Professional Documents
Culture Documents
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Hunter Galvanizing
The hot dip galvanized process has been instrumental in providing protection
for steel items since 1837. Time proven and well documented, this process offers
many benefits unable to be provided by other coating systems:
layered barrier protection system
ease of inspection
high performance in
most environments
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Plant 2:
Project Warranties
UK Galvanizers Association
Hunter Galvanizing
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Hunter Galvanizing
Contents
Differentiating Zinc Coatings
Relevant Standards for Zinc Coatings on Steel
Different Zinc Coatings
Zinc Metallizing, Zinc Rich Paint, Continuous In-Line,
Electroplating, Sheridizing, Mechanical Plating
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1
1
1
2-3
Corrosion
Understanding Corrosion
How Zinc Protects
Cathodic Protection, Galvanic Series of Metals, Galvanic
Corrosion, Other Materials and Hot Dip Galvanized Coatings
4
4
6
6-8
9
9
11
13
13
13-14
19
19
19
20
20-23
Identification of Items
24
Welding
Welding Items for Hot Dip Galvanizing
Weld Quality, Welding Media, Welding Slag & Spatter, Welding
Painted Sections
Welding Galvanized Steel
25
25
25-27
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17-18
27
Distortion
Double (End) Dipping
Plate, Sheet and Coil sections
Channel Sections
Hollow Sections
28
29
30
31
32
33
34
36
37
37
41
42
44-46
47
48
49-51
52
52
53
53-54
Environmental Performance
Coating Life
Warm Dry Atmosphere, Rural Areas, Industrial Areas,
Coastal Areas
Time to First Maintenance
55
55
55-56
Duplex Coatings
Preparation & Pre-Treatment of Galvanized Steel
Abrasive Blasting, Powder Coating, Wet Brush/Spray Coating
57
57
57-58
59
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Electroplating
Continuous In-Line
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Zinc-iron alloy coatings are formed when molten zinc reacts with elements of
the steels surface in the galvanizing bath at a nominal operating temperature
of 450C. Hunter Galvanizing provides hot dip galvanized coatings with zinciron alloy layers in most cases harder than the base metal upon which they are
applied. An average coating mass of 600g/m is achieved on fabricated items of
steel thickness 6mm (and greater) in accordance with AS/NZS 4680. Details of
this process form the basis of this manual.
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In 1999, Australia Standards and New Zealand Committee MT/9 recognized the
unique characteristics of hot dip galvanizing on fabricated items and how these
varied from those of other coating systems. A number of separate standards
were created to distinguish different coating processes and the attributes
of each:
Metallizing
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Sherardizing
Corrosion
Understanding Corrosion
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Zinc Metal
Spraying
600-1500
g/m
Hot Dip
Galvanizing
300-900
g/m
Continuous
Galvanizing
40-240
g/m
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Zinc
Plating
60-80
g/m
Zinc Metal
Spraying
150
micro
ns
Comparison of Zinc Coating Thickness
Typical thickness of zinc coatings range from
10 microns to 150 microns. Protective life
is proportional to the zinc thickness and as
such hot dip galvanizing provides coating
protection second only to thermal spraying.
Electroplating
Hot Dip
Galvanizing
100
microns
10 mic
rons
BAS
EM
ETA
L
Mechanical
Plating
50
microns
Zinc
Sheridizing Rich
Paint
50
microns
BASE METAL
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50
microns
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Continuous
Galvanizing
25
microns
an anode:
an electronegative active metal on which corrosion
occurs (the electrode where galvanic reactions
generate electrons)
a cathode:
an electropositive noble metal protected from corrosion
(the electrode that receives electrons)
conductive material:
the metallic connection for the anode and cathode (under
lying metal which transfers the electrical current)
an electrolyte:
a conducting solution which carries the current (aqueous
solutions, water, moisture, dampness or other liquids)
If unprotected, the electrolytic cells of iron particles and
other impurities in the surface of steel react with moisture
and allow the formation of rust. Steel is a combination of
impurities, oxygen and metal elements both anodic (active)
and cathodic (less active). The metal elements on the
surface of a piece of steel form interlocking areas of anodes
and cathodes connected by the underlying steel which is
the conductive material.
Electrolytic Cell
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Electrolyte
(Water or Humidity)
H2O
H2O
C
C
H2O
A
A
C
Electrolyte
(Water or Humidity)
C
C
C
C
C
Base Steel
A
C
C
C
C
C
Zinc Coating
A
C
C
C
Galvanic Protection
H2O
A
C
C
C
C
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Zinc Coating
H2O
A
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C
C
Electrolyte
(Water or Humidity)
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Cathodic Protection
As discussed in Understanding Corrosion, the variance in
the electrical potential between zinc and steel in the alloy
layers of a galvanized coating will create an electrolytic
cell. When zinc is used to protect an item, it provides
anodic (sacrificial) properties for the base steel. In the
event a zinc coating is damaged and the base steel is
exposed to moisture, an electrochemical reaction will
occur causing the zinc anode to oxidize in preference
to the cathodic bare steel. For this reason, galvanized
coatings are referred to as sacrificial coatings or coatings
with sacrificial properties. Metals which provide sacrificial
properties to others are detailed in The Galvanic Series of
Metals on the following page.
The cathodic properties of a hot dip galvanized coating will protect small areas of bare metal.
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Anodic
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Cadmium
Cast Iron
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Aluminium bronzes
Copper
Copper-nickel alloys
Monel
Titanium
Platinum
Any element listed above mild steel in the Galvanic Series
of Metals is anodic and will sacrifice itself to protect the
cathodic steel.
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Mild steel
Gunmetals
Cathodic
Magnesium
Zinc
Aluminium
Galvanic Corrosion
Galvanic corrosion occurs when an anodic element is in
contact with a cathodic metal whilst subject to moisture.
Zinc, (anodic) a more active metal than most, will rapidly
lose electrons and sacrifice its properties to corrode in
preference to the lesser (cathodic or more noble) metal.
Contact of zinc coated items with aluminium, cadmium
and stainless steel is generally fine in moderate
environments. However, in contact with metals such
as copper, the loss of properties of the zinc will be
extremely high.
An example of galvanic or electrolytic corrosion is where
dissolved particles of copper or brass in run off water from
pipes is in contact with a galvanized item. The cathodic
properties of the zinc will be activated; it will corrode in
preference to the copper; in turn wasting its energy and
depleting its ability to protect the actual steel item it is
coating. Other cathodic metals that have a detrimental
effect when in contact with zinc in a moist environment
or in liquid, include cast irons, chromium, bronze, nickel
and hard solders.
As discussed in Differentiating Zinc Coatings, other
coatings offer various levels of corrosion protection and
service life. When two or more different zinc coatings are
in contact, they will act independently. When moisture is
present on both, the thinnest zinc coating type will be the
first to oxidize and corrode. This is often evident where
zinc plated fasteners are attached to hot dip galvanized
structural steel and exposed to rain and moisture; the
electroplated items will corrode rapidly in comparison.
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insecticides in solution
unseasoned timber
organic lubricants
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The coating is achieved when zinc reacts with iron contained in the steels
surface. A unique, layered protective system is formed as the zinc galvanizes
with the base metal; covering corners, sealing edges and penetrating all internal
and external recesses. Unlike paint based systems, the coating metallurgically
bonds with the entire surface area of the item and does not shrink from the
edges of the steel sections.
The Hot Dip Galvanizing Process.
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SURFACE RUST
REMOVED
COATING
PASSIFIED
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Patina
Eta Layer: Pure outer zinc coating, 70 DPN hardness
Zeta Layer: Zinc-iron alloy containing 94%zinc & 6%iron, 179 DPN hardness
Delta Layer: Zinc-iron alloy containing 90%zinc & 10%iron, 244 DPN hardness
Gamma Layer: Zinc-iron alloy containing 75%zinc & 25%iron, 250 DPN hardness
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HYDROCHLORIC
ACID BATH
MOLTEN ZINC
BATH
QUENCH
BATH
A hot dip galvanizing coating consists of 3 zinc-iron layers, plus 1 layer of pure zinc. A protective
patina forms over time as the coating is exposed to the natural weather conditions.
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Bright lustre on newly galvanized items will weather and gradually become dull over time as the protective zinc oxides form the patina.
Coating Thickness
The thickness of the coating is determined by the reactivity
of the steels metallurgy with the zinc and the thickness of
the steel it is covering.
It is for this reason that minimum coating thicknesses are
stipulated in the Galvanizing Standard AS/NZS 4680 and
are generally easy to achieve. Maximum thickness however
cannot be dictated. High reactivity between zinc and the
steels composition will generate thicker coatings as will
the effect of abrasive blasting prior to galvanizing. This is
advantageous as the coating thickness will determine the
longevity of the coating and subsequent service life of the
steel item.
Further information relating to the composition of steel can
be found in Effects of Steel Chemistry.
AS/NZS 4680:2006 is specific to the hot dip galvanizing
process. It states The galvanized coating shall be continuous,
adherent, as smooth and evenly distributed as possible, and
free from any defect that is detrimental to the stated end use
of the coated article. On silicon killed steels, the coating may
be dull grey, which is acceptable provided the coating is sound
and continuous. The integrity of the coating shall be determined
by visual inspection and coating thickness measurements. With
reference to adhesion the galvanized coating shall be sufficiently
adherent to withstand normal handling during transport
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A different coating standard and coating thickness applies to mass produced in-line continuous galvanized products.
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Local Minimum
35m (microns)
Above 1.5mm-3mm
45m (microns)
Above 3mm-6mm
55m (microns)
70m (microns)
Article Thickness
Local Minimum
Under 8mm
25m (microns)
40m (microns)
and erection.
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Hot dip galvanized coatings are able to be achieved on most ferrous materials
and general steel grades without difficulty. However, as hot dip galvanizing is a
form of heat treatment and items are soaked in acid, some susceptible grades of
steel maybe prone to embrittlement which is outside of our control.
Strain Age Embrittlement
Strain age embrittlement is caused in certain low quality steels when areas
stressed by cold working are exposed to elevated temperatures (including hole
punching and tight radius bending in thicker steel sections). Steels generally
have many impurities which gather in high stress areas and in certain steels
cracking may occur prior to galvanizing. It is recommended where possible that
items are worked after galvanizing; any flaking or cracking will be limited to the
zinc coating which can be repaired using zinc rich paint.
Hydrogen Embrittlement
Generally occurring in steels with a tensile strength equal to or higher than
1000 MPa and harder than 340 DPN, hydrogen embrittlement rarely affects
structural steels. This form of embrittlement is likely to be observed when an
item is in service and under load. Hydrogen is absorbed during the acid
pre-treatment process and then discharged quickly during galvanizing.
Specialised steels such as Bisalloy and other susceptible steels should be
abrasive blasted immediately prior to galvanizing to eliminate the requirement
for soaking in pre-treatment chemicals.
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Other Issues
Other issues related to steel type are generally limited to
old iron work items or castings which are often porous.
Castings may have sand embedded which cannot be
removed by pre-treatment processing. Items should be
abrasive blasted prior to delivery.
Of additional note, soft solder and aluminium rivets
must not be used in any fabrication as they will not
withstand galvanizing temperatures. Brazed itemsshould
be discussed with Hunter Galvanizing staff to confirm
suitability.
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Stainless steel components may require additional processing to achieve successful coatings.
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Extreme reactivity between steel chemistry and zinc will result in coatings which may not be smooth.
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Some manufacturing processes of steel processing can also alter the formation
of the free zinc layer creating a number of effects on hollow sections. Fish bone
effect can occur on large diameter pipes where the difference in the surface
chemistry will cause varying reaction rates between the steel and zinc.
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Delamination
Extremely reactive steel can cause a void to form between
the top two layers of the galvanized coating causing the
outer layer to peel. This is referred to as delamination.
Sufficient zinc generally remains in the underlying (hard
alloy) layers which continue to be metallurgically bonded
to the base steel offering the protective qualities of a
sound hot dip galvanized coating. This effect is often
outside of our control and not a suitable means
of rejection.
Delamination occurring after galvanized items have been
abrasive blasted in readiness for painting, is not the
responsibility of the galvanizer. Procedures for the correct
blasting of hot dip galvanized coatings are detailed in
Duplex Coatings
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Differing cooling rates may produce dull grey areas around edges of
small plates and holes. This is in stark contrast to the remaining bright
shiny coating.
Delaminated coatings are caused by continued alloy growth in highly reactive steel and is outside the control of the galvanizer.
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Steel Coatings
Very thick coatings may form on items which are large and consist of heavy
steel sections. Longer immersion and handling times required to process these
sections may result in the metallurgical properties of the steel having high
reactivity with the zinc whilst in the galvanizing bath. Further information
relating to zinc reactivity is available in Effects of Steel Chemistry.
The bond between the steel and zinc is unable to be achieved if any form of
substance remains on the steel surface after chemical treatment. Resistant
substances which can prevent the coating from forming include (however are
not limited to) pre-existing zinc coatings, paint, lacquer and adhesive residue
from identification labels and stickers.
Rusted Items
Adhesive Residue
Manufacturers steel identification stickers will deteriorate during pre-treatment
processing; however non visible adhesive residue may remain and prevent
successful formation of the zinc coating. Stickers should be removed and the
immediate area prepared by suitable means to remove the adhesive substance
prior to despatch.
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Light mill scale and surface rust on items can be removed within our
pre-treatment process. Heavily rusted steel will require abrasive blasting prior to
delivery to remove the rust layers. If the steel surface is pitted after blasting, this
effect will be evident after the hot dip galvanized coating is applied.
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Cutting Oil
Some cutting lubricants can become baked onto the steel surface during
fabrication. Oil based fluids are not visible during pre-treatment processing and
may contaminate the surface preventing the coating from forming. Cutting oils
should be cleaned from the surface prior to delivery.
Marking Pens
Paint pigmentation from marking pens may be resistant to chemical cleaning.
During pre-treatment processing paint layers are removed, however,
non-visible pigments may remain. The zinc coating will form around the residue
pigmentation and remnants of workshop markings may remain evident after
galvanizing. Oil based paint markings should be removed by suitable means
from steel surfaces prior to delivery for galvanizing.
Painted Sections
Most pipe and tube sections manufactured in Australia are painted with water
based coatings which generally can be removed within our process. Some local
manufacturers of pipe and tube products and most offshore producers coat
their product range with clear varnish or black bituminous paint. These coatings
are resistant to chemical removal within our galvanizing plant and are required
to be abrasive blasted prior to delivery. To avoid additional costs and extended
processing times, hollow sections should be stipulated that they be suitable for
hot dip galvanizing when ordering from your steel supplier.
All steel sections with powder coated, brush or spray paint coatings must be
abrasive blasted prior to despatch to Hunter Galvanizing.
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Oil based paint markings should be ground from the steel surface prior to hot dip galvanizing.
Masking
In some applications, small mating or threaded areas may be required to be
uncoated. This can be achieved by applying a small amount of a suitable
adhesive or sealing product on the area creating a barrier to pre-treatment
acids and zinc. The following products will have varying success in preventing
zinc coatings from forming and some clean up of the surrounding surfaces will
be required by the fabricator after galvanizing.
Tapes high temperature tape / duct tape
Sealants silicone adhesive sealant / petroleum gel / household chalk
Paints Maskote / Stop Galv
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Primer paint coatings can be removed from most domestically produced pipe and tube sections during our process.
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Identification of Items
For permanent identification which will be visible after the hot dip galvanizing
process, item details can be stamped or welded onto the steel surface. Steel
identification tags can also be stamped or welded and wired to individual items.
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If using oil based paint markers, all paint must be removed from each item prior
to delivery, as the paint pigmentation may remain evident after galvanizing.
The immediate area should be ground to remove the paint residue which is not
visible after chemical treatment.
Hunter Galvanizing utilizes proprietary printed tags to assist with traceability.
Tags are produced and wired to individual items upon receipt. Withstanding
pre-treatment acids and galvanizing conditions, they remain on the item for
identification at the customers location.
Welded identification.
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Welding
Welding Items for Hot Dip Galvanizing
Poor welding techniques affect the quality of a hot
dip galvanized coating. By understanding the hot dip
galvanizing process, most issues related to welding
can be avoided.
Welding Media
Zinc reacts differently when in contact with a number of elements; including
silicon deposits in welds. When items are galvanized with welding media
high in silicon, thick coatings form on the weld as the zinc growth is rapidly
accelerated. This is a metallurgical reaction between the silicon and zinc and
outside the control of the fabricator and the galvanizer. This has no detrimental
effect on the integrity of the weld.
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To ensure maximum zinc coverage; flux, slag, residues from welding ferrels or
stud insulators should be ground, brushed, scraped or abrasive blasted from the
welded areas as they prevent the zinc from bonding to the weld surface.
Weld spatter should also be removed prior to delivery as it remains visible after
processing and may later become dislodged leaving uncoated areas.
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Distortion
The percentage of items which are affected by distortion
issues is relatively low given the volume of items which are
hot dip galvanized. An items dimensional stability can be
compromised by a number of factors. By understanding the
causes of distortion and adopting simple design principles,
the effects can be minimised.
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General Guidelines:
Where possible items should be designed so they are able
to be immersed into our galvanizing baths in one
single dip.
Hunter Galvanizing bath sizes are:
Plant 1 10m long x 2.4m deep x 1.5m wide
Plant 2 7m long x 3m deep x 1.8m wide
To allow even heat transfer, avoid using combinations of
thick and thin materials in the same fabrication.
Bend curved members to the largest possible radii.
Venting and draining holes should be as large as possible
to allow timely immersion and withdrawal from the
galvanizing bath.
Heat induced stress can be minimised by staggering
welds. Welding should be as symmetrical as possible and
use opposing weld shrinkage forces to balance each other.
Symmetrical sections such as SHS, RHS and pipe should be
used where possible and avoid designs where plates and
cleats are welded to one side.
Fabricated items which are stronger in one area may
suffer distortion in the weaker plane. Brace items that are
weaker over large areas. Bracing material should be the
same thickness as the item.
Where angles or channels are used to rim or frame a tank,
apertures must be provided in the corners.
Items with large areas of unsupported plate or sheet
may suffer from liquid drag when being withdrawn from
below the surface of the molten zinc. Coupled with
reduced yield strength some loss of shape can occur.
Please note as distortion is generally a result of poor design
and outside of our control, Hunter Galvanizing cannot be
held responsible for items not meeting the
recommended criteria.
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General Guidelines
Subject to overall dimensions and weld stresses, thicker
plate sections hold less risk of distortion. Large areas of
plate 12mm thick and under have a high probability of
distorting if unsupported.
Floors for platforms and panels of perforated sheet
should be galvanized separately then bolted to
supporting structures.
Floors in box trailers will not remain flat and will display
some degree of buckling.
Plate 6mm and under will ripple when hot dip galvanized.
Plate sections should be limited to our bath sizes to
eliminate the requirement for double dipping.
Plate able to be suspended diagonally and submerged in
one dip will allow heat to transfer evenly throughout
the section.
Folded, ribbed or corrugated sheet sections are less prone
to distortion and generally hold their shape.
Long lengths of thin plate will require a number of holes
to allow the plate to be supported along one edge.
Equalize stresses by cutting all edges in the same manner.
Cold cutting methods such as guillotine will induce less
stress than heated methods.
Welding will increase the stress in plate items. A stitch
or staggered weld will induce less stress than a full
continuous weld; however this may lead to blow outs as
discussed in Welding.
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Channels
Welded Beams
Hollow Sections
General Guidelines:
Subject to their length, channels have the tendency to
camber or sweep when galvanized. Where possible these
sections should not be double dipped without discussion
with Hunter Galvanizing staff.
Welding cleats on one side of a channel will encourage
the channel to camber along its length at galvanizing
temperatures.
Lintels fabricated from channel and flat bar present dual
issues. A combination of the cross section, coupled with
welding stresses may increase the opportunity of camber
or sweep. Staggered welding to minimise the additional
stress is recommended, however pre-treatment chemicals
may become trapped and result in blow outs or staining
during galvanizing as discussed in Welding.
All channel sections including those fabricated as lintels
or with cleats, should have holes placed near each end to
enable them to be suspended and dipped with their toes
up. Longer lengths may require additional lifting points;
please confirm with Hunter Galvanizing staff.
General Guidelines:
Sections where the web thickness is less than half that of
the flange thickness are prone to distortion as the thinner
web expands at a faster rate than the thicker flanges.
Subject to the depth of the of the web, the top flange
may cool more rapidly as it is withdrawn from the bath
increasing the stress over the rest of the section.
Twisting may result in large welded beams and columns
due to the combination of longitudinal, transverse and
sheer stresses within the section coupled with the loss
Flange Thickness
of yield strength (up to 50%) at
galvanizing temperatures.
Web
Thickness
Designers incorporating these
sections should select sizes with
the thickest possible web to assist
Flange
Depth
in minimising the twisting action.
Pipe and tube hollow sections (Circular Hollow Sections, Square Hollow
Sections, Rectangular Hollow Sections) hold stresses induced in their rolling and
manufacture. At galvanizing temperatures the relieving of these stresses coupled
with the loss of yield strength may result in camber or sweep forming in
longer lengths.
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Staggered welding is
recommended for fabricated
lintels however this may allow acid
to weep from gaps in the weld.
General Guidelines
Lengths of tubular sections should remain proportional to their diameter or
cross section and lifting lugs or holes should be provided at quarter points.
Venting and draining holes should be as large as possible to allow timely
immersion in the bath and adequate drainage of zinc to prevent the
loss of shape.
Bracing at the end of long pipes may be required to prevent zinc drag or loss of
shape when items are lifted from the galvanizing bath.
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General Guidelines
Subject to weight; items less than 2m require a hole or
lifting lug placed at one end. Longer and heavy items will
require holes or lifting lugs at both ends. Holes should be
a minimum of 10mm diameter, large enough for jigging
wire to be passed through.
Larger fabrications will require numerous wire strands to
be used and hole sizes should be adjusted accordingly.
Further information should be sought from Hunter
Galvanizing staff regarding size and location of holes
specific to each item.
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Touch marks or chain marks are usually completely galvanized affecting only
the outer free zinc layer of the coating and therefore not a reason
for rejection.
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Holes are required where end plates are not available to secure wire.
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The large pipe above (top left) has holes in flanges coupled with
additional lifting lugs.
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Zinc Pooling
Molten zinc is very dense and solidifies immediately upon withdrawal from the
galvanizing bath. Excess zinc will collect in corners of fabrications subject to the
items hanging position. Zinc pooling will increase the overall weight of an item
and may affect the cost and end use application.
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The following aesthetic issues are generally deemed acceptable under the
governing standards for hot dip galvanizing. Simple allowances whilst fabricating
can minimise these effects.
Air Locks
Pre-treatment acids are critical in preparing the steel surface for galvanizing.
The acids remove contaminants including surface rust, soluble oils and water
based paint coatings. When an item is suspended on a headframe, air can
become trapped in corners at the high points. An air pocket prevents cleaning
solutions from preparing the steel surface and the zinc coating will
not form in these areas.
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Ash Formation
Zinc ash is a bi-product of the zinc iron alloying process. Ash forms on
the surface of the molten zinc and is skimmed away from items as they
are withdrawn through the zincs surface. Subject to the number of items
processed in the galvanizing bath at one time, some surfaces may not be
reached by operating staff and ash may adhere to the steel as it is withdrawn.
A light skin or film may form in isolated areas on the surface of an item. Heavier
deposits of ash may remain trapped within a fabricated item or hollow section.
Upon drying the ash appears as a yellow-brown powder or in clumps. As ash is
relatively pure zinc it does not represent any concern to the coating properties
other than aesthetics and can be easily brushed from the surface.
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Hunter Galvanizing | 38
A HOLE IN
Recommended holes or mitres for general fabrications, universal beams and columns.
EVERY CORNER
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General Guidelines:
When steel sections are welded together, air is trapped between the overlapping
surfaces. At galvanizing temperatures, the entrapped air converts to super
heated steam with pressure sufficient to force weak areas within a fabrication
(either in steel thickness or weld) to expand, distort or tear.
Galvanizing staff are at risk as this force may cause steel fragments or molten
zinc to be blown from the galvanizing bath causing injury and rendering
processing equipment inoperable. In order for items to be processed safely, holes
are required to enable air and moisture to escape and pressure to be relieved.
The following rules must apply regarding size and location of relief holes.
General Guidelines:
Overlapping areas 10cm or greater must have one hole every 100mm.
Thin, long overlapping areas require one hole every 300mm in length.
Where possible avoid designing items with back to back channels and angles
unless a gap of 2.5mm or greater is allowed.
Overlapping areas greater than 40cm should be avoided at all times.
Holes may be placed through one or both steel surfaces and must be greater
than 10mm in diameter.
Alternatively, staggered welding can provide sufficient means for air to escape.
In some instances, it may be suitable to leave one edge free of weld.
A s detailed in Welding pre-treatment chemicals become trapped between
overlapping surfaces and may result in aesthetic issues.
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Examples
A section of 100 x 100 SHS or 100 x 50 RHS must have holes at each end equivalent to
approximately 25mm either as:
Preferred Option
1 x 25mm hole each end OR 2 x 12mm holes each end OR 4 x 6mm holes each end
No end
plate
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Preferred Option
No end
plate
Hole Placement Options for CHS & Pipe Sections Holes for
Correct Holes
hanging
A section of 50mm diameter pipe must have holes at each end equivalent to approximately
12mm either as:
1 x 12mm hole each end OR 2 x 10mm* holes each end
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Fabricated items, gates, handrails and fencing require thought regarding placement of holes.
Ideally holes should be placed externally to allow quick visual inspection by the galvanizer.
Preferred Option
Unwanted holes can later be filled with epoxy filler, lead or threaded plugs.
Holes for
Correct
Holes for CHS & Pipe Sectionshanging
Hole Placement
Options
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Air and zinc must flow freely within the hollow sections
No end
plate
Preferred Option
No end
plate
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Holes for
hanging
1. External Holes
2. Internal Holes
3. Mandatory - Holes in Bends
4. Mandatory - Ends Remain Open
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General Guidelines
Venting holes are required to be diametrically opposite.
Minimum acceptable hole size is 50mm in diameter.
Subject to tank size additional holes may be required.
Internal baffles should be cropped top and bottom.
Lifting lugs will be required to facilitate handling.
Design should incorporate an inspection hole to enable
internal surfaces to be viewed.
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Visual inspection and coating thickness testing is simple and the most critical
means of assessing the quality of a hot dip galvanized coating.
General Guidelines:
Patterns, colour and finish will be determined by the metallurgy and the rate of
reactivity between each piece of steel and the molten zinc which bonds to the
surface. The process forms an initial coating of four layers. Later, whilst the item
is in service, the fifth and most important layer forms; the dull grey patina of
zinc carbonate.
Hot dip galvanizing is not a colour; the coating can be dull grey to bright silver.
Colour can vary within the one fabrication and on the same piece of steel.
Coatings on all items will turn dull grey as they are exposed to natural
weathering and the patina forms on the outer surface.
Coating may have a spangled effect, others may display lacework or reptilian
like patterns as elements within the steel chemistry react differently to zinc.
Coatings cannot be ordered as an architectural finish. Smoothness and
roughness are not qualities a galvanizer can control as chemistry and stress
within the surface of the steel will dictate this.
Refer to How the Coating Forms for more information.
Drain
Internal baffles of tanks must be cropped
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Bare Spots
Bare spots are generally a result of issues outside of our
control, such as rolling defects, or contamination from
paints and adhesives as outlined in Suitable Surface
Conditions. Subject to size they may be repaired with zinc
enriched paint. Cathodic protection will prevent corrosion
on small uncoated areas. The governing standard, AS/NZS
4680:2006 states: The size of the area able to be repaired
shall be relevant to the size of the object and the conditions of
service but shall normally be in accordance with the provisions of
AS/NZS 4680 - Repair after Galvanizing. For objects galvanized
after fabrication, the sum total of the damaged or uncoated
areas shall not exceed 0.5% of the total surface area or 250cm.
No individual damaged or uncoated area shall exceed 40cm.
Acid Leeching
Brown or red stains may appear as pre-treatment
chemicals leak from unsealed joints after an item has
been hot dip galvanized. During galvanizing, chemicals
crystallize leaving anhydrous residues in the small holes in
welds or overlapping surfaces. Later the crystals absorb
water from the atmosphere and weep out onto the
immediate surface. Acid leeching is not the responsibility
of the galvanizer and is not cause for rejection.
Information on preventing entrapment of pre-treatment
chemicals can be found in Welding and Requirement
for Holes.
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Smoothness
Drainage spikes form as the molten zinc solidifies as the
item is withdrawn from the galvanizing bath. They are
removed to facilitate safe handling. General zinc runs
are unavoidable in the hot dip galvanizing process and
will not be removed under normal dressing procedures.
If additional processes post galvanizing dictate a high
degree of smoothness, we recommend the fabricator
allows for additional dressing after despatch.
Smoothness of the galvanized coating may be affected
by abrasive blasting prior to galvanizing. Similarly, surface
steel chemistry and manufacturing processes of some
steel products may also result in roughness.
Refer to Suitable Steels for Hot Dip Galvanizing for
more information.
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Oxide Lines
Oxide lines form as items are withdrawn from the
galvanizing bath. This effect will fade over time as the
entire zinc surface oxidizes and the dull grey patina
forms. An aesthetic issue only; they have no effect on the
corrosion performance of the coating and are not a cause
for rejection.
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Dross Pimples
Dross is created when free iron particles in the galvanizing
bath react with the molten zinc. Generally not an issue,
dross inclusions do not affect the corrosion resistance of
the coating.
Spangle
In reference to hot dip galvanizing, spangle is
characterized by a snowflake shape pattern visible in the
coating. Spangles may be small and of a uniform bright
silver finish, or large and an array of matt grey and bright
silver shades. The presence or absence of spangle has
no affect on the performance or quality of a hot dip
galvanized coating. Its occurrence may be subject to many
variables including (but not limited to) coating thickness,
zinc bath chemistry, steel chemistry or the rate and/or
method of cooling. It occurs during the crystallization or
freezing of the outer layers of the zinc.
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Chromate Colouring
As discussed in Passivation & Storage all items are
quenched in a passivation solution to assist in the
prevention of light white oxidisation. Quench colouring
will vary subject to thickness of the steel and will fade
as the hot dip galvanized coating forms its natural
patina whilst the item is in service. Very thick sections
may display deep yellow or green shades which are
unavoidable and not an acceptable cause of rejection.
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Passivation
For a short period after galvanizing the outer layer of the hot dip galvanized
coating is susceptible to the formation of zinc oxides. To minimise effects of light
white oxidisation, items are passed through a bath of passivation solution. This
process can impart a yellowish film to the galvanized coating. On most items the
film will be barely visible; however, on items of heavier thickness it may appear
much darker. This does not detract from the quality or performance of the
coating and will generally remain visible for approximately 6 weeks upon which
time with natural weathering the patina will form. Further information relating
to the patina layer can be found in How the Coating Forms.
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Environmental Performance
Coating Life
Rural Areas
Coating life may be affected by the effects of aerial
spraying of fertilizers or insecticides. In dry form these
elements will pose little threat, however in solution,
fertilizer and insecticides will attack galvanized coatings.
Long term protection can be expected if not subjected
to hostile chemicals with a coating loss of approx 13
microns per year. Based on steel thickness above 6mm it is
plausible to expect coatings to remain effective
25 to 85 years.
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Industrial Areas
In light industrial areas, hot dip galvanized coatings will
generally perform well with coating loss average of 35
microns per year. Based on steel thickness above 6mm
and subject to exposure to adverse contaminants 1530
years may be achieved by coatings. High levels of sulphuric
gases and chemicals located in some heavy industrial areas
will increase coating loss to approximately 58 microns
per year. In this environment, a duplex coating system of
hot dip galvanizing and paint may prove beneficial.
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Coastal Areas
Corrosion rates are higher in the presence of salt air. Hot
dip galvanized coatings perform well in comparison to
other protective systems, however, duplex coating systems
of hot dip galvanizing and paint provide the optimal
protection. Coating loss will average between 515
microns per year subject to the proximity to the ocean and
levels of rainwater to wash marine salts from the coating
surface. Life span of coatings may range between 510
years based on steel thickness over 6mm.
Hunter Galvanizing | 56
Duplex Coatings
Hot dip galvanizing is a long lasting and cost effective means of protecting steel
from corrosion. When organic coatings such as paint or powder coatings are
applied over hot dip galvanized steel, the resulting combination is known as a
duplex coating.
All galvanized items are dressed in accordance with the Australian Standard
for Hot Dip Galvanizing; sharp edges and dags are removed however runs and
general roughness of the zinc surface will remain.
The result of high gloss and smoothness when paint has been applied over
extruded metal, planed timber or pre galvanized sheet, wire and tubing will not
necessarily be achieved when applied to an item which has been
hot dip galvanized.
Additional dressing may be required by the fabricator prior to powder coating or
painting to achieve the smoothness required for a paint finish standard.
Please Note: if undertaking further dressing of items, care must be
taken not to damage the zinc coating by heavy or
excessive grinding.
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Abrasive Blasting
In order to create a suitable surface for paint coatings to adhere to newly hot
dip galvanized coatings an abrasive sweep or brush-blast may be used.
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Powder Coating
Powder coatings are applied by the electrostatic spraying of dry powders
which are then heat fused at moderate temperatures to form a continuous,
homogeneous coating. To ensure surface treatment applications utilised at
Hunter Galvanizing do not interfere with the powder coating process purchase
orders supplied with items should clearly state that a powder coating will be
applied after galvanizing.
Please Note: Hunter Galvanizing cannot be held responsible for the
integrity of the galvanized coating on any item once a
subsequent process outside of our control has commenced.
- Blast material should have a particle size no larger than 0.5mm or between
200 to 500 microns. Aluminium/magnesium silicate, limonite and other suitable
mediums can be used .
-Blast pressure should not exceed 40 psi to ensure the minimum amount of zinc
oxide is removed.
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Notes
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Hunter Galvanizing
Sydney
E huntergal@huntergal.com.au
E sales@huntergal.com.au
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www.huntergalvanizing.com.au
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