FACTORS AFFECTING GAL

ACTORS VANIZING QUALITY AND SER

GALV VICE
SERVICE

There are a number of factors in the nature of steelwork presented for galvanizing that impact on the galvaniz-
ers ability to provide a quality product and service. These are:
1. Surface condition of the steel: rusty
rusty,, painted, previously galvanized.
previously
Steel that is badly corroded will be slow to pickle and
removal of heavy rust on part of the surface may remain
on the surface to cause galvanizing defects. Badly rusted
steel should be abrasive blasted too remove heavy rust
areas prior to delivery for galvanizing.
Steel coated with old paint may not be able to be cleaned
effectively in the caustic pre-treatment. Paint remaining
on the surface will prevent the acid pickling the surface
and galvanizing defects will result.

Previously galvanized steel requires complete stripping

prior to galvanizing. While this can be done effectively,
there is a cost in additional handling and acid
consumption that will add to processing cost. For this
reason, incorporating pre-galvanized components into Steel and iron castings must be sound and free of
fabrications to be galvanized should be avoided. moulding sand. Any sand that is burned onto the surface
will prevent the galvanized coating from forming.
2. Type of pr
Type oduct; castings, old wr
product; ought ir
wrought on-
iron-
work, brazed, solder ed
soldered or riveted assemblies. Brazed components can be galvanized. The brazing
will take on the appearance of a conventional
Old wrought ironwork may be porous and allow galvanized coating after processing.
moisture into voids in the castings. Abrasive blasting
is the preferred method of surface preparation for this Rivetted components containing aluminium pop rivets
material to minimise immersion in process chemicals. should not be processed. The aluminium will rapidly
Soldered items must not be galvanized. The solder will dissolve in both the caustic tank through sodium
melt out at galvanizing temperatures . hydroxide attack or in the zinc bath.

This jig of general work illustrates the variety of conditions that steel is received for galvanizing, including newly
manufactured, rusty and previously galvanized.

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FACTORS AFFECTING GAL
ACTORS VANIZING QUALITY AND SER
GALV VICE (CONT
SERVICE .)
(CONT.)
3. Steel metallurgy

The galvanized coating is formed by the steel reacting with the zinc at galvanizing temperature. The metal-
lurgy of the steel combined with its surface condition will affect the appearance and the thickness of the
galvanized coating.

Steel composition: Most structural steels have low levels of alloying elements that are typically carbon, phos-
phorous, manganese, silicon and sulphur which total around 1% of the constituents. The balance is iron.
The effect of each of these elements is as follows:
1. Iron. Iron (Fe) is the major component in the zinc-steel reaction that forms the galvanized coating. Pure iron
Iron.
is not highly reactive with zinc. Very low alloy steels will produce below Australian Standard (AS 1650) thick-
ness coatings with a smooth and shiny appearance.
2. Carbon. Carbon (C) does not have a significant effect on galvanized coating characteristics. High carbon
steels with tensile strengths over 1000 MPa may be affected mechanically through hydrogen embrittlement
caused by hydrogen absorption into the steel during pickling.
3. Manganese. Manganese (Mn) is a toughening element used in stee. It has little effect on coating appearance at
the levels found in structural steels. Steels with high manganese content may produce galvanized coatings with an
uneven brown or gold colouration and may produce thicker coatings that are less impact resistant.
4. Phosphor
Phosphorous.ous. Phosphorous (P) is a very reactive residual element in structural steels that does not present a
problem at residual levels. It is found as an alloying element only in special electrical grades of steel which are
rarely galvanized. High phosphorous content will produce thick, brittle coatings.
5. Silicon. Silicon (Si) is the most common reactive alloying element in steel. Most hot rolled structural sections
do not have significant reactive silicon content. High silicon levels commonly occur in some plate products and
large diameter pipe and RHS which is produced from the same steel source. Thick, grey or unevenly coloured
galvanized coatings arise with this type of steel.
6. Sulphur
Sulphur.. Sulphur is a reactive residual element in structural steel that does not pose a problem at residual
levels. It is found as an alloying element in free machining steels. Threaded sockets and fittings manufactured
from high sulphur steel are sometimes incorporated into fabrications for galvanizing. Zinc and acid attack on the
steel may be severe with high sulphur steels.

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 FACTORS AFFECTING GAL
ACTORS VANIZING QUALITY AND SER
GALV VICE (CONT
SERVICE .)
(CONT.)
4. Surface Pr ofile
Profile
The rate of reaction between steel and zinc is also af- Heavy gauge wire used in pool and fence panels may
fected by the surface profile. Very smooth surfaces also produce uneven galvanized coatings , typically in
such as those found on cold rolled sheet and tube prod- a spiral pattern, caused by surface stresses induced in
ucts will have a relatively low rate of reaction and may the steel during straightening.
not produce galvanized coatings that comply with the
AS 1650 standard for minimum coating thickness.
Also, very smooth steel surfaces on reactive steels may
give rise to galvanized coatings that may flake or
peel on impact.
Hot rolled sections have a natural surface profile arising
from the presence of mill scale during rolling. The mill
scale is removed by pickling during the galvanizing
process leaving a steel surface that will generally
produce galvanized coatings in excess of the thickness
required by AS 1650.

While badly rusted steel can be easily

regalvanized, the pitted surface condition will
be reflected in the appearance of the coating.

The hot dip galvanized coating reflects the surface
condition and metallurgy of the steel. These
highly finished heat exchanger tubes produce a
very smooth, uniform hot dip galvanized coating.
Heavy galvanized coatings may be created deliberately
by abrasive blasting, which increased the surface area
per unit. Galvanized coatings well above the Australian
Standard requirement can be produced on pre-blasted
steel and the rougher as-rolled surface on hot rolled
merchant sections will also produce thicker galvanized
coatings.
Old steelwork that has been heavily rusted, and cast
iron and steel which has a rough steel surface will
also produce galvanized coatings significatly thicker
that the minimum specified in AS 1650 .
5. Weld quality
Weld
Weld quality can have a direct impact on galvanizing
qualty in both the design of the weld and its execution.
Most welding wire is high in silicon and this will
cause the weld metal to react more vigorously with
the zinc than the parent metal, resulting in thicker
coatings on the weld metal. If weld aesthetics are
important and welds are required to be flush finished
after galvanizing, low silicon welding wire or rods
of similar metallurgy to the parent metal should be
used.

Some tube products will generate uneven galvanized

coatings characterised by longtitudunal striations that
are sharp edged and raised above the base galvanized
coating. These ridges are caused by stress areas on
the steel surface produced in the tube production Weld spatter will be galvanized as well as the steel and
process. should be removed if appearance is a requirement.

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5. Weld quality (cont)
Weld

Weld design will be a function of weld location and
extent. Unsealed welds will allow preparation chemicals
to penetrate joints. Entrapped liquids will boil out and
cause surface defects during galvanizing. Residual flux
crystals left in joints will absorb atmospheric moisture
and cause staining and corrosion problems after
galvanizing. Fully sealed welds offer the best
performance for galvanizing and in service. The surface
tension of molten zinc is such that it will not readily
penetrate gaps narrower than 1 mm.
MIG welding can leave a thin slag layer on welds.
This must be removed prior to galvanizing as it will
cause coating defects in the weld area.
Weld spatter should be removed as it will remain on
the surface and result in an aesthetic defect after
galvanizing.

Some submerged arc welds may contain small flux

particles fused into the surface of the welds which are
typically less than 1 mm in diameter. These particles
are ceramic and unaffected by preparation chemicals
and give rise to pinholes in the galvanized coating on
the weld bead. Because of their small diameter, these
pinholes do not affect the durability of the coating .
If the presence of such pinholes is deemed undesirable
for aesthetic reasons, abrasive blasting of the welds
prior to galvanizing to remove the fused flux is New welding technology significantly redices
required. weld spatter. Lincoln Electric's STT technology
is an example and virtually eliminates spatter.

Weld quality will impact on galvanized coating quality.

Poor welds will result in preparation chemicals
penetrating the weld and leaching out around the weld
perimeter in service.

Slag left on welds will prevent the preparation

chemicals conditioning the surface and will also prevent
the zinc reacting with the weld metal. The galvanized
coating will not form on these areas and these defects
are beyond the control of the galvanizer.

The galvanizing process will highlight defective

welds like this one. Poor weld penetration has
Slag left on welds wil interere with the allowed pretreatment chemicals to penetrate the
pretreatment process and will prevent the joint. These chemicals leach out after galvanizing a
galvanized coating from forming. stain the coating.

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6. Dimensions

Dimensioning fabrications to best suit available

galvanizing bath dimensions will ensure that;

a . The item can be hot dip galvanized at the lowest

cost and without delay.
b . The item can be presented to the molten zinc in a
way that optimises venting and draining to pro
duce the best possible surface finish.
c. The item that can be loaded efficiently into the
dipping jigs and produce a better quality finish.
Some dimensioning rules to consider ar e:
are:

1. Long or deep items that require double-end

dipping will add 30% or more to the galvanizing
cost.
2. Three dimensional items have a low mass per unit
of volume cannot be processed as efficiently as
two-dimensional items.
3. Items that cannot be withdrawn from the molten Industrial Galvanizers larger structural galvanizing
zinc at sufficient an angle will give rise to heavy plants can process beams around 20 metres in length by
double dipping.
zinc buildups and drainage spikes.

Three-dimensional fabrications
require careful design to ensure
proper venting and draining and
awkward fabrications like these have
low weight per unit of volume,
which increases processing cost.

These very large portal frames can

only be dipped one at a time and also
require double dipping. While being
galvanized satisfactorily, the
handling cost increases the
galvanizing cost compared to items
designed in smaller modules.

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 THREADED PARTS
PARTS

Galvanized fasteners should be used with hot dip
galvanized assemblies. When the item to be galvanized
contains threaded assemblies, the pitch diameter of
the female threads must be increased to permit hand
assembly after the addition of a galvanized coating to
the male parts. Internal threads and nuts must be tapped
oversize after galvanizing to accommodate the thickness
of the galvanized coating on the stud or bolt.
While the internal threads that are tapped after
galvanizing have no galvanized coating, the close
contact with the galvanized male threads provide
sufficient cathodic protection for adequate durability.
Items too long or too large to be centrifuged, such as
long threaded rods, may be wire brushed while hot to
remove any excess zinc from the threads.
Studs welded to assemblies may have to be cleaned
after the assembly has cooled. This requires reheating
with an acetylene torch and wire brushing to remove
excess zinc. Alternatives to welded studs should be
considered when possible.
Masking to prevent galvanizing threads on pipe or
fittings on external threads can be done using glass
cloth tape. Internal threads require the application of
a high temerature silicone based masking compound
or otherwise to clean or tap after galvanizing.
Tapped-through holes must be retapped oversize after
galvanizing if they are to contain a galvanized bolt
after assembly. Tapping of all holes after galvanizing
is recommended to eliminate double tapping costs and
the possibility of cross threading.

Galvanized bolts require the nuts to be tapped Threaded assemblies can be

oversize to provide clearance for the hot dip cleaned by heating and wire
galvanized coating. brushing after galvanizing.

The rrecommended
ecommended over tapping for nuts and interior thr
overtapping eads is as follows:
threads

Bolt or Stud Size Minimum Overtapping of FemaleThr

Overtapping eads.*
FemaleThreads.*

12 mm and smaller 0.4 mm

Over 12 mm to 25 mm 0.53 mm
Over 25 mm 0.79 mm
*Applies to both pitch and minor diameters, minimum and maximum limits.
On threads over 38 mm it is often more practical, if design strength allows, to have the male thread
cut 0.79 mm undersize before galvanizing , so a standard tap can be used on the nut.

On hinges all adjacent surfaces must be ground 0.8 mm on both pieces to allow for thickness increase
during galvanizing.

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