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Australian Standard AS1650, Section 1.6 - Appearance (Page 5) defines the requirement for hot dip galvanized coatings as follows:
The galvanized coating shall be continuous, as smooth and evenly distributed as possible, and free from defects that are detrimental to the stated use of the coated article. Methods recommended for the renovation of damaged galvanized coatings or uncoated areas are given in Appendix F (of AS 1650). Notes: 1. Defects cannot be completely quantified. When the presence, size or frequency of any defects in the coating are considered manufacturer.This to be of concern, appropriate arrangements should be made between the purchaser and the manufacturer.This may be achieved by the provision of acceptable samples or methods of test. Where defects are present and the product is submitted for acceptance, the manufacturer should be able to demonstrate fitness for purpose. thicker, 2. A thicker, less smooth coating is obtained on job galvanized articles compared with continuously galvanized sheet or wire. 3. (Not applicable to general hot dip galvanized products) 4. The finish of the coated object may be partly or wholly grey in colour for steels of certain composition or articles that are slowly cooled after galvanizing. Provided that such a coating has adequate adhesion, the grey finish is not detrimental, although premature staining may occur in service. 5. Advice on the transport and storage of galvanized articles is given in Appendix G (of AS 1650)
Unsealed welds where preparation chemicals penetrate the overlap cause blowouts which cause surface contamination and subsequent coating defects.
Welding slag left on or in welds will not beremoved by the galvanizing process and will result uncoated areas on welds.
2. Dark staining adjacent to welds. Preparation chemicals entering unsealed overlaps or through poor quality welds boil out of the connection during galvanizing and cause surface contamination and coating misses during galvanizing. Also, anhydrous fluxing salts left in the connection will absorb atmospheric moisture and leach out onto the adjacent galvanized surface. Leaching of these salts will eventually reach equilibrium. Affected area should be washed clean to remove slightly corrosive leachate. 34
Ash is a by-product of the galvanizing process that floats on the surface of the bath. Ash should be brushed off during inspection and dressing.
Chain marks are unavoidable when galvanizing large items. These defects are normally buffed off during dressing and inspection
Drainage spikes are formed when moltez zinc freezed while draining from horozontal surfaces. Most 3 dimensional sections will always generate drainage spikes in one plane. These are removed by buffing during dressing and inspaction.
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11. Delamination. Very heavy galvanized coatings (over 250 microns thick) may be brittle and delaminate from the surface under impact and require more careful handling in transport and eraction. Thin, cold rolled items with very smooth surface finish and manufactured from reactive steel may also give rise to coating delamination. 12. Black spots. Scattered black spotting is due to residual galvanizing flux crystalising on the surface of the work and is generally due to poor rinsing after galvanizing or flux contaminated rinse water. This defect is usually encountered from galvanizing baths using the `wet' galvanizing process where the flux is on top of the molten zinc. Excess aluminium in the galvanizing bath can also give rise to this defect. 13. Spangled coatings. Some hot dip galvanized coatings exhibit a high level of `spangling' caused by zinc crystal patterns on the surface. This phenomenon arises with galvanizing alloys produced in particular smelting processes and these alloys are commonly used for hot dip galvanizing. There is no difference in coating performance.
Hot dip galvanized coatings will be stained by contact with rusty steel or timber in outdoor exposure conditions. Contact with scrap steel will accelerate local consumption of the galvanized coating. Timber staining can be avoided by using seasoned timber of the right variety.
This Hunter Valley (NSW, Australia) coal mine construction illustrates Industrial Galvanizers ability to supply widely based projects. Steel for this project was galvanized in Industrial Galvanizers facilities in Brisbane, Newcastle, Sydney and Melbourne.