The Company with the Strength of Steel

G GA AL LV VA AN NI I Z ZI I N NG G
Procedure
Rev / Date
: 5-4-00
: 2.0 / 01.02.2013

Page : 1 of 4



Process Related Documents

TABLE OF CONTENTS

SECTION TITLE PAGE

5-1-00
(Manufacture)
5-2-00
(Produce Prototype & Test)
5-3-00
(Plan Production)
5-4-00
(Galvanizing)
5-5-00
(Manufacture Pressure Vessels)
7-11-00
(Control of Welding Consumables)
7-15-00
(Weld Repair)

Guidelines For:
5-1-G1
(Magnetic Particle Inspection)
5-1-G2
(Ultrasonic Testing)
5-1-G3
(Standard Approved Repairs [SS])
5-1-G4
(Standard Approved Repairs [GP])
5-1-G5
(Inspection Sampling & Tower Tolerance)
5-1-G6
(Galvanized for QC Inspection)
5-1-G7
(Dipping Time Control)
5-1-G8
(Repair of Damages & Un-Galva Areas)
5-1-G9
(Brinell Hardness Examination)
5-1-G10
(Penetrating Oil Test)
5-1-G11
(Painting)
5-1-G12
(Storage & Handling of S. Steel Material)
5-1-G13
(Outsourcing of Radiographic Testing)
5-1-G14
(Fab. Tolerance / Acceptance Criteria for Insp. & Test)
5-1-G15
(Weld Visual Inspection {AWS D1.1} [SS])
5-1-G16
(Liquid Penetrant Examination {AWS D1.1} [SS])
5-1-G17
(Storage & Handling of Paints)
5-1-G18
(VacuumBox Examination)
5-1-G19
(Weld Visual Inspection of Storage Tank)
5-1-G20
(Hydrostatic Test for Storage Tanks)
5-1-G21
(Positive Matl. Identification [PMI] Testing)
5-1-G22
(Holiday Testing (HT))
5-1-G23
(Dim. Inspection Tolerance Shop Built ST)

--- Cover Page................................................................... 0
--- Table of Content............................................................1
1 Scope............................................................................ 2
2 Applicable Standard...................................................... 2
3 Galvanizing Process & Applicable In-House W. Ins......2
4 Test Method For Coated Thickness.............................. 3
5 Repair Of Damaged Galvanized Coating......................4
6 Inspection Of Galvanized Material................................ 4
7 Galvanizing Test Certificate.......................................... 4


The Company with the Strength of Steel
G GA AL LV VA AN NI I Z ZI I N NG G
Procedure
Rev / Date
: 5-4-00
: 2.0 / 01.02.2013

Page : 2 of 4


1 SCOPE
This procedure covers the galvanization of iron and steel materials / products.

2 APPLICABLE STANDARD
2.1 In accordance with the requirements laid down in ASTM A123 & A153 "Hot Dip Galvanized
Coatings on Iron and Steel Articles", and BS EN1461 Hot Dip Galvanized Coatings on
fabricated Iron and Steel Articles.
2.2 Other applicable document shall be ASTM A385, 384, B695 and A780.

3 GALVANIZING PROCESS AND APPLICABLE IN-HOUSE WORK INSTRUCTIONS
3.1 Degreasing
Remove oil, grease, lubricant and other dirts which exist on the surface of steel articles by dipping
the articles into hydrochloric acid solution with additive of special degreasing agent in accordance
with Work Instruction Pre-Galvanizing WI 5-1-61.

3.2 Pickling
Remove the scale and rust on steel articles by pickling them in hydrochloric acid solution with
small quantity of inhibitor added in accordance with Work Instruction Pre-Galvanizing WI 5-1-61.

3.3 Rinse
When the pickling is finished, rinse all the iron salt left on the steel articles during pickling in a
water bath where the water is overflowing continuously in accordance with Work Instruction Pre-
Galvanizing WI 5-1-61.

3.4 Fluxing
When pickling and rinsing is finished, fluxing allows to remove any acid and iron salt still left over
the surface of steel articles in pre-fluxing bath.

The fluxes prevent the iron of the articles from oxidation and help the galvanizing reaction to be
more effective.

Flux solution is maintained at 60 5 degrees centigrade.

3.5 Drying
When the fluxing is finished, material is allowed to dry before dipping in zinc bath to avoid
splashing.

3.6 Hot Dip Galvanizing
The hot-dip galvanizing process is through zinc-iron alloy reaction between iron and molten zinc at
the temperature of 445-455 degrees centigrade in accordance with Work Instruction Galvanize
WI 5-1-62 and Guideline Dipping Time Control WI 5-1-G7.
Additive: Small amount of aluminum.

3.7 Water Quench
When galvanizing is finished, the steel articles are cooled in water bath of temperature at about 70
degrees centigrade.


The Company with the Strength of Steel
G GA AL LV VA AN NI I Z ZI I N NG G
Procedure
Rev / Date
: 5-4-00
: 2.0 / 01.02.2013

Page : 3 of 4


4 TEST METHOD FOR COATED THICKNESS
4.1 Measuring by magnetic thickness gauge.

Five location of a member in each lot shall be tested to determine the uniformity of coating.
Thickness readings by the use of magnetic thickness gauge shall be taken as per relevant
standard and recorded.
The zinc coating shall have a thickness according to ASTM A123, A153, or BSEN-ISO 1461 as
required by client specification.

4.2 Sampling

4.2.1 Sampling of each lot shall be performed for conformance with the requirements of Para 7 of ASTM
A123.

4.2.2 A lot is a unit of production or shipment from which a sample is taken for testing. Unless otherwise
agreed upon between the galvanizer and the purchaser, or established within ASTM A123
specification, the lot shall be as follows: For testing at a galvanizers facility, a lot is one or more
articles of the same type and size comprising a single order or a single delivery load, whichever is
smaller, or any number of articles identified as a lot by the galvanizer, when these have been
galvanized within a single production shift and in the same bath. For test by the purchaser after
delivery, the lot consists of the single order or the single delivery load, whichever is the smaller,
unless the lot identity, established in accordance with the above, is maintained and clearly
indicated in the shipment by the galvanizer.

4.2.3 The method of selection and number of test specimens shall be agreed upon between the
galvanizer and the purchaser. Otherwise, the test specimens shall be selected at random from
each lot. In this case, the minimum number of specimens from each lot shall be as follows:

Number of Pieces in lot Number of Specimens

3 or less All
4 to 500 3
501 to 1200 5
1201 to 3200 8
3201 to 10,000 13
10,001 and over 20

4.3 Adhesion test shall be performed in each lot by cutting or prying with the point of a stout knife,
applied with considerable pressure in a manner tending to remove a portion of the coating. The
adhesion shall be considered inadequate if the coating flakes off in the form of a layer of the
coating so as to expose the base metal in advance of the knife point. Do not use testing carried
out at edges or corners (points of lowest coating adhesion) to determine adhesion of the coating.
Likewise, do not use removal of small particles of the coating by paring or whiting to determine
failure.
When required by project specifications, Strip Test and Preece Test shall be carried out in
accordance with WI Preece Test WI 5-1-55 and Stripping Test WI 5-1-56.

The Company with the Strength of Steel
G GA AL LV VA AN NI I Z ZI I N NG G
Procedure
Rev / Date
: 5-4-00
: 2.0 / 01.02.2013

Page : 4 of 4


5. REPAIR OF DAMAGED GALVANIZED COATING
Damaged galvanized coating shall be repaired in accordance with the requirements of ASTM
A780 "Standard Practice for Repair of Damaged Hot-Dip Galvanized Coatings". Guideline Repair
of Damages and un-galvanized Areas Doc. No. 5-1-G8 shall be followed.
6. INSPECTION OF GALVANIZED MATERIAL
Inspection & Test for galvanized material shall be carried out in accordance with Work Instruction
Quality Control Galvanizing WI 5-1-52 and Guideline Galvanized for Quality Control Inspection
WI 5-1-G6.
7. GALVANIZING TEST CERTIFICATE
Galvanizing Test Certificate (GTC) shall be issued to document inspected and accepted
galvanized material using Form No. 5-1-FQ1.