UNIVERSITY OF SCIENCE AND TECHNOLOGY OF SOUTHERN PHILIPPINES

COLLEGE OF ENGINEERING AND ARCHITECTURE

Mechanical Engineering Department

Industrial Processes & Plant Inspection

Title: GALVANIZED STEEL

MANUFACTURING PROCESS

Submitted by:
EDUAGIN, RODIMAR T.

Submitted to:
Engr. Dennis E. Ganas
Instructor

July 2017
HISTORY

The earliest known example of galvanized iron was encountered by Europeans on 17th-century
Indian armor in the Royal Armouries Museum collection. It was named in English via French
from the name of Italian scientist Luigi Galvani. Originally in the 19th century, the term
"galvanizing" was used to describe the administration of electric shocks; this was also
called Faradism. This usage is the origin of the metaphorical use of the verb "galvanize", such
as to "galvanize into action" meaning stimulating a complacent person or group to take action.
In modern usage, the term "galvanizing" has largely come to be associated with zinc coatings,
to the exclusion of other metals. Galvanic paint, a precursor to hot-dip galvanizing, was
patented by Stanislas Sorel, of Paris, in December 1837.
In 1742, French chemist Paul Jacques Malouin described a method of coating iron by dipping
it in molten zinc in a presentation to the French Royal Academy.
In 1772 Luigi Galvani (Italy), galvanizing's namesake, discovered the electrochemical process
that takes place between metals during an experiment with frog legs.
In 1801 Alessandro Volta furthered the research on galvanizing when he discovered the electro-
potential between two metals, creating a corrosion cell.
In 1836, French chemist Stanislas Sorel obtained a patent for a method of coating iron
with zinc, after first cleaning it with 9% sulfuric acid (H2SO4) and fluxing it with ammonium
chloride (NH4Cl).

17th-century Indian armor

METHODS & PROCESSES
Hot-dip galvanizing deposits a thick, robust layer of zinc iron alloys on the surface of a steel
item. In the case of automobile bodies, where additional decorative coatings of paint will be
applied, a thinner form of galvanizing is applied by electrogalvanizing. The hot-dip process
generally does not reduce strength on a measurable scale, with the exception of high-strength
steels (>1100 MPa) where hydrogen embrittlement can become a problem. This deficiency is
a consideration affecting the manufacture of wire rope and other highly-stressed products.
The protection provided by hot-dip galvanizing is insufficient for products that will be
constantly exposed to corrosive materials such as acids, including acid rain in outdoor uses.
For these applications, more expensive stainless steel is preferred. Some nails made today are
galvanized. Nonetheless, electroplating is used on its own for many outdoor applications
because it is cheaper than hot-dip zinc coating and looks good when new. Another reason not
to use hot-dip zinc coating is that for bolts and nuts of size M10 (US 3/8") or smaller, the thick
hot-dipped coating fills in too much of the threads, which reduces strength (because the
dimension of the steel prior to coating must be reduced for the fasteners to fit together). This
means that for cars, bicycles, and many other light mechanical products, the practical
alternative to electroplating bolts and nuts is not hot-dip zinc coating, but making the fasteners
from stainless steel.
The size of crystallites in galvanized coatings is a visible and aesthetic feature, known as
"spangle". By varying the number of particles added for heterogeneous nucleation and the rate
of cooling in a hot-dip process, the spangle can be adjusted from an apparently uniform surface
(crystallites too small to see with the naked eye) to grains several centimeters wide. Visible
crystallites are rare in other engineering materials, even though they are usually present.
Thermal diffusion galvanizing, or Sherardizing, provides a zinc diffusion coating on iron- or
copper-based materials. Parts and zinc powder are tumbled in a sealed rotating drum. Around
300 C (572 F), zinc will diffuse into the substrate to form a zinc alloy. The advance surface
preparation of the goods can be carried out by shot blasting. The process is also known as "dry
galvanizing", because no liquids are involved; this can avoid possible problems caused by
hydrogen embrittlement. The dull-grey crystal structure of the zinc diffusion coating has a good
adhesion to paint, powder coatings, or rubber. It is a preferred method for coating small,
complex-shaped metals, and for smoothing rough surfaces on items formed
with sintered metal.

Galvanizing Process
Hot-dip galvanizing is the process of immersing iron or steel in a bath of molten zinc to
produce a corrosion resistant, multi-layered coating of zinc-iron alloy and zinc metal. While
the steel is immersed in the zinc, a metallurgical reaction occurs between the iron in the steel
and the molten zinc. This reaction is a diffusion process, so the coating forms perpendicular
to all surfaces creating a uniform thickness throughout the part.
 Figure 1: Model of the Hot-Dip Galvanizing Process

The hot-dip galvanizing process (Figure 1) has been used since 1742, providing long-lasting,
maintenance-free corrosion protection at a reasonable cost for decades. Although hot-dip
galvanizing has been utilized to protect steel for generations, the galvanizing process
continues to evolve with new technologies and creative chemistries. The three main steps in
the hot-dip galvanizing process are surface preparation, galvanizing, and post-treatment, each
of which will be discussed in detail. The process is inherently simple, which is a distinct
advantage over other corrosion protection methods.

Figure 2: Corroding Steel Structures

Figure 2 shows a series of steel structures with visible evidence of corrosion. Rust and
corrosion are expensive for owners and taxpayers. Deteriorating buildings, roads, bridges,
etc. are costly to repair, and without sufficient corrosion protection, maintenance is done
often, or in the worst cases, the structure must be rebuilt. With the push toward sustainable
development, specifying structures with longevity that require little maintenance over time
provide both environmental and economic benefits.

Surface Preparation
The purpose of surface preparation in the hot-dip galvanizing
process is to obtain the cleanest possible steel surface by
removing all of the oxides and other contaminating residues.
Thorough surface preparation is paramount as zinc will not react
with unclean steel. In order to move the steel parts through the
cleaning steps and galvanizing bath, the articles are hung using
chains, wires, or specially designed dipping racks (Figure 3).
Cleaning steel to prepare for the hot-dip galvanized coating
consists of three steps:
Figure 3: Hanging of Steel Products
Degreasing/Caustic Cleaning

First the steel is immersed in an acid degreasing bath or caustic solution to remove organic
contaminants such as dirt, oil, and grease from the surface of the steel. After degreasing the
steel is rinsed with water.

Pickling

Next the steel is pickled in a dilute solution of either

hydrochloric or sulfuric acid (Figure 4), which removes oxides
and mill scale. Once all oxidation has been removed from the
steel, it is again rinsed with water and sent to the final step of the
surface preparation.
Figure 4: The Pickling Tank
Fluxing
Finally, the steel is dipped in the flux. The purpose of the flux is to clean the steel of all
oxidation developed since the pickling of the steel and to create a protective coating to prevent
any oxidation before entering the galvanizing kettle. One type of flux is contained in a separate
tank, is slightly acidic, and contains a combination of zinc chloride and ammonium chloride.
Another type of flux, top flux, floats on top of the liquid zinc in the galvanizing kettle, but
serves the same purpose.

After degreasing, pickling, and fluxing, the surface of the steel is a near white metal clean,
completely free of any oxides or other contaminants that might inhibit the reaction of the iron
and molten zinc in the galvanizing kettle.

Galvanizing
Once the steel has been completely cleaned, it is ready for
immersion in the zinc bath. The galvanizing kettle contains
zinc specified to ASTM B6, a document that specifies any
one of three grades of zinc that are each at least 98% pure.
Sometimes other metals may be added to the kettle to
promote certain desirable properties in the galvanized
coating.
Figure 5: Hot-Dip Galvanizing Kettle

The galvanizing kettle (Figure 5), is heated to a temperature ranging from 820-860 F (438-460
C), at which point the zinc is in a liquid state. The steel products are lowered into the
galvanizing kettle at an angle, and stay in the bath until the steel heats to the bath
temperature. Once the diffusion reaction of iron and zinc is complete, the steel product is
withdrawn from the zinc kettle. The entire dip usually lasts less than ten minutes, depending
upon the thickness of the steel.
The coating, as seen in Figure 6, is typical for low silicon steels with silicon impurities less
than 0.04% and where the thickness of the coating is limited by the interdiffusion of iron and
zinc

Figure 6: Photomicrograph of the galvanized coating

Post-Treatment

When the steel is removed from the galvanizing kettle, it may

receive a post-treatment to enhance the galvanized coating. One
of the most commonly used treatments is quenching. The quench
tank contains mostly water but may also have chemicals added to
create a passivation layer that protects the galvanized steel during
storage and transportation. Other finishing steps include removal
of zinc drips or spikes, by grinding them off.

Filing Zinc Drips

Time to First Maintenance

The Time to First Maintenance (Figure 7) for hot-dip galvanized coatings in atmospheric
exposure is linear to the zinc coating thickness. Time to First Maintenance is defined as the
time to 5% rusting of the substrate steel. Structural steel pieces that are -thick or greater are
required to have at least 3.9 mils of zinc, according to the specification. As the TFM Chart
shows, this would equate to 72-73 years of life before maintenance in an industrial
environment.

Figure 7: Time to First Maintenance Chart for Hot-Dip Galvanized Coatings

Other Corrosion Protection Systems

There are many other types of corrosion protection systems, such as coating steel with oil,
grease, tar, asphalt, polymer coatings or paints, or corrosion resistant materials such as
stainless and weathering steel, sacrificial anodes, plating systems and impressed current
systems. These are some of the most commonly used corrosion protection materials and
systems and are sometimes used in conjunction with hot-dip galvanized steel. Most of these
materials rely on barrier protection, while some of them rely on cathodic properties to resist
steel corrosion. The most effective system that provides both barrier and cathodic protection
is hot-dip galvanizing.

In addition to the systems and materials listed above, there are a wide variety of other zinc
coatings used for corrosion protection. Many people use galvanizing to describe all of these
coatings, but each has its own unique characteristics and performance. These coatings have
several applications based on their properties and respective thicknesses. The corrosion
protection offered by a zinc coating is directly linear to the coating thickness. The most
commonly used coatings are hot-dip galvanized, metallized, zinc-rich paint, continuous
galvanized sheet, and electroplated. The relative thickness for each of these zinc coatings can
be seen in the photomicrograph (Figure 8). Below is a brief explanation of each type of zinc
coating

Figure 8: Photomicrogrpah of Zinc Coatings Thicknesses

Metallizing

Metallizing is the general name for the technique of

spraying a metal coating on the surface of non-
metallic or metallic objects. This process is
accomplished by feeding zinc in either wire or
powder form into a heated gun, where it is melted and
sprayed onto the surface to be coated using
combustion gases and/or auxiliary compressed air to
provide the necessary velocity. The limitations of this
process include a difficulty in reaching recesses,
cavities, and hollow spaces as well as achieving a
uniform coating thickness and the higher cost.
Zinc-Rich Paint

Zinc-rich paint is applied to a clean, dry steel

surface by either a brush or spray and contains an
organic or inorganic binder. There are a number of
zinc-rich paints, as they can contain varying levels
of zinc in dry film and binding materials. These
coatings will be discussed in more detail later in
this course.

Continuous Galvanizing

The continuous galvanizing process is a hot-dip

process where steel sheet, strip, or wire is cleaned,
pickled, and fluxed on a processing line
approximately 500 feet (154 m) in length, and
running at speeds between 100 to 600 feet per
minute (30 to 185 m per minute). In this process,
the galvanizing kettle contains a small amount of
aluminum, which suppresses the formation of the
zinc-iron alloys, resulting in a coating that is
mostly pure zinc. A post-galvanizing, in-line heat
treatment process known as galvannealing can also
be used to produce a fully alloyed coating.
Figure 9: Continuous Galvanizing Plan
Galvannealing is usually ordered by those wanting to paint over the zinc surface because the
presence of alloy layers on the steel surface promotes paint adhesion. A photo of a continuous
galvanizing plant is seen in Figure 9 and the common plant setup is shown in Figure 10.

Figure 10: Example of a Continuous Process

Electroplating

The electroplating process, or zinc-plated coating, has a dull

gray color, a matte finish, and a thin coating that ranges up to
one mil (25 m) thick. This very thin coating restricts the use of
zinc-plated products to indoor exposures. The specification
ASTM B633 lists the classes of zinc-plated steel coatings as
Fe/Zn 5, Fe/Zn 8, Fe/Zn 12, and Fe/Zn 25, where Fe represents
iron and Zn represents zinc, while the number indicates the
coating thickness in microns. The main uses for this type of
coating include screws, light switch plates, and other small
products or fasteners.

Specification
A hot-dip galvanized coating is relatively easier and cheaper to specify than an organic paint
coating of equivalent corrosion protection performance. The British, European and
International standard for hot-dip galvanizing is BS EN ISO 1461 which specifies a minimum
coating thickness to be applied to steel in relation to the steels section thickness e.g. a steel
fabrication with a section size thicker than 6 mm shall have a minimum galvanized coating
thickness of 85 m.
Further performance and design information for galvanizing can be found in BS EN ISO
14713-1 and BS EN ISO 14713-2. The durability performance of a galvanized coating depends
solely on the corrosion rate of the environment in which it is placed. Corrosion rates for
different environments can be found in BS EN ISO 14713-1 where typical corrosion rates are
given with a description of the environment in which the steel would be used.

Galvanizing Standards

There are certain specifications that have been

developed for hot-dip galvanizing in order to
produce a high-quality coating. There are three main
standards that govern the hot-dip galvanized steel,
and a handful of supporting specifications that
design engineers and fabricators should become
familiar with to promote a high-quality coating and
ensure their steel design is suitable for hot-dip
galvanizing.
 ASTM Standards

The three governing ASTM specifications for hot-dip galvanizing are:

ASTM A123/A123M: Standard Specification for Zinc (Hot-Dip Galvanized) Coatings on
Iron and Steel Products
o Single pieces of steel or fabrications with different types of steel products
ASTM A153/A153M: Standard Specification for Zinc Coating (Hot-Dip) on Iron and
Hardware
o Fasteners and small products that are centrifuged after galvanizing to remove excess zinc
ASTM A767/A767M: Standard Specification for Zinc-Coated (Galvanized) Steel Bars for
Concrete Reinforcement
o Reinforcing steel or rebar
Other Galvanizing Standards
There are also a few international governing standard to be aware of:
CSA G164: Hot-Dip Galvanizing of Irregularly Shaped Articles
ISO 1461: Hot-Dip Galvanized Coatings on Fabricated Iron and Steel Assemblies
Specifications and Test Mehtods
In addition to the governing standards, there are a handful of pre- and post-galvanizing
supporting specifications that a specifier/designer should also be familiar with:
Pre-Galvanizing
ASTM A143/A143M: Standard Practice for Safeguarding Against Embrittlement of Hot-
Dip Galvanized Structural Steel Products and Procedure for Detecting Embrittlement
ASTM A384/A384M: Standard Practice for Safeguarding Against Warpage and Distortion
During Hot-Dip Galvanizing of Steel Assemblies
ASTM A385/A385M: Standard Practice for Providing High-Quality Zinc Coatings (Hot-
Dip)
ASTM B6: Standard Specification for Zinc
Post-Galvanizing
ASTM A780: Practice for Repair of Damaged and Uncoated Areas of Hot-Dip Galvanized
Coatings
ASTM D6386: Practice for Preparation of Zinc (Hot-Dip Galvanized) Coated Iron and Steel
Product and Hardware Surfaces for Paint
ASTM D7803: Practice for Preparation of Zinc (Hot-Dip Galvanized) Coated Iron and Steel
Product and Hardware Surfaces for Powder Coating
ASTM E376: Standard Practice for Measuring Coating Thickness by Magnetic-Field or Eddy-
Current (Electromagnetic) Examination Methods
 EQUIPMENTS
Degreasing Bath

Hot Alkaline Rinsing Bath

For the low speed production, hot alkaline rinsing is
usually used for the degreasing of steel wire, sheet
metal, and so on.

Electrolytic Degreasing Bath

Electrolytic alkaline bath degreasing is commonly
used for high speed production. The degreasing
bath tank is design to be in an overflowing
circulation type.

Water Rinsing Bath

The bath is welded by the reinforced PP plate, and the overflowing circulation rinsing design
and air knife are available. Thus the desirable cleaning performance can be achieved and the
cleaning solution utilization rate is enhanced.

Hot water rinsing bath Water rinsing bath

 Fumeless Pickling Bath
The bath is welded by reinforced PP plate, and four water screens are used for the sealing,
ensuring that no acidic fume will leak out. Thus the production environment will be greatly
enhanced, The bath comes with a fluid heating system to enhance the cleaning speed and
hydrochloric acid utilization rate.

Enclosed type fumeless pickling bath Fumeless pickling bath

Flux Solution Bath

A bath solution heating system is used in the
galvanizing equipment to maintain the fluid at a
proper temperature in according to production
techniques.

Drying Oven
The drying oven is available in two types, electric heating type and gas heating type. A hot air
circulation system is also designed. The frame of the furnace is welded by stainless steel, while
the internal walls are welded by grade 316L stainless steel which can prevent the corrosion
from the ammonium salt. Alumina silicate cellucotton is chosen as the high temperature
resistant lining material for the purpose of heat conservation.

Drying oven (electric heating) Drying oven (gas heating)

 Ceramic hot dip galvanizing kettle
The internal heating ceramic galvanizing kettle is a kind of advanced zinc-plating industry. Its
heating efficiency could reach more than 80%. Limited zinc dross will be produced and the
zinc consumption is also very low. The service life could be more than 10 years, while the
temperature control accuracy is 2.

Electric ceramic galvanizing kettle Gas fired galvanizing kettle

Cooling
In hot-dip galvanizing line, the air cooling and water cooling are combined together to cool the
steel rapidly. Thus, we can effectively control the thickness of the zinc-iron alloy layer, and
enhance the smoothness of galvanized steel.
 APPLICATION

Application of Galvanized Steel

The selection of a steel coating system is an integral part of all engineering design. The main
consideration for the engineer in the selection of the most suitable corrosion protection system
would be the performance of a steel coating and the economics of the application of the steel
coating system. There is no other corrosion protection system that could match the performance
and economics of hot dip galvanizing.

POWER GENERATION AND POWER TRANSMISSION

In the building of a power station for power generation, steel is a major construction material.
Galvanized steel is used in platforms, equipment buildings, stairs and handrails. In the area of
fuel supply to the main power generating plants galvanized steel conveyor systems are common
in a coal fired power station. Cooling water, water reticulation and fire protections systems
consume huge amounts of galvanized steel in the form of piping and it fittings. As for power
transmission every piece of steel in a transmission tower is completely galvanized from the
main steel frame, every piece of bolt and nut used to fasten the angles together to the cable
support systems are completely galvanized. They are now many transmission towers that are
also painted with special paint system for identification purposes.

TELECOMMUNICATION TOWERS

Telecommunication steel towers are difficult structures to maintain considering its location
which normally are difficult to access since it is situated on hills slopes and on top of mountains.
For easy installation these Steel Towers are fabricated from Steel Tubes in different sections
and steel Angles of various sizes and lengths, Hot Dip Galvanized and fastened with
Centrifuged Hot Dip Galvanized Bolts, Nuts and Washers. These 3 Leg Telecommunication
Towers are 100% Hot Dip Galvanized and Duplex coated for long term corrosion protection
and aerial Identification.

Tower Transmissions and Telecom Tower

INFRASTRUCTURE DEVELOPMENT

Government of many countries now invest and spent huge part of their budgets in improving
the infrastructure such as road highways and expressways, railways, Light Rail Transport
system (LRT) and Mass rapid Transportation system (MRT) , Port terminals and airport
facilities. These projects consume huge amounts of exposed steel and as such hot dip
galvanizing is the preferred corrosion protection system.
As for other developments such as schools, hospitals, community halls and other public places
galvanized steel are mainly in galvanized products such as galvanized water tanks for fire
protections systems, street lights, safety barriers and road and drain covers.
Hot dip galvanized reinforcement steel was only used in critical construction areas such as
coastal or marine concrete structures. In the last decade the use of hot dip galvanized
reinforcement steel increased with the rapid expansion of the road, highways and expressways.
Steel rods and strips for reinforced earth (RE) walls and soil nails are always hot dip galvanized.
Guardrails, crash cushions, decorative street lights, high masts, pedestrian overhead bridges,
noise barriers, parapet handrails are some of the other products that are corrosion protected
with hot dip galvanizing

BUILDING AND CONSTRUCTION

The Twin Tower in Kuala Lumpur and the Kuala Lumpur Tower are prestigious projects in
Malaysia. For durability most steel are Hot Dip Galvanized and Duplex coated. Commonly
found in the open areas are Forged Welded Gratings hot dip Galvanized, Garden Lighting Poles
Hot Dip Galvanized and Children Play Stations all Hot Dip Galvanized and Duplex Coated.

Industries and Building

Tower Application of Galvanized Steel