Hot Dip Galvanized Coating
Hot Dip Galvanized Coating
Hot Dip Galvanized Coating
Contents
INTRODUCTION 3 4
Preface Capacity & Manpower
PROCESS 5 6
Galvanizing Process @SHG The hot dip galvanizing process
Tappan Zee Bridge
Date Galvanized :2008
Environment Temperate Marine Industrial/Urban Reason for Galvanizing: Lifecycle Cost Durability Location New York City, NY Projected First Maintenance 85 years
TECHNIQUE 7 8 9 27 28
Hot dip galvanized coating Hot dip galvanized benefit Coating Defect Repairing galvanized Zinc rich paint
Speed of Execution
PREPARING PARTS 14
Design articles/ fabrication for galvanizing
QUALITY ASSURANCE 21 22 23
Inspection coating and continuity Specifications relating to hot-dip galvanizing Standardization
WARNING 20
Effect of silicon on coating
reface
Sangchareon Hot Dip Galvanize is the second factory. It was established in year 2005 with the register capital of 30million baht on the area 52,800 square meters - able to support the work through the kettle size 9 meters with capacity more than 4,500 tons a month. Our kettle (made in Germany) and furnace system was designed by British engineering team with British standard and looked at environment by using LPG energy and water treatment system. Recently we have a plan to expand the factory I from 6,400 square meters to 28,800 square meters to support the expansion of the future infrastructure construction.
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Tel: 0-2976-2118-20, 0-2976-3021-2 Fax: 0-2976-2118-20 Kettle 1 Size 7.0 x 1.5 x 2.0 metres Capacity: 3,000 Tons/ Month Kettle 2 Size <Spinning> 4.0 x 1.2 x 1.5 metres Capacity: 1,000 TM Worker: 50 persons
Certification
Preparing/Classified
For fresh & clean steel or regalvanized ( Grit Blasting, Special Treatment on Request at Extra Charge) Caustic Soda (NaOH)
Degreasing
Rising
Visual Inspection
Pickling
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Hydrochloric Acid (HCl) Concentrate Controlled at 818% Temp: Room Ferrous content 110 g/l
Pickling
Pickling
Rinsing
Zinc Ammonium Chloride (ZnCl2) Chemical Composition ZnCl2 = 60% by volume NH4Cl = 40% by volume pH = 4.0
Visual Inspection
Pre-Flux
Zn Content > 98% [ASTM B6] Al Content <0.007% Temp: 440-450 C
Quenching
Sodium Dichromate (Na2Cr2O7) Content: 300-1000 ppm Controlled following to ASTM A123/A123 M, AS/NZS 4680, and
Treatment
Testing/Finishing
Packing/ Storage
COATING DEFECT
5 summarizes variations in finish which may be observed. The variations are often caused by surface features of the steel itself, and the acceptability of a coating should usually be judged primarily on its longterm performance and corrosion resistance.
De-lamination
Figure 1: De-lamination
De-lamination or peeling creates a rough coating on the steel where the zinc has peeled off. There are a number of causes for zinc peeling. Many large galvanized parts take a long time to cool in the air and form zinc-iron layers after they have been removed from the galvanizing kettle. This continued coating formation leaves behind a void between the top two layers of the galvanized coating. If there are many voids formed, the top layer of zinc can separate from the rest of the coating and peel off the part. If the remaining coating still meets the minimum specification requirements, then the part is still acceptable. If the coating does not meet the minimum specification requirements then the part must be rejected and re-galvanized. If delamination, as seen in Figure 1, occurs as a result of fabrication after galvanizing, such as blasting before painting, then the galvanizer is not responsible for the defect.
Drainage Spikes
Drainage spikes or drips are spikes or tear drops of zinc along the bottom edges of the product. These result when the surfaces of the product are processed horizontal to the galvanizing kettle, preventing proper drainage of the zinc from the surface as the product is withdrawn from the kettle. Drainage spikes, as seen in Figure 2, are typically removed during the inspection stage by a buffing or grinding process. Drainage spikes or drips are excess zinc and will not affect corrosion protection, but are potentially dangerous for anyone who handles the parts. These defects must be removed before the part can be accepted.
Distortion
Distortion, as seen in Figure 3, is defined as the buckling of a thin, flat steel plate or other flat material such as wire mesh. The cause of this is differential thermal expansion and contraction rates for the thin, flat plate and mesh than the thicker steel of the surrounding frame. In order to avoid distortion, use a thicker plate, ribs, or corrugations to stiffen flat sections or make the entire assembly out of the same thickness steel. Distortion is acceptable, unless distortion changes the part so that it is no longer suitable for its intended use. Figure 3: Distortion
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Flaking
Flaking results when heavy coatings develop in the galvanizing process, usually 12 mils or greater. This generates high stresses at the interface of the steel and the galvanized coating and causes the zinc to become flaky and separate from the surface of the steel. Flaking can be avoided by minimizing the immersion time in the galvanizing kettle and cooling of the galvanized steel parts as quickly as possible. Figure 5 shows a micrograph of flaking. In addition, using a different steel grade, if possible, may also help avoid flaking. If the area of flaking is small, it can be repaired and the part can be accepted; however, if the area of flaking is larger than allowed by the specifications, the part must be rejected and re-galvanized.
Figure 5: Flaking
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Figure 7: Runs
Rust Bleeding
Rust bleeding appears as a brown or red stain that leaks from unsealed joints after the product has been hot-dip galvanized. It is caused by pre-treatment chemicals that penetrate an unsealed joint. During galvanizing of the product, moisture boils off the trapped treatment chemicals leaving anhydrous crystal residues in the joint. Over time, these crystal residues absorb water from the atmosphere and attack the steel on both surfaces of the joint, creating rust that seeps out of the joint. Rust bleeding, as seen in Figure 8, can be avoided by seal welding the joint where possible or by leaving a gap greater than 3/32 (2.4mm) wide in order to allow solutions to escape and zinc to penetrate during hot-dip galvanizing. If bleeding occurs, it can be cleaned up by washing the joint after the crystals are hydrolyzed. Bleeding from unsealed joints is not the responsibility of the galvanizers and is not cause for rejection.
Weld Spatter
Welding spatter appears as lumps in the galvanized coating adjacent to weld areas. It is created when welding spatter is left on the surface of the part before it is hot-dip galvanized. In order to avoid welding spatter, welding residues should be removed prior to hot-dip galvanizing. Welding spatter, as seen in Figure 9, appears to be covered by the zinc coating, but the coating does not adhere well and can be easily removed. This type of defect can leave an uncoated area or bare spot if the zinc coating is damaged and must be cleaned and properly repaired.
Figure 11 : Wet Storage Stain Wet storage stain is a white, powdery surface deposit on freshly galvanized surfaces. It is caused by newly galvanized surfaces being exposed to fresh water, such as rain, dew, or condensation that react with the zinc metal on the surface to form zinc oxide and zinc hydroxide. It is found most often on tightly stacked and bundled items, such as galvanized sheets, plates, angles, bars, and pipes. Wet storage stain can have the appearance of light, medium, or heavy white powder on the galvanized steel product. Each of these appearances can be seen from right to left in Figure 49. One method to avoid wet storage stains is to passivate the product after galvanizing by using a chromate quench solution. Another precaution is to avoid stacking products in poorly ventilated, damp conditions. Light or medium wet storage stain will weather over time in service and is acceptable. In most cases, wet storage stain does not indicate serious degradation of the zinc coating, nor does it necessarily imply any likely reduction in the expected life of the product. However, heavy wet storage stain should be removed mechanically or with appropriate chemical treatments before the galvanized part is put into service. Heavy storage stain must be removed or the part must be rejected and regalvanized.
Dross Inclusions
Dross inclusions are a distinct zinc-iron intermetallic alloy that becomes entrapped or entrained in the zinc coating. This is caused by picking up zinc-iron particles from the bottom of the kettle. Dross, as seen in Figure 32, may be avoided by changing the lifting orientation or redesigning the product to allow for proper drainage. If the dross particles are small and completely covered by zinc metal, they will not affect the corrosion protection and are acceptable. If the dross particles are large, then the dross must be removed and the area repaired.
Bare spots, defined as uncoated areas on the steel surface, are the most common surface defect and occur because of inadequate surface preparation, welding slag, sand embedded in castings, excess aluminum in the galvanizing kettle, or lifting aids that prevent the coating from forming in a small area. Only very small areas, less than 1 inch in the narrowest dimension with a total of no more than 0.5%of the accessible surface area, may be renovated using ASTM A 780. This means narrow, bare areas may be repaired; however, if they are greater than one inch-square areas, the product must be regalvanized. In order to avoid bare spots, like those seen in Figure 13, the galvanizer must ensure the surfaces are clean and no contaminants are present after pretreatment. If the size of the bare spot or total surface area causes rejection, the parts may be stripped, regalvanized, and then re-inspected for compliance to the standards and specifications.
Touch Marks
Another type of surface defect is known as touch marks, which are damaged or uncoated areas on the surface of the product. Touch marks are caused by galvanized products resting on each other or by the material handling equipment used during the galvanizing operation. Touch marks, as seen in Figure 15, are not cause for rejection if they meet the size criteria for repairable areas. They must be repaired before the part is accepted.
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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. 2. 3. 4. Holes for venting and draining should be as large as possible. Further information is given in table 4. 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. With hollow sections sealed at the ends, holes should be provided, again diagonally opposite one another, as near as possible to the ends. Where holes are provided in end plates or capping pieces, they should be placed diagonally opposite one another, off centre and as near as possible to the wall of the member to which the end plate is connected. Internal and external stiffeners, baffles, diaphragms, gussets etc, should have the corners cropped to aid the flow of molten zinc.
5.
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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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 takes responsibility to ensure that articles being delivered free from contamination. (otherwise, an additional charge for shotblasting may be added)
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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 is 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.
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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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STANDARDIZATION
Sangchareon Hot Dip Galvanize Co. Ltd. supply the service in hot dip galvanizing coatings comply with the standards and specifications of British / European Standard (BS EN ISO 1461), Australia & New Zealand Standard (AS/NZS 4680), American Standard (ASTM A123 / A123M), Japanese Standard (JIS H 8641) and International Standards (ISO 1460), etc. ASTM A123/A123 M: Standard Specification for Zinc (Hot-Dip Galvanized) Coatings on Iron and Steel Products.
NO
NO
YES
YES
NO
NO
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STANDARDIZATION (Continued)
ASTM A123/A123 M-09: Standard Specification for Zinc (Hot-Dip Galvanized) Coatings on Iron and Steel Products. Table 1 Minimum Average Coating Thickness Grade by Material Category (unit measured in m)
Material Category mm. inches. Structural Shapes Strip and Bar Pipe and Tubing Wire Reinforcing Bar <1.6 <1/16" 45 45 45 35 All Specimens Tested Steel Thickness Range (Measured). 1.6 to 3.2 3.2 to 4.8 4.8 to 6.4 1 1 3 /16" to 1/8" /8" to 3/16" /16" to 1/4" 65 75 85 65 75 85 45 75 75 50 60 65
ASTM A153/ A153M 09: Specification for Zinc Coating (Hot-Dip) on Iron and Steel Hardware Table 2 Minimum Weight and Thickness Coating on Samples that are centrifuged
Class of Material Weight [Mass] of Zinc Conting, oz/ft2 [g/m2] of Surface, Minimum Average of Any Specimens Individual Tested Specimen 2.00[610] 1.80[550] Coating Thickness,mils [microns],Minimum Average of Any Specimens Individual Tested Specimen 3.4[86] 3.1[79]
Class A-Castings-Malleable Iron,Steel Class B-Rolled, Pressed, and forged articles (except those which would be included under Classes C and D): B-1-3/16 in.(4.76 mm.)and over in thickness and over 15 in. (381 mm) in length B-2-under3/16 in (4.76 mm) in thickness and over 15 in. (381 mm) in length B-3- any thickness and 15 in. (381 mm) and under in length Class C-Fasteners over 3/8 in. (9.52 mm) in diameter and similar articles. Washers 3/16 in.and 1/4 in. (4.76 and 6.35 mm) in thickness Class D-Fasteners 3/8 in. (9.52 mm) and under in diameter , rivets, nails and similar articies. Washers under 3/16 in. (4.76 mm) in thickness
1.00[305]
0.85[259]
1.7[43]
1.4[36]
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STANDARDIZATION (Continued)
British Standard
BS EN ISO 1461:2009 Hot dip galvanized coatings on fabricated iron and steel articles - Specifications and test methods
Note : Table 3 is for general use: individual product standards may include different requirements including different categories of thickness. A requirement for thicker coatings or additional requirements can be added without otherwise affecting conformity to this standard.
Note : Table 4 is for general use: fastener coating standards and individual product standards may have different requirements.
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STANDARDIZATION (Continued)
Australian/New Zealand Standard
AS/NZS 4680:2006 Hot-dip galvanized (zinc) coatings on fabricated ferrous articles
Table 5Requirements for coating thickness and mass for articles that are not centrifued
Table 6Requirements for coating thickness and mass for articles that are centrifuged
Notes : 1. 2. For requirements for threaded fasteners refer to AS1214 1 g/m2 coating mass = 0.14 m coating thickness.
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REPARING GALVANIZED
If the galvanized product does not meet all of the requirements of the specification, it must be repaired or rejected along with the lot it represents. When repair of the product is allowed by the specification or bare spots are present, the galvanizer is responsible for the repair unless directed otherwise by the purchaser. The specifications allow for some retesting of products that represent lots or retesting after the lot has been sorted for non-conformance. The coating thickness of the repaired area must match the coating thickness of the surrounding area. However, if zinc-rich paint is used for repair, the coating thickness must be 50% higher than the surrounding area, but not greater than 4.0 mils because mud cracking tends to result when the paint coating is too thick. The maximum sizes for allowable areas that can be repaired during in-plant production are defined in the specifications as summarized below. Maximum Size of Repairable Area ASTM A 123/A 123M: One inch or less in narrowest dimension. Total area can be no more than 0.5% of the accessible surface area to be coated or 36 square inches per piece, whichever is less ASTM A 153/A 153M: The bare spots shall have an area totaling no more than 1% of the total surface area to be coated, excluding threaded areas of the piece ASTM A 767/A 767M: No area given If the coating fails to meet the requirement for finish and adherence, the bar may be stripped, regalvanized, and resubmitted. Damage done to the coating due to fabrication or handling shall be repaired with a zinc-rich formulation Repair Methods Any repairs made to galvanized products must follow the requirements of ASTM A 780, which defines the acceptable materials and the required procedures. Repairs are normally completed by the galvanizer before the products are delivered, but under certain circumstances, the purchaser may perform the repairs on their own. The touch-up and repair materials are formulated to deliver an excellent color that matches either brightly coated, newly galvanized products or matte gray, aged galvanized products. Materials used to repair hot-dip galvanized products include zinc-based solder, zinc-rich paint, and zinc spray metallizing, and are explained in the following sections Zinc rich paints The application of an organic zinc rich paint is the most rapid and convenient method of repair. The paint should conform to ASTM A 780 "Zinc rich organic priming paint" applied in two coats by brush to provide a total film thickness of 100 m and for optimum performance should contain not less than 65% zinc in the dried paint film. Where color matching is required aluminum paint or aerosol lacquer (Bright Silver) may be applied over the hardened zinc rich paint. Zinc metal spraying. In certain circumstances, by prior agreement, zincs metal spraying may be used as a method of coating repair. The damaged area must be grit blasted to SSPC-SP5 (White metal) followed by zinc metal spraying to a coating thickness equivalent to that of the undamaged coating, and seal coated using an aluminum vinyl paint.
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Surface Preparation
According to ASTM A 780, the surface to be repaired shall be blast cleaned to SSPC-SP10/NACE No.2 near white metal for immersion applications and SSPC-SP11 near bare metal for less aggressive field conditions. When blasting or power tool cleaning is not practical, hand tools may be used to clean areas to be reconditioned. The blast cleaning must extend into the surrounding, undamaged, galvanized coating.
Application
This method of repairing galvanized surfaces must take place as soon as possible after preparation is completed and prior to the development of any visible oxides. The spraying or brushing should be in an application of multiple passes and must follow the paint manufacturers specific written instructions. In addition, proper curing of the repaired area must occur before the product is put through the final inspection process. This repair can be done either in the galvanizing plant or on the job site and is the easiest repair method to apply because limited equipment is required. Zinc-rich painting should be avoided if high humidity and/or low temperature conditions exist because adhesion may be adversely affected.
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