Following a request by the engineering section of the KZN committee of the Institute we approached Terry Smith of the Hot Dip
Galvanizers Association to supply us with some information about whether pre-galvanized sheet was suitable for making cold formed
lipped purlins and girts to be used in a naturally corrosive environment such as Durban.
Terry has excelled himself in supplying us with a wealth of information comparing general or batch type hot dip galvanizing (galvanizing)
with continuous sheet hot dip galvanizing (pre-galv). The result is this and a following article in the next issue of Steel Construction.
The use of a table to compare the various aspects, whilst it will take some concentration and studying for the reader, is in fact the
only practical way Terry (and us for that matter) could find to present the paper. Read on and find out lots about the galvanizing
process, its methods, its alloying. The information will be informative to anyone who has an interest in the process, both as specifier,
applicator or end product user.
BACKGROUND INFORMATION
GENERAL OR BATCH TYPE HOT DIP GALVANIZING CONTINUOUS SHEET HOT DIP GALVANIZING
SPECIFICATIONS
Coating Steel thickness Local coating Mean coating Coating Average mass of Individual mass of Min. coating
thickness #6 (mm) thickness (m) thickness (m) designation #7 coating coating thickness
on one face. (m)
t>= 6 70 85 Z200 200 170 9.7
3<= t <6 55 70 Z275 275 235 13.4
1.5<= t <3 45 55 Z450 450 385 22
t<1.5 35 45 Z600 600 510 29
Steel thickness Any steel thickness but preferably greater than 2.0 thick From 0.28 to 2.9mm thick. Note: The steel thickness is described by overall
particularly if not shaped or work-hardened. thickness including the applied zinc coating.
Smoothness and Relatively smooth, depending on steel type, complexity of Gas Knives (usually high pressure air) wipe off excess molten metal as the
acceptance of the component and dipping exit angle. Free from roughness and continuous sheet exits the zinc bath, leaving behind a closely controlled thickness
coating sharp points, particularly at pre-defined significant surfaces. of coating.
Ordering, Steel that has been hot dip galvanized by the general process The coating grade that has been specified may be difficult to assess in terms of
identification and is relatively easy to identify that it is in fact hot dip coating grade (and therefore coating thickness) on receipt at site in terms of
receipt at site. galvanized. Silver paint that may have been incorrectly used specification conformity. The specifications do not permit random coating thickness
for repair can easily be scrapped off. readings using a calibrated coating thickness instrument. They do provide a
reasonable idea of what the coating thickness is and hence the grade
delivered. The method required by the specification is described in #8.
Process Items that are fully fabricated, welded and cleaned are dipped Continuous sheeting is rapidly (100 to 140m/min) passed through a bath of
in a bath of molten zinc at about 450C and removed at a molten zinc at about 450C and as it exits the bath the sheeting travels through
relatively steep angle and slow speed. gas air knives that wipe off the excess coating, resulting in the coating thickness
designation that was specified.
Composition of the The coating comprises a series of iron/zinc (Fe/Zn) alloy The coating comprises mostly pure zinc with very little iron/zinc alloy layer
coating layers, normally over coated by a relatively pure zinc layer. (about 1 2 m), thus ensuring ductility.
Influences on Silicon and Phosphorus and combinations of these two Effectiveness of the gas knives.
coating thickness elements in the steel have a major effect on coating thickness
and appearance. Steel thickness and surface roughness also
have an effect on coating thickness.
Zinc melt 98.5% Zn, 1.2%Pb and about 0.007% max. Al. 99.95% Zn, 0.008%Pb and about 0.02% max Al.
Passivation Components quenched in water which contains a small Mill passivation: A chemical treatment is normally applied to zinc coatings to
percentage of sodium dichromate. Chrome 6 is not a friendly minimize the hazard of wet storage stain.
material and is being phased out. Mill phosphating: This is applied so that subsequent painting after normal cleaning
can be relatively easily achieved.
Oiling: This treatment method further prevents the formation of wet storage stain.
Testing adhesion Testing of adhesion is not necessary in accordance with In order to test the adhesion of a coating, a bend test and impact cupping test is
SANS 121. conducted. See #9
#9 Because of the formation of the iron/zinc alloy at the interface between the steel and the zinc it is not necessary to do an adhesion test for galvanized items.
For pre-galv material it is necessary to do bend tests. Samples are bent through 180 in either direction must not show flaking of the coating on the outside of
the bend. There are numerous rules relating to this test in the specs.
Primarily the process slows down the formation of white rust and so has it uses. White rust is zinc oxide and especially on pre-galv sheets
stored such that water can penetrate between the sheets resulting in the quick formation of white rust and as the zinc coat is thin the
ongoing process is for the base steel to quickly rust.
If any paint system is to be applied to either galvanised steel or pre-galv sheets then the sodium dichromate solution should not be used
as the paint will not adhere properly. If the galvanised steel has been chromate passivated it is necessary to remove the layer before
applying paint.
Part 2 of the article will continue with a comparison of durability of the two systems (looking at the ISO 9223 corrosion categories for
the comparison), whether the product(s) can be altered, how defects should be repaired.
The answer to the KZN query will be quite obvious by the time you get to the end of the next article in the March 2009 Issue.