Quality test for Hot-Dipped Zinc-Coated (Galvanized)

Longitudinal Welded Steel Pipe for Ordinary Use

Ma. Noreen S. Tonog
Department of Mechanical and Manufacturing Engineering, School of Engineering, University of
San Carlos (Talamban Campus), Sitio Nasipit, Barangay Talamban, Cebu City 6000 Cebu,
Philippines
[email protected]

Abstract

Metal corrodes when it responds with another substance like oxygen, hydrogen, and
electrical flow or even dirt and microbes. Corrosion can likewise happen when metals like steel
are put under an excessive amount of pressure making the material break. This experimental
activity determines and verify the quality of a welded steel pipe using the dimensional test,
flattening test, and weight of zinc coating test. To compare the recorded data with the
specification Philippine National Standard (PNS) 26:1992 specifications for Black and Hot
Dipped Zinc-Coated Pipe Light Series II. In the experiment, the Universal Testing Machine (UTM)
is used to determine the strength of the weld and the material and an acid bath procedure for
the zinc coating test. It shows that both samples are qualified for the dimensional test and
flattening test and has meet the Philippine National Standard. However, in the weight of zinc
coating test, the material failed to qualify the standards of the Philippines National Standards.
The average mass of zinc coating has met the requirement but one of the samples did not qualify
the specific mass for a sample.

Keywords: Philippine National Standards, corrosion, galavanized

1. Introduction

Corrosion results when a metal is exposed to oxygen and water. It causes the formation of
rust that deteriotes and weakens the material or structure. Replacing the corroded metal as
preventing its corrosion can be quietly costly. Corrosion can be prevented through several ways.
One of the easiest is by coating the surface of the metal with paint to avoid its exposure to oxygen
and moisture.[1]

Galvanization or galvanizing is another rust prevention method by which the surface of iron or
steel is coated with zinc. Galvanizing works in two ways in preventing rusting. First, the zinc
coating imparts a corrosion-resistant property. Second, zinc functions as a sacrifical anode. Thus
the iron remains protected as long as there is some zinc remaining on its surface. Plating a metal
with a less active metal also helps prevent corrosion. [1]

Zinc coatings by and large consume because of the slow general disuntegration of zinc from the
surface. Zinc can shape defensive layers containing essentials carbonates, oxides or hydrated
sulfates relying on the idea of the climate or nature of it’s environment. At the point when
protective layers have framed and totally covered the outside of the covering, erosion continues at
an enormously diminished rate. [2]

To determine the mass of zinc coating is expressed as:

M1 - M2
M = x 100 (1)
A

Where,
M is the mass of the zinc coating
M1 is the initial mass of the sample
M2 is the final mass of the sample
A is the coated are of the sample

The Philippine National Standards was implemented by the Department of Trade and Industry
of the Philippines where in accordance to the law of protecting the consumers which a Department
Administrative Order, No4, Series of 1996. PNS 26:1992 of the Philippine National Standard is
the standards that is set for ordinary use – Specification. As stated in the Philippine National
Standards.

As per PNS 26:1992, a material fulfills the measurements to have the option to satisfy the
guidelines where the wall thickness have no greated qualities to pipes. The zinc coating mist not
be less than 550g/m2 as the average amount while either sample should not be under 490g/m2

2. Experimental Method

2.1 Equipment and Materials Used

The equipment used in the experiment were weighing scale, tong, beaker, vernier caliper,
micrometer caliper, hacksaw, and the Universal Testing Machine (UTM) shown in Fig. 1 to Fig. 7
respectively. The material used in the experiment was the steel pipe specimen and 100 ml – 37%
HCl Acid shown in Fig. 8 and Fig. 9, respectively.
Fig. 1. Weighing Scale [5]

Fig. 2. Tong [5]

Fig. 3. Beaker [5]

 Fig. 4. Vernier Caliper [5]

Fig. 5. Micrometer Caliper [6]

Fig. 6. Hacksaw [5]

 Fig. 7. Universal Testing Machine (UTM) [5]

Fig. 8. Steel Pipe Specimen [5]

Fig. 9. 100 mL – 37% HCl Acid [5]

2.2 Experiment Setup

2.2.1 Dimensional Test Setup

 For the dimensional test setup, the vernier caliper and micrometer caliper were checked for any
defects. Once checked, the outside diameter of the steel pipe was measured in mm. It was measured
5 times using the vernier caliper. Lastly, the average thickness of the steel pipe was measured in
mm also for 5 times at different locations using the micrometer caliper. The data obtained was then
recorded.

Fig. 10. Measuring the Outside diameter [5]

In Fig. 10 shows the measuring of the outside diameter of the steel pipe.

2.2.2 Flattening Test Setup

For the flattening test setup, the Universal Testing Machine (UTM) was checked for any
problems. The compression plates were assembled on the Universal Testing Machine (UTM). The
first two loads at the back of the machine were removed since it required lesser load. The dial was
adjusted and set to zero before turning on the power supply. The steel pipe specimen was placed
on the top of the plate and was positioned at the center of the plate. For the first specimen, it was
positioned with the weld at zero degrees. The machine was turned on by switching the power knob.
The button was pressed to start the machine. When the top portion of the specimen be in contact
with the upper plate, the distance between the two parallel plates were measured using a vernier
caliper. The 75% of the measured distance was calculated. The vernier caliper was positioned with
the calculated value. The gap between the caliper with the graduations found on the universal
testing machine was aligned. It was made that the zero of the vernier caliper is aligned with the
topmost parts of the scale found on the machine. The measurement was recorded. The machine
was stopped when the elevation of the raising part of the machine reached to the recorded
measurement. The specimen was checked for any cracks. The same procedure was repeated but
calculated the recorded of the diameter by 60%.
 Fig. 11. Measuring the outside diameter of the pipe [5]

In Fig. 11. shows the measuring of the outside dimeter of the pipe when it was compressed
using the Universal Testing Machine (UTM). The procedure for the weld positioned at 0 degrees
was repeated for the weld positioned at 90 degrees.

2.2.3 Weight of Zinc Coating Test Setup

For the weight of zinc coating test setup, a 1” x 1” was cut from the two compressed
galvanized pipe with the use of hacksaw. Each sample was weighted using the weighing scale of
platform balance. The thickness at the corners and at the center was recorded. The 100ml of HCl
was poured in the beaker and placed the two pieces of the compressed galvanized pipe into the
acid. The beaker was covered with rag since it can irritate the eyes and produce an irritating smell.
The two pieces of the compressed galvanized pipe were removed from the acid, and it was rinsed
with water and wiped dry. The final thickness of the sample was measured and recorded.

Data Gathering

As stated in the Philippine National Standards, the table below shows that standards in
terms of outside diameter and wall thickness. These data were used to compare the data gathered
from the experiment.

Table 1. Heavy Gauge Pipes (PNS 26:1992)

Table 2. Light Gauge Pipes (PNS 26:1992)

Table 3. Outside Diameter Limits in Millimeters (PNS 26:1992)

3. Results and Discussions

3.1 Collected Data

The data collected during the experiment are shown in Table 4 - 7. The material used in the
experiment was a steel pipe specimen with a nominal size of 15.

Table 4. Outside Diameter

Sample A Sample B
Trial
Outside Diameter (mm) Outside Diameter (mm)
1 21.24 21.30
2 21.22 21.26
3 21.26 21.34
4 21.26 21.28
5 21.20 21.32

Table 5. Wall Thickness

Sample A Sample B
Trial
Wall thickness (mm) Wall thickness (mm)
1 2.82 2.80
2 2.84 2.88
3 2.84 2.84
4 2.80 2.88
5 2.86 2.86

Table 6. Flattening Test

 Observation when
Sample Position of Weld distance is 60% of
Outside Diameter
0 degree No Crack
A
90 degrees No Crack
0 degree No Crack
B 90 degrees No Crack

Table 7. Weight of Zinc Coating Test

Initial Weight Final Weight Final
Sample
of Sample (g) of Sample (g) Thickness (mm)
A 9.98 9.39 2.22
B 9.94 9.88 1.91

Comparison to Philippine National Standards

From the data collected, the experiment showed the quality of the steel pipe. The experiment
conducted some test which were dimensional test, flattening test and weighing of zinc coating
tests. Table 4, Table 5, Table 6, and Table 7 express the data gathered in the experiment activity.

The mean outside diameters and the mean wall thickness of bot sample A and sample B were
calculated using the mean formula showed below provided by the data gathered from the
dimensional test.

∑x
Mean = (2)
n

Mean Outside Diameters:

21.24𝑚𝑚 + 21.22𝑚𝑚 + 21.26𝑚𝑚 + 21.26𝑚𝑚 + 21.20𝑚𝑚

𝑀𝑒𝑎𝑛𝐴 = = 21.236mm
5

21.30𝑚𝑚 + 21.26𝑚𝑚 + 21.34𝑚𝑚 + 21.28𝑚𝑚 + 21.32𝑚𝑚

𝑀𝑒𝑎𝑛𝐵 = = 21.3mm
5

Table 8. Mean Outside Diameter

Mean Otuside PNS Limits
Sample Remarks
Diameter (mm) (mm)
A 21.236 20.5 - 21.7 Qualify
B 21.3 20.5 – 21.7 Qualify
 From the table above, it showed that the reading of different trials is not that far to each
other even to the mean measurements calculated showing more accuracy in the reading. Both
Sample A and Sample B qualified the Philippine National Standard (PNS) for nominal size of 15
having the outside diameter of the material within the range of the standard.

Mean Wall Thickness:

2.82𝑚𝑚 + 2.84𝑚𝑚 + 2.84𝑚𝑚 + 2.80𝑚𝑚 + 2.86𝑚𝑚

𝑀𝑒𝑎𝑛𝐴 = = 2.832mm
5

2.80𝑚𝑚 + 2.88𝑚𝑚 + 2.84𝑚𝑚 + 2.88𝑚𝑚 + 2.86𝑚𝑚

𝑀𝑒𝑎𝑛𝐵 = = 2.852mm
5

Table 9. Mean Wall Thickness

Mean Wall
PNS Thickness
Sample Thickness % Difference Tolerance Remarks
(mm)
(mm)
A 2.832 2.8 +1.14% -10% Qualify
B 2.852 2.8 +1.86% -10% Qualify

The readings showed in Table 9 is similar to Table 8. It showed that the data are close to each
other making it more realible in terms of accuracy. The both sample have similar wall thickness that has
a very small difference. Comparing the data gathered to the Philippine National Standard for thickness,
the measurements acquired fir the tolerance level of the requirement making the material qualified for
the thickness in dimensional test.

Table 10. Flattening Test Analysis

Weld at 0 Weld at 90
Sample Remarks
degree degrees
A No cracks No cracks Qualified
B No cracks No cracks Qualified

Sample A and Sample B showed no signs of fractures or cracks on the material based on
the data acquired in Table 10. It shows that the material is qualified and also means that the material
is ductile since it passed the Philippine National Standards.

Table 11. Differences during Weight of Zinc Coating Test

Difference of Initial and Difference of Initial and Final
Sample
Final Weight (g) Thickness (mm)
A 0.59 0.612
B 0.14 0.942

In the Table 11, the experiment actovoty shown that a 1 inch by 1 inch steel plate was cut
from the pipe. The texture and color of the plates changed after immersing the steel plate to the
HCl bath. Bubbles are seened or present were occuring of chemical reaction can be assumed. The
color of the steel plate change from a shiny gray color texture to dark dull gray color texture as
observed in the activity assuming the chemical reaction is present to it. From the data acquired that
shown in Table 11, it showed that there is a difference in the initial weight and final weight of the
samples.

The mass of the zinc coating was then computed using the formula from Equation 1.

𝑚1 + 𝑚2
𝑚=
𝐴

𝑚1 − 𝑚2 0.59𝑔 1𝑖𝑛2 𝑔
𝑚𝐴 = = 𝑥 −4 2
= 914.50 ⁄𝑚2
𝐴 1𝑖𝑛𝑥1𝑖𝑛 6.4516𝑥10 𝑚

𝑚1 − 𝑚2 0.14𝑔 1𝑖𝑛2 𝑔
𝑚𝐵 = = 𝑥 −4 2
= 217.00 ⁄𝑚2
𝐴 1𝑖𝑛𝑥1𝑖𝑛 6.4516𝑥10 𝑚

Table 12. Mass of Zinc Coating

Difference of Initial and Final Coating Mass of Zinc
Sample
Weight (g) Area (in2) coating (g/in2)
A 0.59 1 914.50
B 0.14 1 217.00

𝑔 𝑔
𝑚𝑍𝑛(𝐴) + 𝑚𝑍𝑛(𝐵) 914.50 ⁄𝑖𝑛2 + 217.00 ⁄𝑖𝑛2 𝑔
𝑚𝑎𝑣𝑔 = = = 565.75 ⁄𝑖𝑛2
2 2

The average mass of zinc coating pass the standards for the Philippine National Standards
however sample B, falls short to the minimumm mass of zinc coating allowed. Thus, makes the
material not qualified.

4. Conclusion

From the experiement, the steel sample was tested for dimensional test, flatenning test, and
zinc coated test. The sample of the material is qualified for the dimensional test for bith sample A
and sample B and has meet the Philippine National Standards specifically, the outside diamter of
the sample met the range of allowable outside dimater measurement and thickness of the material
also meet the minimum thickness required for the specified material.

In the flattening test, the sample A and sample B have no cracks were seen on the material
after the test run on both 0 and 90 degrees. Both samples met the requirements and are qualified.
In the weight of zinc coating test, the material failed to qualify the standanrds of the Philippines
National Standards. The average mass of zinc coating met the requirement but one of the samples
did not qualidy the specific mass for a sample.

In conlusion, zinc coating helps to increase the duaration of a certain material it is helpful
to prevent creating causes for tarnishing or rust. Establishing of the Philippine National Standards
is important specially to the customers or consumers and helps the to identify that there are no
flaws or defficiency in a certain product. It is important because every materials has different
characteristics and chemical reations thus setting its own standard. It is important for engineers to
know this standards for it helps in designing products better.

References
[1] A. Bayquen et al., “Exploring life through Science General Chemistry 2”, Abiva Publishing
House, Inc.
[2] W.J. Smith et al, “Zinc Coating”, Retrieved from https://www.sciencedrect.com/topics/mat
erialsscience/zinc-coating

[3] Department of Trade and Industry. (n.d). PNS 26:1992.

[4] A. McMullen, “The 4 Advantages of Using Zinc Plating.” Retrieved from https://www.dorse
tware.com/the-4-advantages-of-using-zinc-plating

[5] Experiment 2. Retrieved from https://drive.google.com/file/d/1vD7H0a1zCzwoX0Nw8iufCI

_ b4olWOoIT/view

[6] Micrometer Caliper. Retrieved from https://shopee.ph/MITUTOYO-0-25mm-OUTSIDE-

MICROMETER-CALIPER-(103-137)-i.53586057.860425497