Hot-Dip Galvanizing

What We Need to Know

National Institute e of Steel Detailin Detailing tailing

Fred Tinker National Institute of Steel Detailing, Inc. With Assistance From: Christine McCulloch - Education Committee National Institute of Steel Detailing, Inc. Andrew Lesko - Calwest Galvanizing Melissa Lindsley - American Galvanizers Association Paul Parks - Infosight Corporation
Photos contributed by the American Galvanizers Association First Printing: March 1, 2009
2009 National Institute of Steel Detailing and the American Galvanizers Association. The material provided herein has been developed to provide accurate and authoritative information about after-fabrication hot-dip galvanized steel. This material provides information only and is not intended as a substitute for competent professional examination and verication as to suitability and applicability. The information provided herein is not intended as a representation or warranty on the part of the NISD or AGA. Anyone making use of this information assumes all liability arising from such use.

Contributors

Hot-Dip Galvanizing
Table of Contents
Introduction..........................................................5 Galvanizing History..............................................5 Hot-Dip Galvanizing Process.................................6 Surface Preparation..................................6 Degreasing..................................6 Pickling........................................6 Fluxing.........................................6 Galvanizing.............................................7 Inspection................................................7 Galvanized Coating Characteristics Metallurgical bond...................................7 Coating Uniformity....................................7 Cathodic protection..................................8 Galvanized Coating Performance Time to First Maintenance.........................8 Exposure to High Temperature....................8 Additional Galvanizing Information Galvanizing vs. Painting: By the Numbers.....9 Painting Hot-Dip Galvanized Steel.............9 Sheet Steel/Continuous Galvanizing...........9 Design Considerations........................................10 Welding Procedure................................11 Flux & Slag Removal....................11 Stitch and Seal Welding .............12 Drilling and Cutting.................................................12 Venting and Drainage..............................................12 Handrail..........................................13 Cap and Base Plates.......................13 Cropping for Drainage.....................14 Repair of Vent Holes........................14 Masking.....................................................14 Marking.....................................................14 Barcode Tags..............................................15 Galvanized Bolts, Nuts, and Holes.................15 Temporary Bracing.......................................15 Lifting Aids..................................................16 Galvanizing Oversized Pieces......................16 Touchup and Repair.....................................16 Appearance................................................17 ASTM Standards.....................................................18 Canadian Standards Association..............................18 Frequently Asked Questions.....................................19 Appendix of Detailed Sketches................................21 Special Thanks........................................................27

Introduction
Hot-dip galvanized steel has been effectively used for more than 150 years. The value of hot-dip galvanizing stems from the relative corrosion resistance of zinc, which, under most service conditions, is considerably better than iron and steel. In addition to forming a physical barrier against corrosion, zinc, applied as a hot-dip galvanized coating, cathodically protects exposed steel. Furthermore, galvanizing for protection of iron and steel is favored because of its low cost, the ease of application, and the extended maintenance-free service it provides. This book is to help the architect, design engineer, fabricator, and detailer better understand the process of preparing steel for the highest quality corrosion resistant coating (galvanizing). This book will assist you in your hot-dip galvanizing foundation by providing a look at the galvanizing history, galvanizing process, galvanized coating characteristics, performance, and design considerations. Following the information provided, the designer, fabricator, and detailer can ensure the highest quality galvanized coating.

Galvanizing History
79 AD 1742 1772 1801 1829 1837 1850 1870 Today
Historical records show zinc usage in early construction. P.J. Malouin, a French chemist, presents to the Royal Academy of Sciences several experiments involving the coating of iron by molten zinc. Luigi Galvani, galvanizings namesake, discovers the electrochemical process that takes place between metals during an experiment with frog legs. Alessandro Volta discovers the electro-potential between two metals, creating a corrosion cell. Michael Faraday discovers zincs sacricial action, during an experiment involving zinc, salt water and nails. French engineer Stanislaus Tranquille Modeste Sorel took out a patent for the early galvanizing process. British galvanizing industry is consuming 10,000 tons of zinc annually for the production of galvanized steel. First galvanizing plant opened in the United States. Steel was hand-dipped in the zinc bath. 600,000+ tons of zinc is consumed in North America to produce hot-dip galvanized steel.

Hot-Dip Galvanizing Process

Surface Preparation

Caustic cleaning

Rinsing

Pickling

Rinsing

Flux solution

Drying

Zinc bath

Cooling and inspection

Figure 1: The Hot-Dip Galvanizing Process The hot-dip galvanizing process (Figure 1) consists of the following steps: Surface preparation a series of three cleaning processes to prepare the steel for immersion in the zinc bath, as zinc will not react with, nor adhere to unclean steel. Galvanizing total immersion of the steel in the molten zinc bath. Inspection visual inspection and coating thickness measurement to ensure conformance to appropriate specications. Small parts, such as fasteners, brackets, and clips less than 30 (76cm) in length, are galvanized with the same process. However, these parts are spun or centrifuged after galvanizing to remove excess zinc.

Fluxing
Steel is immersed in liquid ux (a zinc ammonium chloride solution) for two purposes. First, the ux will remove any remaining iron oxides. Additionally, the ux will create a protective lm to prevent oxidation prior to dipping into the molten zinc bath (Yellow Tank, Figure 1).

Surface Preparation
Degreasing
In the degreasing step, a hot, alkaline solution removes dirt, oil, grease, shop oil, some paints, and soluble markings (Green Tank, Figure 1). It will not remove some surface contaminants, such as epoxies, vinyls, asphalts, or welding slag. These contaminants must be mechanically cleaned by grinding or blasting prior to shipment to the galvanizing facility. Degreasing

Pickling
Dilute solution (between 8% to 15%) of either ambient hydrochloric or heated sulfuric acid removes surface rust and mill scale to provide a chemically clean metallic surface (Red Tank, Figure 1).

Pickling

Galvanizing
The steel article is immersed in a bath of molten zinc heated to between 815-850F (435-455C). During galvanizing, the zinc metallurgically bonds to the steel, creating a series of abrasion-resistant zinc-iron alloy layers, topped by a layer of pure zinc. As the steel is withdrawn from the zinc bath, excess zinc is removed by draining, vibrating, or for small items, centrifuging. It is important to remove all excess to ensure the part is suitable for its intended use. The galvanized item is either cooled by air or water, or dipped in a passivation solution to prevent oxidation.

Hot-Dip Galvanizing Process

Inspection
The nal step in the galvanizing process is the inspection of the surface condition and coating thickness. The inspection of galvanizing is relatively easy because zinc does not adhere to unclean steel. So, if the steel has a continuous coating of zinc, it should meet the required specication. To conrm conformance, the coating thickness is measured using a magnetic thickness gauge.

Hot-Dip Galvanized Coating Characteristics

Metallurgical Bond
During the galvanizing process, the zinc in the kettle and the iron in the steel metallurgically react to form the galvanized coating. This diffusion reaction creates a series of intermetallic zinciron alloy layers, which are harder than the base steel (see Figure 2). The metallurgical bond is much stronger than a mechanically bonded coating, as galvanized steel bond strength is around 3,600 psi compared to several hundred for most other coatings.

Figure 2: Photomicrograph of Galvanized Coating

Diamond Pyramid Number (DPN) = measure of hardness, the higher the number, the greater the hardness

Coating Uniformity

surface, which means coating thickness at corners and edges is at least as thick as at surfaces. Paint tends to be Galvanizing is a total immersion process, which ensures thinner at edges and corners, and painted hollow structures all surfaces are coated, including the inside of hollow have no protection on the inside. These areas are where structures. During the diffusion reaction in the galvanizing corrosion often starts. kettle, the intermetallic layers grow perpendicular to the

Cathodic Protection
Galvanized coatings also offer cathodic protection, which simply means the zinc will sacrice itself to protect the underlying base steel. Often steel pieces are roughly handled during shipment and/or erection, which can damage organic coatings. Galvanized steel can withstand this rough handling, and if damaged, the steel will still be cathodically protected by the surrounding zinc (see Figure 3). The same principle is used to protect outboard boat engines.

Figure 3: Cathodic Protection

Galvanized Coating Performance

100
Time to First Maintenance* (years)

90 80 70 60 50 40 30 20 10 0 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0

Key
Rural Suburban Temperate Marine Tropical Marine Industrial

*Time to first maintenance is defined as the time to 5% rusting of the substrate steel surface.

Average Thickness of Zinc (mils)

1 mil = 25.4m = 0.56oz/ft2

Figure 4: Time to First Maintenance Chart For more information on the performance of hot-dip galvanized coatings, visit the American Galvanizers Associations website at www.galvanizeit.org and The Time to First Maintenance Chart (Figure 4) was download the publications Hot-Dip Galvanizing for developed from decades of real world corrosion data Corrosion Protection: A Speciers Guide and/or collected from galvanized steel samples exposed to Service Life Chart for Hot-Dip Galvanized Coatings. environments all over the world. This data was sorted into ve characteristic environmental categories: rural, suburban, industrial, temperate marine and tropical marine. There are some concerns with using hot-dip galvanized Time to rst maintenance is dened as the period of steel in an elevated temperature environment. The time until 5% of the substrate steel surface is showing industry recommends the service temperature for iron oxide (rust). At this point, it is unlikely the galvanized coatings be less than 390F (200C) for underlying steel has been weakened or the integrity of long-term exposure. Possible concerns at continued the structure is compromised, but it is time to begin a exposure to temperatures above 390F (200C) maintenance cycle on the structure to protect it from include peeling, some further corrosion. Some Peeling No Peeling changes in mechanical Peeling properties, and obvious As the chart illustrates, the zinc coating thickness is reduction in corrosion directly proportional to the time to rst maintenance. Other factors that inuence the corrosion performance protection. of the coating are: relative humidity, sulfur dioxide, Figure 5: Galvanizing airborne salinity, precipitation, and temperature. Performance at High 390 F 480 F Temperatures

Time to First Maintenance

Exposure to High Temperature

Temperature

Examples of duplex systems

Additional Galvanizing Information

Galvanizing vs. Painting: By the numbers
An economic analysis of galvanizing vs. painting on both an initial and life-cycle basis should be performed prior to the selection of either corrosion protection method. Galvanizing has long been known to be less expensive on a life-cycle basis, but many speciers do not realize galvanizing is also competitive on an initial cost basis. In order to facilitate the process of performing an economic analysis, an online Life-Cycle Cost Calculator was created at www.galvanizingcost.com. The interactive calculator allows the user to input information about any job and compare the initial and life-cycle cost of galvanizing to a number of paint systems.

Sheet Steel or Continuous Galvanizing

Another series of hot-dip galvanized steel products also exists. Continuous galvanizing or sheet steel products are still formed by dipping steel into molten zinc, but the process is fully mechanized and done at very high speeds. Coils of steel sheet metal are fed as ribbon through a molten zinc bath where it reacts to leave a protective surface coating. The operation grew out of traditional afterfabrication hot-dip galvanizing into a very sophisticated process that can be used to apply thin and specic coating Galvanized Sheet grades. These coating grades are in the form of a letter G, Z, and A followed by a coating weight in mass per area. For example, a G90 grade means the sheet has been galvanized with 0.90 oz/ft2 (0.45 oz/ft2 per side) and an A60 grade means the galvanized sheet was further annealed and has 0.60 oz/ft2 overall (0.30 oz/ft2 per side). This process is also called continuous galvanizing and is specied in ASTM A 653/A 653 M, Steel Sheet, Zinc-Coated (Galvanized) or Zinc-Iron Alloy-Coated (Galvannealed) by the Hot-Dip Process. Common coating weights specied for sheet products are: G60, G90 and G185. These also exist as metric counterparts with G90 being equivalent to a Z275 coating. For more information about sheet steel products, contact the GalvInfo Center at www.galvinfo.com.

Painting Hot-Dip Galvanized Steel

Painting over hot-dip galvanized steel, called a duplex system, is a common practice for a number of reasons, including aesthetics, safety marking, and extended life. Creating a successful duplex system requires proper surface preparation and communication with the galvanizer about the intent to paint after galvanizing. ASTM D 6386 has been developed to provide best practices for preparing a hot-dip galvanized surface for painting. Many products have been galvanized and painted successfully for decades, including automobiles and utility towers. For more information on duplex systems, visit www.galvanizeit.org and download the publications Duplex Systems: Painting Over Hot Dip Galvanized Steel and/or Practical Guide for Preparing Hot Dip Galvanized Steel for Painting.

Design Considerations

Now that we know the history, processes, and performance characteristics of galvanizing, lets examine characteristics for quality galvanizing. Protection against corrosion begins at the drawing board. No matter what corrosion protection system is specied, it must be factored into the products design.

Once the decision has been made to hot-dip galvanize steel for maximum corrosion protection, the design engineer should ensure the pieces can be suitably fabricated for the highest-quality galvanizing. There are a few considerations when designing components for galvanizing. These guidelines are relatively simple and will help ensure maximum corrosion protection.

Things to consider while designing, detailing, and fabricating steel to be galvanized:

The weight of fabricated items should be considered in the design of pieces for hot-dip galvanizing because the cranes/hoists used in the handling processes required to move items though the galvanizing facility have maximum limits. Design a eld splice at every other oor for heavy and long columns. Increase the column size so doubler plates and cover plates are not required at the web and ange to satisfy the loads. Use W & WT members for bracing in place of back to back stitched angle. Use connections that can be welded all around. Provide shear plate connections in place of clip angles (Figure 6). Incorporate one-sided clip connections in place of clip angles (Figure 7).
Figure 6: Shear Connection

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Figure 7: One-sided Clip Angle

 Use seated connections in place of clip angles (Figure 8). Design end plate connections in lieu of clip angles (Figure 9). Attach curb plates after galvanizing. Avoid combining different materials & nishes because pickling time and immersion time in the zinc bath may affect the coating appearance and/ or cause slight warpage and/or distortion due to varying temperature gradients (Figure 10). Asymmetrical steel sections Use W shapes for ll beams to avoid the distortion of asymmetrical pieces. Weld stair stringer and steps into frames to add symmetry and support during galvanizing. Steel section of unequal thickness and size There are ways to fabricate steel weldments to guard against warping. Typically, bracing or using structural steel of symmetrical shape and similar thickness provides quality nished product with little or no distortion or warpage. See ASTM A 384 for best practices, and then contact your local galvanizer for more information.
Figure 8: Seated Connection

Figure 9: End Plate Connection

Ductile iron pipe with machined ange

Welding Procedure
It is common practice to weld steel prior to galvanizing, which ensures the entire structure is coated with zinc. There are a few things to consider when welding before galvanizing, including the removal of contaminants and the viscosity of zinc.
Machine surfaces on pitted steel

Forged bolt with machined threads

Flux & Slag Removal

As with any fabrication to be galvanized, the steels surface needs to be completely free of any residues including weld ux and weld slag. Welding ux is the material used to prevent the formation of, or to dissolve and facilitate removal of, oxides and other undesirable substances. Weld slag is the material resulting from the combination of weld material and weld ux and both will inhibit localized formation of the galvanizing coating. Neither can be removed by the chemicals used in the galvanizing process, and thus they will need to be removed by mechanical means before shipping to the galvanizers facility.

Ol

ted Pit & d

New

&C

lea

Castings with mild carbon steel

Steel with dierent surface conditions

Figure 10: Design Guidelines to Avoid

Overlapping Surfaces

11

Good Weld Seal Weld For highest quality galvanizing and nal appearance, smooth clean welds free of ux and slag are required.

Best welding practice for galvanizing is to stitch weld with a gap greater than 3/32 or seal-weld when this gap distance is not possible. If the areas to be enclosed by seal welding are greater than 16 in2, vent holes must be supplied in the design to allow the expanding gas in the enclosed area to be vented during galvanizing. ASTM A 385 gives guidance on hole sizes and quantities based on the area to be enclosed.

Seal-welding a weld used primarily to obtain

tightness and prevent the ow of cleaning solutions and zinc into otherwise enclosed areas, to prevent ash steaming causing localized ungalvanized areas.

Stitch- and Seal-welding

Stitch-welding a weld with at least 3/32 gap which Stitch-welding and seal-welding are both commonly will allow cleaning solutions and zinc to ow into and used in fabrications for galvanizing. However, there are out of the weld area. best practices for using one or the other. Consider the following:

Drilling and Cutting

The viscosity of molten zinc is low and thus prevents it from entering gaps of 3/32 and smaller, but cleaning solutions used in the process can penetrate such openings. Overlapping and contacting surfaces, like stitch welds, allow the cleaning solutions used in the galvanizing process to penetrate between the steel. If cleaning solutions penetrate a gap, and zinc cannot, pressure and steam can build up along the weld. This not only may result in ash steaming that prevents the galvanized coating from forming around the weld but also creates steam pressure that may compromise the integrity of the weld. Also, the trapped solutions may eventually react with the uncoated steel hidden by the weld or overlapping surfaces. This manifests as iron oxide that weeps out to form an unsightly brown stain on the galvanized surface..

Drill holes in place of punching in thicker material and gas cut in place of shearing to avoid cracks at edges. Punching and shearing are cold-working forces that put internal stress on steel. The punched hole or shear location may result in an accelerated rate of embrittlement of the steel.

Sheared Edge
If these edges are exposed during the hot-dip galvanizing process, the microcracks that formed on the sheared edges may propagate into the steel. These edges may need to be ground to remove any microcracks formed during shearing.

Venting & Drainage

Proper venting is required on tubular assemblies such as handrails, pipe columns and pipe trusses. This allows trapped air to escape the part and prevents the air from becoming superheated steam in the

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Sheared Edge Embrittlement

Punched Hole Embrittlement

molten zinc that could build up pressure. This built up pressure may not only damage the coating, but can also physically explode and endanger galvanizing personnel. Structures may be internally or externally vented (see Figure 11).

Drainage the act, process, or mode of becoming

emptied or freed of molten zinc.

Venting providing holes in fabrications to be

galvanized to allow entrapped, heated liquids and gases to escape as temperature and pressure increase. Proper Baseplate Drainage

Venting and Drainage: Cap & Base Plates

There is a reason for base and cap plates to have venting and drainage holes as shown here. When they enter the galvanizing bath air can escape and allow zinc to come in contact with the entire inside surface of the pipe or tube. Additionally, when they are removed from the galvanizing bath, zinc is not trapped inside. In the picture above, the end plate design is such that the holes are used for drainage but only in the orientation shown. If turned 90 degrees the base plates will trap zinc upon removal from the galvanizing bath. Contact your local galvanizer for the proper way to vent pipes and tubes. If steel is not adequately or properly vented, it may become a danger to galvanizer personnel, as well as allow explosive pressure to build, resulting in irreparable damage to the steel.

Figure 11: Internal and External Venting

Handrail Preferred Venting & Drainage

In the picture below, the numbers correspond to the following items: 1. External vent holes 2. Internal vent holes 3. Open end drains

(See detail sketch, page 21, for more information)

(See detail sketch, page 22, for more information)

Common baseplate venting

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Cropping For Drainage

To achieve effective galvanizing, the cleaning solutions and molten zinc must ow completely into, over, through and out of the fabricated steel. Below (Figures 12-15) are recommended types of drainage design to avoid improper drainage resulting in poor appearance, bare spots, and/or excessive buildup of zinc. This buildup may make the part heavier than anticipated in the design. Proper communication throughout the project will help attain good design for drainage.

Masking
It is possible to mask sections of a part to avoid the development of the galvanized coating. Examples where masking is commonly used: 1. Field welded shear studs 2. Slip critical bolt surfaces 3. Field welded splice areas

Masking

All stiffeners and gusset plates should be cropped There are 4 categories of masking material: (See Figure 12&14) to provide an opening with a Acid-resistant, high temperature tapes 2 minimum of 0.3 in or 13/16 in. hole at the corners of Water-based pastes and paint-on formulations all stiffeners. (See Figure 13&15). Resin-based, high temperature paints High temperature greases
Masking using a material to produce intentionally ungalvanized areas, typically used on surfaces to be welded, on faying surfaces, or areas where the galvanized steel coating is not necessary for uniform corrosion protection.

Marking
Figure 12: Cropped Corners (Preferred) Figure 13: Hole close to corner

Permanent identication practices include: Stamping the surface of the material using diecut deep stencils or a series of punch-marks toward the center of the pieces. A series of weld beads to mark letters or numbers directly onto the material. It is essential that all weld ux be removed in order to achieve the highest-quality galvanized coatings. Deep stenciling a steel tag (minimum #12 gauge) and rmly afxing it to the material with a minimum #9 gauge steel wire. If desired, tags may be seal-welded directly onto the material.

Figure 14: Cropped Corners (Preferred)

Figure 15: Holes at Corner (Alternative)

(See detail sketch, page 23-24, for more information)

Repair of Venting Holes

If vent holes need to be closed after galvanizing, as they often are in handrail pieces, aluminum or zinc plugs can be used.

Before

After

Common identification practices

14

A similar process is suggested for oversizing open holes. The hot-dip galvanizing process adds a coating of zinc to steel in the range of 2-8 mils. When designing open holes, it is necessary to plan for the increased thickness on both the fastener and the hole (see Table 1). If after galvanizing, the hole is still not large enough, it can be reamed. A small amount of reaming will not affect the corrosion protection.

Barcode Tags

Galvanized Table for Oversized Holes Not certified by AISC or AGA

Nominal bolt Diameter (db) (in)
db < 1/2 1/4 (4/16) 1/2 (8/16) 1/2 < db < 1 5/8 (10/16) 3/4 (12/16) 7/8 (14/16) 1 < db < 1 1/8 1 (16/16) db > 1 1/8 1 1/8 (18/16)

Barcode Tags
Metal barcode tags can also be used to identify materials. These tags are resistant to caustic wash and acid pickling. The tags will survive the molten zinc bath with minimal damage, as they are durable in a wide temperature range (-22F to 1400F (-30C to 760C)). Additional information can be stored in the bar code besides the piece mark, including job name and number, grade of steel, weight of piece, name of customer, etc.

Standard Clearance Hole Diameter (in.)

db + 1/16 5/16 9/16 db + 1/16 11/16 13/16 15/16 db + 1/16 1 1/16 (17/16) db + 1/16 1 3/16 (19/16)

Oversized Clearance Hole Diameter (in.)

db + 2/16 3/8 (6/16) 5/8 (10/16) db + 3/16 13/16 15/16 1 1/16 (17/16) db + 4/16 1 1/4 (20/16) db + 5/16 1 7/16 (23/16)

Galvanized Bolts, Nuts, and Holes

Nuts and threaded holes fabricated in steel to be hotdip galvanized should be retapped or rethreaded after galvanizing to remove the zinc coating and provide clearance for the coated bolt. When the fastener system is assembled, the coating from the bolt will provide protection for the uncoated threads on the nut or hole since zinc coatings cathodically protect uncoated steel. Retapping is done to the nut so no uncoated threads (Figure 16) on the bolts (outside the nut) are exposed to weather without galvanized protection. Standard practice for structural connections is to galvanize the nuts as blanks and then tap the threads after galvanizing.

Table 1: Standard Clearance Hole Diameter The numbers in the parenthesis are equal to the number outside of the parenthesis and can be used for easier calculations. Note: When over-sizing holes, check with the design engineer for bearing surface area of the bolt head.

Figure 16: Bolt Micrograph

Bolts used in a bridge structure

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Temporary Bracing
Large diameter, thin-walled pipe and many long or complex fabrications may require temporary bracing to prevent possible distortion. The slow (3 ft/min) immersion of steel items into the zinc bath creates an uneven heating and cooling gradient.

Progressive Dipping

Galvanizing Oversized Pieces

Progressive dipping, sometimes erroneously referred to as double dipping, is used when pieces are too large to t in the galvanizing kettle in one pass. Progressive dipping Temporary bracing increases the potential for warpage and distortion since a Temporary bracing metal attached to a fabrication section of the steel fabrication will be outside the molten prior to galvanizing in order to provide added support zinc, and therefore, cold and stiff while the immersed so the steel does not change shape during heating section of the steel is hot and ductile. and cooling. Temporary bracing is removed after This uneven temperature gradient may cause distortion galvanizing. of the steel fabrication. Other issues associated with progressive dipping include additional handling costs and an overlap line (albeit having no effect on the corrosion protection provided). When possible, design With respect to providing lifting points, consider the for a splice to allow pieces to be dipped in one pass. following:

Lifting Aids

Touchup and Repair

Where possible, lifting points (see illustration below) should be provided at the quarter points for ASTM A780 describes three acceptable methods of repairing symmetrical parts; this avoids chain or wire marks hot-dip galvanized steel (zinc solder, metallizing, and zinc rich paint). The touch-up and repair method chosen should consider on the sides of the parts. Holes for hooks may be included in the design to allow the galvanizer to hang the material from overhead xtures.
the specic use of the galvanized steel and the performance characteristics of each method. Corrosion protection should always be the primary consideration, but certain uses and conditions may warrant selection on the basis of other performance characteristics.

Lifting points connectors (sometimes temporary)

directly on the steel article that aid the galvanizer in handling the article throughout the galvanizing process, especially if the piece to be galvanized is oversized
1/4 points

(See detail sketch, page 25, for more information)

Zinc Rich Paint

16

Appearance
When steel parts are removed from the molten zinc bath, the hot-dip galvanized coating can appear bright and shiny, spangled, matte gray, or a combination of these. Regardless of the appearance, the corrosion protection afforded is the same. After a few months of exposure to the atmosphere, hot-dip galvanizing forms a protective layer of zinc corrosion byproducts that will give all pieces a uniform, matte gray appearance. To learn more about design guidelines for galvanized steel, visit www.galvanizeit.org and download the publications The Design of Products to be Hot-Dip Galvanized After Fabrication and/or Recommended Details for Galvanizing Structures.

Shiny surface

Dull surface

Dull and Shiny surface

Spangled surface

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ASTM STANDARDS RELATING TO HOT-DIP GALVANIZING AND HOT-DIP GALVANIZED MATERIALS

A 36 A 123/ A 123 M A 143 A 153/ A 153 M A 384/ A 384 M A 385 A 500 A 501 A 563 A 572 A 767/ A 767 M A 780 A 992 B6 D 6386 E 376 Specification for Structural Steel Specification For Zinc (Hot-Dip Galvanized) Coatings On Iron And Steel Products Practice For Safeguarding Against Embrittlement of Hot-Dip Galvanized Structural Steel Products and Procedure for Detecting Embrittlement Specification For Zinc Coating (Hot-Dip) On Iron And Steel Hardware Practice For Safeguarding Against Warpage And Distortion During HotDip Galvanizing Of Steel Assemblies Practice For Providing High-Quality Zinc Coatings (Hot-Dip) Specification for Cold-Formed Welded and Seamless Carbon Steel Structural Tubing in Rounds and Shapes Specification for Hot-Formed Welded and Seamless Carbon Steel Structural Tubing Standard Specification for Carbon and Alloy Steel Nuts Specification for High-Strength Low-Alloy Columbium-Vanadium Steels of Structural Quality Specification For Zinc-Coated (Galvanized) Steel Bars For Concrete Reinforcement Practice For Repair Of Damaged And Uncoated Areas Of Hot-Dip Galvanized Coatings Specifications for Steel Structural Shapes For Use in Building Framing Specification For Zinc Practice For Preparation Of Zinc (Hot-Dip Galvanized) Coated Iron And Steel Products And Hardware Surfaces For Painting Practice For Measuring Coating Thickness By Magnetic-Field Or EddyCurrent (Electromagnetic) Test Methods

CANADIAN STANDARDS ASSOCIATION

G40.8* G164 Structural Steel with Improved Resistance to Brittle Fracture Galvanizing of Irregularly Shaped Articles G40.12* General Purpose Structural Steel
* Superseded by G40.20/G40.21 General Requirements for Rolled or Welded Structural Quality Steel

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Frequently Asked Questions

1. How does galvanizing protect steel from corrosion?
Zinc metal used in the galvanizing process provides an impervious barrier between the steel substrate and corrosive elements in the atmosphere. It does not allow moisture and corrosive chlorides and suldes to attack the steel. Zinc is more importantly anodic to steel meaning it will corrode before the steel, until the zinc is entirely consumed. 7. Isnt galvanizing more expensive than paint? Depending on the product mix, square feet per ton, and condition of the steel surface, galvanizing is often less expensive on an initial cost basis. However, as with any purchase, the life-cycle costs should be considered when making a project decision on the corrosion protection system to utilize. And, with galvanizing, the lifecycle cost, i.e. the cost per year to maintain, is almost always less than a paint system. Paint systems require maintenance, partial repainting and full repainting several times over a 30-year project life. The costs can be staggering, making the decision to paint a costly one in the long run. To run the comparison yourself, visit www.galvanizingcost.com. 8. What if the article to be galvanized is larger than the dimensions of the galvanizers kettle? Can it still be galvanized? Galvanizers can progressively dip such a fabrication or article of steel. They dip one half in the molten zinc bath, remove it, turn it around or over and immerse the other half in the zinc. This method is sometimes erroneously referred to as double dipping. 9. Are there any special design and fabrication considerations required to make steel ready for hotdip galvanizing? Yes. Specically, fabricated steel must allow for easy ow of the cleaning chemicals and molten zinc metal over and through it. This means that gussets must be cropped, holes put in the proper location for draining and venting of zinc from tubular congurations, weld ux removed, overlapping surfaces must be sealwelded, and light gauge material temporarily braced. 10. Sometimes, the galvanized coating is shinier in some places than others. Why is that? The galvanized coating appearance may either be bright and shiny resulting from the presence of an outer layer of pure zinc, or duller, matte gray as the result of the coatings intermetallic layers being exposed. The appearance has no affect on the corrosion performance of the coating. Over time and exposure to the environment, all galvanized coatings become a uniform, matte gray. 11. Is the zinc coatings thickness consistent over the entire piece? Coating thickness depends on the thickness, roughness, chemistry, and design of the steel being galvanized. Any or all of these factors could produce galvanized coatings of non-uniform thickness.

2. How long can I expect my galvanized steel projects to last in service? Hot-dip galvanized steel resists corrosion in numerous environments extremely well. It is not uncommon for galvanized steel to last more than 70 years under certain conditions. 3. Does the galvanized steel coating of zinc resist abrasion? The three intermetallic layers that form during the galvanizing process are all harder than the substrate steel and have excellent abrasion resistance. 4. Why do galvanized steel appearances differ from project to project and galvanizer to galvanizer, and is there any difference in the corrosion protection offered by the different appearing coatings? The appearance of the coating (matte gray, shiny, spangled) does nothing to change the corrosion protection of the zinc coating. The corrosion protection is a function of the amount of zinc in the coating, more zinc equals longer life. 5. Can galvanized steel in service withstand high temperatures for long periods of time? Constant exposure to temperatures below 390F (200C) is a perfectly acceptable environment for hot-dip galvanized steel. Good performance can also be obtained when hot-dip galvanized steel is exposed to temperatures above 390F (200C) on an intermittent basis. 6. Why would you want to paint over galvanized steel? Called duplex coatings, zinc and paint in combination (synergistic effect) will protect a structure 1.5 to 2.5 times the sum of the corrosion protection each alone would provide. Additionally, duplex coatings make for easy repainting, excellent safety marking systems, and good color-coding. Painting over galvanized steel that has been in service for many years also extends the life of the zinc coating.

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12. How much weight will my material gain from galvanizing? As an average, the weight of the article will increase by about 3.5% due to zinc picked up in the galvanizing process. However, that gure can vary greatly based on numerous factors. The fabrications shape, size, and steel chemistry all play a major role in the nal weight. 13. Im interested in specifying hot-dip galvanizing for reinforcing steel. Are there any concerns with fabricating rebar after galvanizing? Rebar can be fabricated after galvanizing, but the fabrication process may induce damage into the protective coating and reduce the life of the material. 14. Can I specify how much zinc to put on the steel? No, the steel chemistry and surface condition are the primary determinants of zinc coating thickness. Leaving the steel in the molten zinc a little longer than optimal may have one of two effects: 1) it may increase the coating thickness, but only marginally; 2) or it may signicantly increase the coating thickness and cause a brittle coating. 15. What does it mean to double-dip steel? Double-dipping is the progressive dipping of steel too large to t into the kettle in a single dip. Doubledipping cannot be used to produce a thicker hot-dip galvanized coating. 16. What is the reason for incorporating venting & drainage holes into a projects design? The primary reason for vent holes is to allow otherwise trapped air and gases to escape; the primary reason for drain holes is to allow cleaning solutions and molten zinc metal to ow entirely into, over, and throughout the part, and then back into the tank or kettle.

17. Is there a way to provide for intentionally

ungalvanized areas? Yes, but because masking or stop-off materials may not be 100% effective, contact your galvanizer for suggestions.

18. Is there any environmental impact when the zinc coating sacricially corrodes? Is zinc a safe metal? There are no known studies to suggest zinc corrosion products cause any harm to the environment. Zinc is a naturally occurring element (27th most abundant element in the earths crust), and necessary for all organisms to live. It is a recommended part of our diet (RDA 15 mg) and necessary for reproduction. It is used in baby ointments, vitamins, surgical instruments, sunscreens and cold lozenges. 19. Should I be concerned when galvanized steel comes in contact with other metals? Zinc is a noble metal and will sacrice itself (i.e. corrode, give up its electrons and create a bi-metallic couple) to protect most metals. So, it is recommended to insulate galvanized steel so it doesnt come in direct contact with dissimilar metals. Rubber or plastic, both non-conductive, are often used to provide this insulation. 20. What is cold galvanizing? There is no such thing as cold galvanizing. The term is often used in reference to zinc-rich paint. Galvanizing by denition means a metallurgical reaction between zinc and iron to create a bond between the zinc and the steel of approximately 3600 psi. There is no such reaction when zinc-rich paints are applied and the bond strength is only several hundred psi.

For additional information please visit the American Galvanizers Associations website www.galvanizeit.org

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For additional information please visit the American Galvanizers Associations website www.galvanizeit.org

Special Thanks To:

Michael Tinker Pacific Drafting Inc. Rodelio Carpio Pacific Drafting Inc. Bernardo Duran American Galvanizers Association Jenny Clawson - American Galvanizers Association Cecile Elliott American Galvanizers Association Kevin Hobson Calwest Galvanizing

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National Institute of Steel Detailing 7700 Edgewater Dr. Ste. 670 Oakland, CA 94621-3022 510.568.3741 www.nisd.org