

Visual
Inspection

Pickling 1
Hydrochloric Acid (HCl)

Concentrate Controlled at 8—18%

Pickling 2 Temp: Room

Ferrous content 110 g/l

Pickling 3

Rinsin
g
Zinc Ammonium Chloride
(ZnCl2)
Visual
Chemical Composition
ZnCl2 = 60% by volume Inspection

NH4Cl = 40% by volume

Pre-Flux Zn Content > 98% [ASTM B6]
pH = 4.0
Al Content <0.007%
Galvanizin Temp: 440-450 C
g
Air Cooling
Quenchin
g Sodium Dichromate (Na2Cr2O7)

Content: 300-1000 ppm

Treatmen
t Controlled following to

ASTM A123/A123 M, AS/NZS 4680, and

Testing/Finishing BA EN ISO 1461 Standard

Packing/ Storage
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GALVANIZING PROCESS

The galvanizing process consists of three basic steps: surface preparation, galvanizing and inspection.

SURFACE PREPARATION
Surface preparation is the most important step in the application of any coating. Any failures or
inadequacies in surface preparation will immediately be apparent when the steel is withdrawn from the
molten zinc because the unclean areas will remain uncoated and immediate corrective action must be
taken.

Caustic Cleaning - A hot alkali solution often is used to remove organic contaminants such as dirt,
paint markings, grease and oil from the metal surface. Epoxies, vinyl’s, asphalt or welding slag must be
removed before galvanizing by grit-blasting, sand-blasting or other mechanical means.

Pickling - Scale and rust normally are removed from the steel surface by pickling in a dilute solution of
sulfuric acid (5-15% by volume) or ambient temperature hydrochloric acid.

Fluxing - Fluxing is the final surface preparation step in the galvanizing process. Fluxing re- moves oxides
and prevents further oxides from forming on the surface of the metal prior to galvanizing.

GALVANIZING -In this step, the material is completely immersed in a bath consisting of a minimum of
98% pure molten zinc. The bath temperature is maintained at about 840 F (449 C). Fabricated items are
immersed in the bath until they reach bath temperature. The zinc metal then re- acts with the iron on the
steel surface to form a zinc/iron intermetallic alloy.

INSPECTION - A variety of simple physical and laboratory tests may be performed to determine thickness,
uniformity, adherence and appearance. Products are galvanized according to long- established, well-
accepted, and approved standards of ASTM A123/A123M, AS/NZS 4680, and BS EN ISO 1461.

HOT DIP GALVANIZED COATING

Coating Structure
Galvanizing forms a metallurgical bond
between the zinc and the underlying steel or
iron, creating a barrier that is part of the metal

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itself. The figure (left side) is a

photomicrograph of a galvanized steel coating
cross-section and shows a typical coating
microstructure consisting of three alloy layers
and a layer of pure metallic zinc.
 Coating Uniformity
The galvanizing process naturally produces coatings that are at least as
thick at the corners and edges as the coating on the rest of the article. As
coating damage is most likely to occur at the edges, this is where added
protection is needed most. The figure below is a photomicrograph
showing a cross-section of a corner of a galvanized piece of steel.
Galvanizing provides protection on both exterior and interior surfaces of
hollow structures. Hollow structures that are painted (but not galvanized)
have no corrosion protection on the inside.

Coating Thickness
The chemical composition of the steel
being galvanized is very important. The
amount of silicon and phosphorus in the
steel strongly influences the thickness
a n d appearance of the galvanized
coating. Silicon, phosphorous or
combinations of the two elements can
cause thick, brittle galvanized coatings.
The coating thickness curve shown in
the figure below relates the effect of
silicon in the base steel to the thickness
of the zinc coating. The carbon, sulfur
and manganese con- tent of the steel
also may have a minor
effect on the galvanized coating thickness. The combination of elements mentioned above, known as
“reactive steel” in the galvanizing industry, tends to accelerate the growth of zinc-iron alloy layers. This
may result in a finished galvanized coating consisting entirely of zinc-iron alloy. Instead of a shiny
appearance, the galvanized coating will have a dark gray, matte finish. This dark gray, matte coating will
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provide as m u c h corrosion protection as a galvanized coating having a bright appearance.

HOT DIP GALVANIZED BENEFITS

CORROSION RESISTANCE - Galvanized coatings protect steel in three ways:

1. The zinc weathers at a very slow rate giving a long and predictable life.

2. The coating corrodes preferentially to provide sacrificial protection to small areas of steel exposed
through drilling, cutting or accidental damage.
3. If the damaged area is larger, sacrificial protection prevents sideways creep which can undermine
coatings.
COATING TOUGHNESS - Galvanizing is unique. The process produces a coating which is bonded
metallurgical to the steel.
COMPLETE COVERAGE - All parts of the surface of the steelwork are coated - external, internal,
awkward corners and areas with narrow gaps.

RELIABILITY - Able to specified too many standard

SPEED OF APPLICATION - Can be applied in minutes

FASTER CONSTRUCTION - No site surface preparation is necessary

LOWEST LIFETIME COST - Competitive initial cost and long life make hot dip galvanizing the most
versatile, economic method of protecting steelwork.

LONG LIFE - Often exceeding 10 years

EASE OF INSPECTION - The nature of the process is such that if the coating looks continuous and
sound, it is so.
COMPETITIVE FIRST COST - For many applications the cost is lower than alternative coatings.

BARRIER PROTECTION -Galvanizing provides a barrier between all internal and external steel
surfaces and their environment. Galvanizing is a term often wrongly used to describe zinc coatings in
general. The diagram below illustrates how the different types of zinc coatings vary in terms of coating
thickness. The life expectancy of a zinc coating is largely determined by its thickness. Thicker coatings
give longer life.
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(Steel Structure)

COATING DEFECT

(i) De-lamination

(ii) Drainage Spikes

(iii) Distortion

(iv) Flux Inclusion

(v) Flaking

(vi) Rough Surface Condition

(vii) Runs

(viii) Rust Bleeding

(ix) Weld Spatter

(x) Welding Blowouts

(xi) Wet Storage Stain

(xii) Dross Inclusions

(xiii) Bare Spots

(xiv) Sand Embedded in

Casting

(xv) Touch Marks

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Design Articles/Fabrications for Galvanizing

Early consultation between galvanizer, fabricator and designer is the key to

obtaining the best results from the galvanizing process. Design features which aid
the access and drainage of molten zinc will improve the quality of the coating.

Good design requires:

 Means for the access and drainage of molten zinc
 Means for escape of gases from internal compartments (venting)

It is important to bear in mind that the steelwork is immersed into and withdrawn from a bath of
molten zinc at about 450C. Thus any features, which aid the access and drainage of molten zinc,
will improve the quality of the coating and reduce costs.

General principles
1. Holes for venting and draining should be as large as possible.

2. Holes for venting and draining should be diagonally opposite to one another at the high
point and low point of the fabrication as it is suspended for galvanizing.

3. With hollow sections sealed at the ends, holes should be provided, again diagonally
opposite one another, as near as possible to the ends.

4. Where holes are provided in end plates or capping pieces, they should be placed diagonally
opposite one another, off center and as near as possible to the wall of the member to which
the end plate is connected.

5. Internal and external stiffeners, baffles, diaphragms, gussets etc., should have the corners
cropped to aid the flow of molten zinc.

Base metal and combinations

Plain carbon steel, some low-alloy steels and iron and steel castings can all be galvanized. A
fabrication consisting of a variety of materials with different surface conditions should be avoided as
this could affect the uniformity and appearance of the coating. Where differing materials are used,
grit blasting the entire assembly can minimize any differences which may arise due to differing
effects of pre-treatment. Preferably, the fabrication should be of similar steel type throughout.
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Size and shape

When the length or depth of the item exceeds the size of the bath, special techniques may be employed to
facilitate dipping. The galvanizer should be consulted.

Moveable parts
Adequate clearance on mating surfaces, such as hinges, should allow if they are to move freely after
galvanizing. An extra clearance of at least 1mm is usually sufficient.

Overlapping surfaces
Overlapping surfaces should be avoided as far as possible. Care must be taken not to specify sealed
articles for galvanizing. If overlaps are completely sealed by welding there is a risk of explosion during
dipping due to increased pressure of any entrapped air. If overlaps are not completely sealed there is a
danger of cleaning fluid entering the cavity and then weeping out and causing localized staining.

Distortion
Efforts can be made at the design stage and elsewhere to minimize residual stresses, for example:

1. Controlling welding procedures during fabrication.

2. Arranging weld seams symmetrically. The size of weld seams should be kept to a minimum.

3. Avoiding large changes in structural cross-section which may increase distortion and thermal stress
in the galvanizing bath.

Surface contamination

Clean steel surfaces are an essential requirement for good hot dip galvanizing. Contamination in the form of
grease, tar paint and weld slag cannot be removed by chemical cleaning and may result in black bare spots
after hot dip galvanizing. Fabricator should take responsibility to ensure that articles being delivered free
from contamination. (Otherwise, an additional charge for shot- blasting may be added)

Design of structures to be hot-dip galvanized is no different from that for good structural, surface treatment
and welding practice in general. However, certain components require special attention.

It is important that larger structural components are matched to the size of the pickling tank and zinc bath
(Fig A). Sometimes “double-dipping”, which involves the handling of structural components longer than the
zinc bath, is employed. (Fig.B).

Bolted joints are preferred instead of welding, since welding burns off the galvanized coating, which haves
to be repaired. The weight of the construction. The galvanizing plants can only handle constructions that the
cranes can handle.
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Fig. A. Schematic diagram of hot dip galvanizing. Fig. B. Schematic diagram of double-dipping.

Safety requirements
Hot-dip galvanizing involves dipping components and structures in both pretreatment baths and molten
zinc. This means that hollow structures, such as pipes, tubing, and containers and also beam structures,
which are welded round the connection point, must be provided with holes for drainage and venting. If a
sufficient number of holes are not provided to enable complete venting, there is a significant risk that the
structure will explode on immersion. Also, pickling acid is capable of penetrating pores in welds. Upon
dipping in the zinc bath the residual pickling liquid is vaporized and the pressure can be so high that the
object explodes. The risk of serious injury to personnel, or damage to materials, is great when such
explosions occur.

Suitable dimensions for venting holes are given in table below. The holes must be located to enable total
venting and to enable pickling acid and molten zinc to run in and out easily. Illustrations show this point.
Examples of the location of the holes are given in the illustrations. It is also advisable to contact the
galvanizer to discuss alternative hole sizes and locations. Holes can be formed by drilling, grinding or gas
cutting.

EFFECT OF SILICON ON COATING

The presence of silicon in the base steel significantly affects the structure and properties of the resulting
galvanized coating. Certain silicon levels can be responsible for excessively thick galvanized
Coatings which are often brittle and dull in appearance.
Pickup occurs between 0.05 and 0. 1% Si followed by a trough at around 0.15% to % Si after which the
Reaction rate increases again. Galvanizing temperature and immersion time also affect the location of the peak
and trough of the graph.

Since the life of the coating is proportional to its thickness, heavy grey coating, provided they are sound and
continuous, are beneficial.
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INSPECTION COATING AND CONTINUITY

As a final step in the galvanizing process, the hot-dip galvanized coating is inspected for compliance with
specifications. The coating thickness is the single most important component in determining a galvanized
coating’s quality. Coating thickness, however, is only one inspection criteria. Coating uniformity, adherence,
and appearance should also be checked. Inspection of the galvanized product can be most effectively and
efficiently conducted at the galvanizer’s plant where questions can be asked and answered quickly.

There are a number of simple magnetic gauges used to give a convenient a n d reliable measurement of the zinc
coating thickness, provided the instruments are properly calibrated. The three most common types of metal
coating thickness gauges are: Magnetic balance gauges, sometimes called “banana gauges,” measure variation
in the force of attraction between two ferromagnetic bodies as a function of the distance between them. This
type of gauge has the advantage of being able to measure the coating thickness in a horizontal or vertical
position.

Pull-off magnetic gauges are also based on magnetic attraction to the underlying steel. These devices are
shaped somewhat like a pen and are very convenient to make quick, rough estimates to determine whether
the coating thickness meets specification. Electronic gauges are the easiest and most accurate coating
thickness measurement gauges available. They have the ability to connect to an assortment of probes,
providing the ability to measure on any orientation. One of the major advantages to specifying hot-dip
galvanized steel is the ease of identifying coating defects immediately after galvanizing. Any areas that may
re- main uncoated are easily identifiable. If large areas of the steel remain uncoated due to residues left on
the steel from fabrication, then the steel must be stripped free of zinc and processed again. If small areas are
left un-galvanized, they can be reconditioned using one of the three accepted methods of touch-up and
repair.

STANDARDS RELATED TO HOT DIP GALVANIZING

I) IS-2629 - Recommended practice for Hot-dip galvanizing of Iron or steel sections.

II) IS-4759 - Specification for Hot-dip coatings on structural steel and other allied products.

III) IS-729 - Zinc for galvanizing – specification

IV) IS-2633 - Method for testing uniformity of coating on zinc coated articles.

v) IS-6745 - Method for determination of mass of zinc coating on zinc coated iron and steel articles.