Publication g User’s Guide to Hot Dip Galvanizing for Corrosion Protection in Atmospheric Service ANACEFOREWORD This document has been prepared as a guide for users and, as such, is not intended to be an all-inclusive treatise on the subject of hot dip galvanizing after fabrication. It is the opinion of the Task Group that protective systems should be viewed as investments and that criteria such as life cycle cost of the coating system should be considered in the coating selection process. Initial cost, however, is only one factor. Other considerations covered in this document include suitability of hot dip galvanizing or the possible need for more sophisticated coating systems, required service life, environmental conditions, and total cost of the coating system for the expected life of the structure. In addition, a limited discussion of painting on galvanized steel and other post-galvanizing treatments is included. The use of galvanizing as a protective coating in other than atmospheric service is not addressed. Finally, through this user's guide, the Task Group has sought to highlight the importance of effective communication between specifiers, fabricators, and galvanizers. This manual was prepared by NACE Task Group T-6H-19 on Hot-Dipped Galvanizing, a component of Unit Committee T-6H on Coating Materials for Atmospheric Service, and is published by the National Association of Corrosion Engineers under the auspices of Group Committee T-6 on Protective Coatings and Linings.TABLE OF CONTENTS Foreword Characteristics of Hot Dip Galvanized Coatings .........00ee Corrosion Protection Mechanism « Classification of Atmospheres . . Factors Influencing Life Expectancy of the Coating Degree of Protection Required ...... Balancing Initial and Long Term Costs « I 1 2 2 3 4 Designing and Specifying «2+ Proper Design and Coating Quality Specifications ...... Surface Preparation . . Quality Control Aspects Appearance ... Measurement of Coating Weight o or Thickness Post Treatment ...ss0ees Painting Galvanized Steel . . Passivation of Coatings... . as Renovation of Damaged Areas and Imperfections Working with the Galvanizer Notice Required... ....5 Appendices A. The Galvanizing Process ........+. i Satetuabe ana ol® B. ASTM Standards Relating to Hot Dip Zine-Coated. (Galvanized) Materials ..... pin 9 2 munceyeunisvan «a alsvenesnioaese x ¥ 10 C. Recommendations for Proper Preparation of Materials Prior to Hot Dip Galvanizing i? D. Conditions for Inspection ...... ~ 24 E. Paint-Over-Galvanizing Procedure +30 Bibliography « Index...CHARACTERISTICS OF HOT DIP GALVANIZED COATINGS The normal after-fabrication hot dip galvanized coating consists of a layer of zinc with iron reaction compounds and an outer covering of zinc of the same composition as the bath. The type and thickness of the coating which is formed is influenced primarily by reaction kinetics between the basis metal and the molten zinc. The usual galvanized coating consists of three distinct iron-zinc alloy compounds (zeta, delta, and gamma layers) formed by the metallurgical reaction between iron and zinc and covered by a layer of free zinc (eta) (See Figure 1). ETA Wi (i00%Zn) Be ZETA OLE 7 (gaint nore) - DELTA Nc znionie) 2 GAL ss (To%Zn 2o%Fe) . STEEL FIGURE | - Micrometallograph of Hot Dip Galvanized Coating Several factors should be taken into consideration before a galvanized coating is specified: the corrosion protection mechanism, atmospheric factors influencing the life expectancy of the coating, the degree of protection required, and the initial and long term cost. Corrosion Protection Mechanism Protective coating systems fall into two major groups. The first includes systems, such as most paints and plastics, which provide a barrier coating but give no protection around the edges or at points of mechanical damage. The second group includes barrier systems, such as most zinc coatings, which protect by sacrificial action, even when they are moderately damaged. Zinc coatings are further divided into those which are alloyed to the metal, and those which are not. Hot dip galvanizing is the chief member of the first subgroup; organic and inorganic zinc rich paints, mechanical galvanizing, and electro-deposited zinc coatings are examples of non-alloyed sacrificial coatings. The resistance of zinc to atmospheric corrosion depends largely upon theprotective nature of the surface films formed as the coating oxidizes. These films usually consist primarily of zinc oxide, zinc hydroxide, and basic zinc carbonate. Classification of Atmospheres The extent of atmospheric corrosion of galvanized material depends upon whether the environment is industrial, marine, or rural. Subclassifjegtions, frequently used with American Society for Testing and Materials (ASTM) data, reflect more exactly the classification of predominant prevailing conditions: severe industrial, Atlantic Coast marine, rural marine, and urban. This manual will use the three general classifications. Factors Influencing Life Expectancy of the Coating Zinc is attacked only slightly by pure air, even when the air has a moderate moisture content. However, the corrosion rate of zinc increases in the presence of high relative humidity, rain, and impurities in the air. These factors have similar effects on the corrosion rate of other metals, but the corrosion rate of zinc is significantly lower than that of steel in all these atmosphere classifications (See Table 1). TABLE | - Corrosion Rates of and Steel in Various Environments: weight(2) Loss, g Steel: Zinc Location Type Steel Zinc Loss Ratio Phoenix, AZ Desert 2.2 0.13 17:1 State College, PA Rural 11.2 0.51 22:1 Monroeville, PA Semi-Industrial 23.8 0.84 28:1 East Chicago, IN Industrial 4. 0.79 5231 Kure Beach, NC Marine 71.0 0.89 80:1 (1)From Metal Corrosion _in the A osprey H. Guttman, ASTM STP 435, Copyright, American Society for Testing and Materials (ASTM), 1916 Race Street, Philadelphia, PA 19103. Reprinted with permission, (height loss of 4 in. by 6 in. plate in a 2-year exposure. Each atmosphere, as classified above, contains impurities that may attack zinc under certain conditions. Hydrochloric acid, acetic acid, hydrogen sulfide, sodium chloride, and organic sulfur compounds, often found alone and in combination in atmospheres typical to the chemical process industry, can influence the performance of galvanized coatings. It is generally acknowledged that urban/industrial atmospheres are characterized by the presence of varying (1) American Society for Testing and Materials, 1916 Race St., Philadelphia PA 19103levels of sulfur oxides, Under conditions of high relative humidity and dew formation, protective surface films on galvanized coatings are attacked slowly. In marine atmospheres, the presence of chloride ions causes the formation of soluble chloride salts on exposed areas, which may slow the formation of the characteristic protective film. Another atmospheric factor that can influence the performance of a galvanized surface is the alternate wetting and drying found in tidal and splash zones of humid and marine climates. The protective film that sometimes forms in these environments is water soluble and can inhibit the rate of formation of the protective film. Under the more aggressive atmosphere conditions, it is recommended that a duplex, i.e., paint over galvanizing, protective system be considered for optimum service life. (See section on Post Treatment.) Degree of Protection Required Galvanizing is unique in that empirical data accumulated over the years provide guides for estimating the life of galvanized coating in a wide range of specific exposure conditions (See Figure 2). However, the user must exercise caution when applying performance data for a general atmospheric classification to a specific application. FIGURE 2 - Expected Life of Galvanized Steel Under Various Exposure Conditions Rural Tropical Marine i ‘Temperate Marine g Suburban 8 Moderate Industrial 5 Heavy Industrial 2 .50 .75 1.00 1.25 1,50 1.75 2.00 2.25 2.50 2,75 3.00 Oz. of Zinc/Sq.Ft. of Surface Oo 0312 17 ZL 25 10 Lh 18 42 46 5.0 Thickness of Zinc in Mils Since the length of time a zinc coating will last is directly proportional to the thickness ‘of the zinc coat, each of the straight line graphs shown above may be extended to show the life expectations with heavier coats of zinc.Balancing Initial and Long Term Costs In practice, the choice of a protective coating system depends in large part on how maintenance-free the user wishes the structure to be. Some users prefer low initial cost/high maintenance cost systems while others prefer higher initial cost and low maintenance cost systems. For many kinds of service, galvanized steel competes favorably with other systems, even on an initial cost basis. For the knowledgeable use, the choice of coating involves a consideration of life cycle costs and coating serviceability. The corrosion engineer should have a good working familiarity with the principles of NACE Recommended Practice RP-02-72, "Direct Calculation of Economic Appraisals of Corrosion Control Measures" (See Bibliography). DESIGNING AND SPECIFYING Proper Design and Coating Quality By following certain procedures, building in various ‘safeguards, and considering the specific size and shape requirements, a high quality galvanized coating can be assured for a wide array of items. These procedures, rules, and safeguards must be applied in a logical fashion. ‘They are contained in a number of Pamphlets published by the Zing Institute) and the American Hot Dip Galvanizers Association (AHDGA)™) and are referenced as ASTM Specifications and Recommended Practices (See Appendix B). To facilitate good results, the project designers should maintain close contact with the galvanizer during initial design stages and specify galvanizing in standard methods and terminology. The designer should be cognizant of his role in this regard. Often the galvanizer can provide design suggestions for large structural shapes, intricate components with moving parts, and weldments (See Appendix C). When the galvanizer is consulted during the design stage prior to fabrication, he can often suggest ways to save money through simple design modifications. A helpful pamphlet, "The Design of Products to be Hot Dip Galvanized After Fabrication," is available from the AHDGA and the Zinc Institute, Specifications ASTM has devoted considerable effort to the development of specifications covering galvanized steel products. These specifications are reviewed every five years and published annually by ASTM. The AHDGA distributes a compilation of the standards and recommended practices entitled, "ASTM Standards for Materials Hot Dip Galvanized After Fabrication." The complete set is available through the AHDGA and is a useful standard reference for all specifiers of galvanizing. Zinc Institute, 212 Madison Ave., New York, NY 10017 American Hot Dip Galvanizers Association, 1000 Vermont Ave. N.W., Washington, D.C. 20005 (2) @)Surface Preparation It is the fabricator's responsibility to see that material to be galvanized is free from welding slag, paints and varnishes, and rolled-in mill scale. Normal cleaning procedures will not remove these contaminants, and if the galvanizer has to clean the material before pickling the steel, additional costs will be involved. Overlapping surfaces should be cleaned before fabricating because residual oil and grease may trap moisture, thus creating a safety hazard during the galvanizing process. Immersion into the molten zinc changes this moisture into steam which causes miniature explosions in the zinc bath. The effect of this phenomenon, in addition to creating potentially unsafe conditions, is to produce uncoated areas adjacent to the unsealed areas. QUALITY CONTROL ASPECTS Appearance Unlike many other coating processes, visual inspection is usually adequate to ensure good quality galvanizing. The coating should appear free from gross surface imperfections such as cracking, peeling, bare spots, blisters, and lumpiness, and be free from dross protrusions (See Appendix D). Differences in luster, spangle, and color do not affect the corrosion resistance of galvanized coatings. Under atmospheric exposure conditions, galvanized coatings will weather to a dull blue-grey hue. Depending upon the chemistry and sometimes the mass of a particular steel, coating weight (and thickness) will vary above specification minimums. Measurement of Coating Weight or Thickness Coating weight can be measured with a weigh, strip, and weigh technique (ASTM Standard Test Method A 90) or with a nondestructive test instrument. Magnetic and eddy current type gauges are the most accurate of the nondestruc- tive test instruments and have gained wide acceptance, particularly for field use (ASTM Recommended Practice E 376). POST TREATMENT Painting Galvanized Steel Ordinarily, the life expectancy and pleasing finish of galvanized coatings are sufficient to satisfy service requirements. However, in particularly aggressive atmospheres it may be necessary to paint over galvanizing. Over a long term, this procedure can result in substantial savings for the user. The service life for both the galvanized coating and the paint are prolonged significantly for paint over galvanized (duplex) systems. When a paint film over steel is damaged by a nick, scratch, holiday, or abrasion, corrosion may occur at that point. It can spread quickly from there, moving along the steel surface below the paint film, rusting the surface and blistering the paint (Figure 3). However, when the surface below the paint is galvanized, the paint extends the life of the zinc coating, and the zinc coating protects the paint from rust-induced blistering. Paint over galvanizing may last up to two or three times longer than a 5comparable paint system over bare steel. Some general guidelines on surface preparation for duplex systems are presented in Appendix E. FIGURE 3 - Illustrating Underfilm Corrosion Failure of Paint Coating on Bare Steel In some instances, as with zinc dust-zinc oxide primers, galvanized steel can be topcoated directly without pretreatment. When galvanized steel is to be painted, it is advisable to pretreat or properly prime to ensure maximum adherence of the topcoat. There is yet another advantage to the paint-over-galvanizing system--an advantage realized when the time comes to repaint. Surface preparation before repainting usually involves only wire-brushing the surface and topcoating. If the service involves a highly corrosive environment, it is generally preferable to paint a galvanized structure before erection or at initial installation. In this way, the zinc coating is preserved for its primary function of providing galvanic protection. For a more comprehensive discussion of this subject, refer to the Zinc Institute pamphlet, "Painting Galvanized Steel," which offers both suggestions on many aspects of the subject and a table of suggested paints for galvanized steel. An additional NACE study entitled, "Coatings for Galvanized Steel Surfaces" was in progress at the time this manual was published. Passivation of Coatings A passivation treatment may be applied to limit the possibility of storage stain, When unweathered galvanized structural elements are closely packed for ) Proposed NACE Technical Committee Report "Coatings for Galvanized Steel Surfaces," under preparation by Task Group T-6H-40.storing or transporting and are inadequately ventilated, they may remain damp and undergo accelerated attack. This can produce a voluminous corrosion product which may be aesthetically displeasing. If such conditions are anticipated, it should be specified that the galvanized steel be passivated or, if painting is contemplated, treated with an appropriate non-chromate inhibitor. Renovation of Damaged Areas and Imperfections If small areas of the galvanized coating are damaged or removed through cutting, welding, or excessively rough treatment, local repairs can be readily performed in the field. Comparable corrosion resistance can be achieved only if an equivalent amount of zinc ‘is applied using one of the following touch up 1) painting with zinc rich paint, 2) using zinc based solders, and 3) ing. Information on these methods is provided in ASTM Standard Practice WORKING WITH THE GALVANIZER The galvanizer usually acts as a specialist subcontracted to the steel fabricator and, as such, has a contractual relationship with the fabricator and not the ultimate user. As a result, it is important for the user to ensure that his requirements for galvanizing are clear to the fabricator. In addition, it is important for a user to have some knowledge of the fabricator's choice of galvanizer. The galvanizer's capability depends not only on kettle size but also on his expertise in handling the materials. Competitive bids should be based on equal conditions. For example, some galvanizers may include collection and delivery charges in their bid quotation, whereas others may not. It is also recommended that the galvanizer be provided with drawings prior to quoting and/or fabrication. In this way, changes required for galvanizing can be made early enough to minimize cost and delay. Notice Required Very often quotations for galvanizing standard items can be obtained on the telephone. However, for unfamiliar material, the galvanizer may wish to have a trial run to determine the galvanizing requirement before quoting the job. Manufacturers of nuts and bolts may stock only a limited number of galvanized fasteners. For some sizes, there may be a delay if the threads have to be custom cut to accommodate galvanized coatings. Therefore, orders for galvanized fasteners should be placed as early as possible prior to the date they are needed.APPENDIX A ‘The Galvanizing Process {!) Galvanizing is a versatile process. Steel and iron material ranging in size from nuts and bolts to structures 450 m (1475 ft) tall have been protected with galvanized coatings after fabrication. The largest kettles in North America today can galvanize material up to 17 m (57 ft) by a single dip. Objects longer than the kettle can be coated by using a procedure referred to as double dipping (first dipping one end and then the other end), These large kettle sizes, along with providing the ability to bolt or weld prefabricated sections after galvanizing, permit a wide range of structural materials to be galvanized. All types and forms of plain carbon and alloy steels, as well as iron and steel castings, can be galvanized. The coatings used can be characterized as follows: A A thick zinc and multi-layer zinc alloy protective coating is metallur- gically bonded to the iron or steel base. This coating corrodes at a rate of about 3 to 10 percent that of steel in the atmosphere. For most material coaged after fabrigation, the coating weight minimum is about 610 g/m* (2 ounces/ft*) of surface or a thickness of 86 microns (3.4 mils). In most environments, the life of the coating is proportional to the weight (or thickness) of the coating. B. An even thickness of the galvanized coating is applied to edges and flat surfaces, The molten zinc also covers corners, edges, seams, and rivets to give complete protection to what may be. potential failure points in other protective systems. C. The hot dip galvanized coating applied after fabrication is tough and will tolerate handling which would damage most other coatings. The zinc alloy layer shown in Figure 3 is harder than mild steel. The softer zinc outer layer provides an energy buffer to withstand impact and abrasion. D. While some steps in the process may vary from plant to plant, the basic hot dip galvanizing procedure for fabricated material consists of three steps: lL Cleaning - In most plants, this is a two step operation. The material is first immersed in a hot caustic bath or some other similar solution to remove oil, grease, and other organic contaminants. The workpiece is then rinsed and taken into a mineral acid bath to remove rust, mill scale, and other inorganic contaminants. The material is then rinsed and is ready for the next step in the process. 2 Fluxing - The steel is immersed in a tank containing an aqueous Preflux solution to remove any oxides which may have formed on the material during the handling process. A molten flux blanket on the surface of the molten zinc in the kettle is also ) Readers desiring a more comprehensive technical description should refer to bibliographic entries | and 2.3. often used to clean the steel surface before the part is immersed or dipped into the bath. Coating - The workpiece is then submerged in the molten zinc bath where it remains until the alloying reaction is complete. Depending upon the chemical composition of the steel, configuration, and mass of the material being coated, this process can take from 30 seconds to 8 hours. When the alloying reaction is complete, the steel is removed from the kettle. After the material is removed it is either allowed to air cool or is immersed in‘a water quench tank. The quench tank operation "freezes" any further reaction between the base steel and the coating. The quench water may be treated with other chemicals to give the coating certain post-treatments, as described in Appendix E.Specifications 47 A 43 A 53 A il2 A 120 A 123 A 153 A 307 A 325 A 363 A 386 A 390 A 392 A 394 444 A 767 B 6 Standard Practices A 780 APPENDIX B ASTM Standards Relating to Hot Dip Zinc-Coated (Galvanized) Materials Malleable Iron Castings Gray Iron Castings Welded and Seamless Stee! Pipe Zinc-Coated (Galvanized) Steel Tie Wires Pipe, Steel, Black and Hot-Dipped Zinc-Coated (Galvanized) Welded and Seamless for Ordinary Uses. Products Fabricated from Rolled, Pressed, and Forged Steel Shapes, Plates, Bars, and Strip Zinc Coating (Hot Dip) on Iron and Steel Hardware Carbon Steel Externally Threaded Standard Fasteners High Strength Bolts for Structural Steel Joints Zinc-Coated (Galvanized) Steel Overhead Ground Wire Strand Zinc Coating (Hot Dip) on Assembled Steel Products Zinc-Coated (Galvanized) Steel Poultry Netting (Hexagonal and Straight Line) and Woven Steel Poultry Fencing Zinc-Coated Stee! Chain-Link Fence Fabric Galvanized Steel Transmission Tower Bolts and Nuts Steel Sheet, Zinc Coated (Galvanized) by the Hot-Dip Process for Culverts and Underdrains Zine Coating (Hot Dip) Bars for Concrete Reinforcement Zinc Metal (Slab Zinc) Repair of Damaged Hot-Dip Galvanized Coatings 10Methods of Test A 90 Weight of Coating on Zinc-Coated (Galvanized) Iron or Steel Articles BLZ Salt Spray (Fog) Testing Recommended Practices A 143 Safeguarding Against Embrittlement of Hot-Dip Galvanized Structural Steel Products and Procedure for Detecting Embrittlement A 384 Safeguarding Against Warpage and Distortion of Hot-Dip Galvanizing of Steel Assemblies A 385 Providing High Quality Zinc Coating (Hot Dip) on Assembled Products 201 Testing Chromate Coatings on Zinc and Cadmium Surfaces D 2092 Preparation of Zinc-Coated Steel Surfaces for Painting 376 Measuring Coating Thickness by Magnetic-Field or Eddy- Current (Electromagnetic) Test MethodsAPPENDIX C Recommendations for Proper Preparati Materials Prior to Hot Dip Galvanizing’ VENTING AND DRAINING OF ENCLOSED AND SEMI-ENCLOSED PRODUCTS Great care is required in the galvanizing of tanks and enclosed fabrications to produce uniform coatings of proper weight and freedom from defects, particularly on the inside surface, but an even more important factor is the design of the tank or fabrication itself which either does or does not allow this careful handling to be effective. In the submersion of a tank or fabricated product in molten zinc at approximately 850F (450 C), the proper design allows for fast and complete filling of the tank with zinc through a bottom opening while gas and moisture can be freely liberated from a top opening. For the safety of all galvanizing personnel, it is essential that internal pressures produced by the combination of heat, air, and moisture be allowed to vent to atmosphere. As close to end as practical — max. of 2”” Min. of 4 couplings as shown. Dia. of coupling should be 1”/foot of tank dia. with a min. of 2”. Use half-couplings flush with inside, Tanks over 48” dia. should have man hole in one end. Openings must be so placed that the flux on the part can float to the surface of the bath and must also prevent air pockets which will keep the acid bath from completely cleaning the inside areas. Simply stated, the structure must be lowered into the solution without trapping any air. It must be raised from the solution without trapping or retaining any solution. Consequently, ample passageways in and out must be designed into the assemblies. (1) Information in this Appendix taken from "The Design and Fabrication of Galvanized Products" and "Proper Venting," both published by the American Hot Dip Galvanizers Association (AHDGA), 1000 Vermont Ave., Washington, D.C., 20005. 12Free flow of cleaning solutions, zinc, air, and fluxes is accomplished with full open mitre and butt joining and by fully cutting out base plates to provide minimum obstruction to a full, free flow into and out of the pipe. In critical de- signs, base plates may need to be increased in size or thickness. Trapped Moisture, Air, Acid Tank design should and Flux During jays provide for flush Submersion interiors. Trapped Zinc Good Drainage During Removal When housing design requires return flanges, provide drain holes in all comers. Provide through holes for venting and drain- ing in at least two opposite surfaces. Fabricated pipework and venting require special consideration. 13Where gusset plates are used, generous clipping provides for free drainage. Stiffeners should be clipped to provide drainage . . . «OR use bar stiffener. Many galvanizers prefer that venting be visible from the outside of the assembly when received. This is necessary to check the adequacy of the venting as well as to determine that it has not been omitted by mistake. The decision to use pipe to replace structural sections in welded fabrications should be made only after careful consideration, as disadvantages in galvanizing cost to the consumer may be inherent. ‘Use open joints ‘on pipework. 14BOX SECTIONS Drawing shows location of holes and clipped corners which must be flush. Using the following formulas, the chart shows typical sizes of holes and clipped corners. INTERNAL GUSSETS -- Should be spaced a minimum of 36". Box Sections — H + W = 24" or larger - Area of hole plus clips should equal 25% of the area of the box (H x W). Box Sections —- H + W less than 24" to and including 16" - use 30%. Box Sections -—- H + W less than 16" to and including 8" - use 40%. Box Sections — H + W under 8" leave completely open; no end plate or internal gussets. The following chart is for square box sections only. For rectangular sections, calculate required area and check with your galvanizer for positioning of openings. BOX SIZE H+W HOLES A-DIM CLIPPED CORNERS B-DIM aa 7 a 36m 3M 30" yn 330 3" uN 30 20" 16" 3n 1" ra 15PIPE COLUMNS, PIPE GIRDERS, STREET LIGHT POLES and TRANSMISSION POLES w/base plates with or without cap plates. LOCATION OF OPENINGS 1 Most desirable - completely open "same diameter" as section top and bottom. 2.& 3. Equa! substitutes if full opening is not allowed. 4 Must be used together with # 2 or # 3 if holes are not allowed on top of sections. Two (2) half circles 180 degrees apart in line with cutouts on # 2 and # 3. 5. Openings each end must be at least 30% of I.D. area of pipe for over 3" pipe and 45% of I.D. area for 3" pipe or smaller. The following is an example of sizes for a 6" diameter section. Allow 30% of the area of the I.D. hole sizes each end. = 1-3/4" Re Center Hole C = 3" Diameter. # 4 Half Circle D = 1-5/8" R. 16TAPERED - SIGNAL ARM A. Small end open completely; POLE PLATE END 1, Most desirable - completely open. 2. & 3. Acceptable alternates -- half circles or slots and round hole on 3" and larger must equal 30% of the area of the I.D. of the pole end of the tapered arm. Under 3" must equal 45% of the area of the pole end of the tapered arm. 17RECTANGULAR TUBE TRUSS Hole location for verticals should be located as shown in Examples A and B and by arrows on drawing. Each vertical should have two (2) holes at the top and bottom, 180 degrees apart in line with horizontal members as indicated by arrows. Size of holes at each end should equal 30% of the area of the section. END PLATE - HORIZONTAL 1, Most desirable - completely open, 2, Acceptable substitutes - clipped corners and holes as shown. H + W = 24" or larger -- use 25% of sq. area of cube H x W = area of hole plus clips. If H + W less than 24" to and including 16" -- use 30% If H + W less than 16" to and including 8" -- use 40% If H + W under 8"PIPE TRUSS 3" and LARGER Hole location for vertical should be located as shown in Examples A andB and by arrows on drawing. Each vertical should have two (2) holes at the top and bottom, 180 degrees apart in line with horizontal members as indicated by arrows. Size of holes at each end should equal 30% of area of the I.D. of the vertical. END PLATES - HORIZONTAL 1, Most desirable - completely open "Same Diameter." 2, & 3. Equal substitutes — holes as shown should be 30% of the area of the inside of the pipe. 19HANDRAIL The above drawing illustrates the most desirable design for fabrication of handrail that requires galvanizing. 1. Vent holes must be as close to the weld as possible and not less than 3/8" diameter. 2. Internal holes should be the full I.D. of the pipe for best quality and lowest galvanizing cost. 3. Vent holes in end sections or similar section must be 1/2" diameter. 4. & 5, Any device used for erection in the field that prevents full openings on ends of horizontal rails and vertical legs should be attached after galvanizing. Most galvanizers require visible vent holes on the outside of any pipe assembly. 20HANDRAIL The above drawing illustrates an acceptable alternate if full internal holes (the full ILD. of the pipe) are not incorporated in the design of the handrail. i Vent holes must be as close to the weld as possible and must be 25% of the I.D. of the pipe, but not less than 3/8" diameter. The two (2) holes at each end and each intersection must be 180 degrees apart and in the proper location as shown. 2. Vent holes in end sections or in similar sections must be 1/2". 3. & 4 Any device used for erection in the field that prevents full openings on ends of horizontal rails and vertical legs should be attached after galvanizing. Vent holes should be visible on the outside of any pipe assembly. 21MINIMIZING DISTORTION Some fabricated assemblies have a tendency to distort as a result of the stresses induced during the manufacture of the steel and subsequent fabrication and assembly. To minimize distortion, design engineers should observe the following recommendations: , le Where possible, use symmetrical rolled sections in preference to angle or channel frames. 2. Specify staggered welding techniques to reduce thermal stresses. Wide Radius Staggered Welding Symmetrical, Ed a ——— Heavy Frame Avoid combination of extremes in weight and cross section of structural Thin Sheet members. 22CASTINGS Castings do not respond to the conventional chemical cleaning process employed by most galvanizers. The primary reason is the presence of burned-on sand from the casting operation. This siliceous material is not removed by hydrochloric or sulfuric acid pickling. Thus, to ensure an acceptable galvanized coating, all castings should be cleaned abrasively. Conventionally, this is accomplished by grit, shot, or sand blasting. Grit blasting or a combination of grit and shot is generally preferred, Usually castings are cleaned at the foundry since most commercial galvanizing shops do not have grit blasting facilities. Other design considerations important in achieving quality galvanized castings are as follows: 1. Avoid sharp corners and deep recesses. 2. Large pattern numerals and generous radii will facilitate abrasive cleaning. 3. Non-uniform wall thicknesses in certain casting designs may lead to distortion and/or cracking as a result of the stresses developed as the temperature of the casting is increased during the galvanizing process. Uniform wall sections and a balanced design will reduce the likelihood of this occurring. 4. Under certain conditions of composition and thermal history, the impact resistance of malleable iron castings may be significantly reduced as a result of galvanizing. This loss of ductility can be avoided if the castings are heat treated prior to galvanizing as follows: a. Heat at a temperature of 677 C (1250 F) until all sections have reached that temperature (no soak required). b. Water quench. 5. Any finish machining and/or heat treating should be done after sand blasting. 23APPENDIX D Conditions for Inspection The material in this appendix is presented to aid users in assessing the condition of galvanized coatings by their appearance. Table D-I contains a list of visual characteristics together with their causes and significance. From a visual standpoint, the only requirements of a hot dip galvanized coating are that it be continuous and free of gross surface imperfections such as bare spots, lumps, blisters, and inclusions of flux, ash, or dross. While galvanized coatings will weather under atmospheric exposure to a dull blue-gray tint, differences in luster or color have no bearing on the effectiveness of the coating. The color photographs show variations encountered with hot dip galvanized coatings. conditions referred to elsewhere in the manual, in finishes which may be They illustrate many of the TABLE D-1 - Some Visual Inspection Conditions Condition Causes Grounds for Rejection -Paint, grease or oil residues. -Scale or rust residues. Bare Spots _-Residual welding slag. Yes, except where bare -Rolling defects in basis steel. spots are small -Articles in contact during and suitable for galvanizing. patching. -Original surface condition of steel. General -Overpickling. No, except by prior Roughness -High galvanizing temperature agreement. and/or long immersion time. Dross -Entrapped dross particles No, unless dross Pimples contamination is heavy. Surface defects in steel. No. Blisters -Absorbed hydrogen Not if due to stee! composition. 24TABLE D-1 - Some Visual Inspection Conditions (continued) Condition Causes Grounds for Rejection -Withdrawal speed to high. ~"Cold" galvanizing bath. Only on basis of Lumpiness layed run-off from seams, prior agreement. and Runs ints, bolt holes, etc. -Articles in contact during withdrawal. -Stale flux burnt on during dipping. Yes Flux Inclusions Surface residues on steel. Yes. -Flux picked up from top of bath. Yes, unless removed. Ash -Ash burnt on during dipping. Inclusions -Ash picked up from top of bath. Yes, if in gross lumps. ~Steel composition (high silicon, Not if due to steel Phosphorus or carbon) or severe Dull Gray cold work. composition or Coating condition, or limited ~Slow cooling after galvanizing. to occasional areas. ~"Weeping" of acid, etc. from No. Rust Stains seams and folds. 25APPENDIX D (continued) Variations in Finish(!) hi ined a apa 1 Figure A - Dull grey coating may appear as local gray patches, as a lace pattern, or may extend over the entire surface. This finish indicates an extended zinc-iron alloy phase caused by steels which are unusually reactive with molten zinc. The normal bright coating indicates that a layer of free zinc is transposed over the zinc-iron alloy; however, the dull coatings are usually thicker and provide a longer life. Figure B - Rust stains often are the result of contact with or drainage from rusted steel, or the rusting of the iron in a thick zinc-iron alloy layer (See A). In both instances, the zinc coating will continue to protect the basis steel. Rust staining can also be the result of pickling acid weeping from joints and seams and is damaging to the coating. This weeping may be avoided through improved design. (1) Provided by the Galvanizers Association, 34 Berkeley Square, London WIX 6AJ, England. 26APPENDIX D (continued) Figure C - General roughness can be due to uneven growth of the alloy layers and usually indicates a thicker coating. When there are aesthetic objections to this, the galvanizer, if forewarned, can take precautions to avoid roughness. Figure D - Lumpiness and runs are usually the result of uneven zinc drainage. This does not affect coating performance. 27Figure E - Pimples are caused by the inclusion of impurities in the coating. The impurities may be dross from the bottom of the zinc bath or iron salts carried over from the pickling bath. Major dross inclusions can be grounds for rejection. F - White rust (wet storage stain) is a porous deposit formed on the surface of galvanized materials stacked together in damp or poorly ventilated areas. Although in extreme cases the protective value of the coating may be impaired, attackis often superficial despite the relative bulkiness of the corrosion product. White rust can be prevented or delayed by chromate treating the material after galvanizing. 28APPENDIX D (continued) Figure G - Flux staining is caused by flux which adheres to the base steel and appears as black inclusions on the coating. These deposits do not warrant rejec- tion provided that when they are removed the underlying coating remains visually sound. Impurities such as granular debris, which can be picked up off the shop floor, should not be mistaken for flux staining. Figure H - Bare spots can be small flaws, 3 mm (1/8 in.) across, which do not affect the coating performance, or large flaws which will affect the coating integrity. Gross uncoated areas are the result of faulty processing and such coatings should be rejected. 29APPENDIX E Paint-Over-Galvanizing Procedure 1) Remove soil, cement, spatter, and other surface dirt with a stiff brush, scraper, or other suitable device. 2) Remove oil and grease by wiping or scrubbing with solvent soaked rags or brushes. Final wiping must be done with clean, dry rags or brushes. 3) Prior to painting, the surface must be clean, dry, oil and chromate free. A wide variety of paints will offer good adherence to galvanized surfaces. There are a few listed below, however, which have been demonstrated to give superior results. It is suggested that these be used whenever possible. 1) Wash primers, also referred to as etch primers, contain phosphoric acid, resin, and a corrosion inhibitor and react with the zinc surface to form a tight bond. The vinyl and acid components are mixed immediately prior to use and, for best results, should be applied by spray or brushed to a thickness of 0.5 - 0.7 mils (12.7 - 17.8 microns). They tend to be sensitive to surface contaminants, and very close control is required in application. They can be topcoated with a multitude of paints, a feature that is most important. They must be topcoated within twelve hours or in accordance with manufacturer's directions. 2) Another effective approach, and one that is more adaptable to field application, is the use of zinc dust-zinc oxide primers. While these adhere well, the choice of top coats is somewhat restrictive. There is a wide variety of primers available, all conforming to Federal Specification TT-P-641. Select the one that conforms best with the particular application. 3) Phosphatizing, a procedure performed by some galvanizers after galvanizing and prior to shipping, involves immersion of the steel in a 82 C (180 F) acidic solution, quite frequently zinc phosphate. It serves the same purpose as vinyl primers in allowing for tight adherence of topcoats to the galvanized surface. 30