Industrial Galvanizers Corporation Pty Ltd

Galvanizing Design Manual

2nd edition

INTRODUCTION.
In this manual, the fundamental design rules that will ensure that steel sections and fabrications
are hot dip galvanized to the highest quality standards and at the lowest cost are featured. There
is additional supplementary information included in this 2nd Edition of the manual to provide
affect
information on important aspects of galvanizing that af
fect its durability in service. Industrial
stafff are available for consultation on detailed aspects of design on specific
Galvanizers' technical staf
projects.
GAL
VANIZING FUNDAMENT
ALS
GALV
FUNDAMENTALS
Hot dip galvanizing is an immersion process where steel sections and fabrications undergo the following
operations:
easing (removal of oil, organic materials, mill primers and paint)
1. Hot caustic degr
degreasing
ochloric acid pickling (removal of rust and mill scale)
2. Hydr
Hydrochloric
3. Rinsing (removal of pickling acid residues)
efluxing in zinc ammonium chloride solution (surface conditioning)
4. Pr
Prefluxing
.
Hot
dip galvanizing (at 455-460 degrees C)
5.
omate quenching (passivation of the zinc surface to prevent early oxidation)
6. Chr
Chromate

IMPOR
TANT DESIGN F
ACT
ORS
IMPORT
FACT
ACTORS
Hot dip galvanizing is a self inspecting process that
relies heavily on proper design to achieve a quality
result. The major difference between hot dip
galvanizing and all paint coatings is that hot dip
galvanized coatings can only be applied to
epar
ed surfaces.
perfectly pr
prepar
epared
- The zinc will not rreact
eact with the steel to form the
galvanized coating unless the surface of the steel
is perfectly clean .
- The hot dip galvanized coating will not form
unless the zinc can intimately contact the steel
surface.

- The hot dip galvanized coating will not form

unless the steel is heated to 455-460 degr
ees C.
degrees
- Items cannot be galvanized unless the item will
fit in the pr
eparation tanks and galvanizing
preparation
bath.
These requirements are the fundamentals of Design
for Galvanizing and fall into the four major design
categories: Venting,

Draining,
Dimension instability and
Design.

A consequence of poor venting; this RHS frame exploded due to moisture entrapment

THE PRINCIPLES OF VENTING

While steel is heavier than zinc (molten zinc density 6620 kg/m 3, steel density - 7850kg/m3), the difference
is relatively small. To ensure that the steel fabrication
can be immersed in the molten zinc, both the preparation
chemicals and the zinc must be able to flow into and
onto the item so that all surfaces are contacted.
Any air trapped in pockets in or on the item will prevent
the preparation chemicals adequately preparing the
surface and prevent the zinc contacting the steel and
forming the galvanized coating.

The size of vent holes

The dimensions of vent holes will be determined by:
- the trapped volume of air in the fabrication
- the surface area of the steel in the vented area.
Each square metre of steel surface produces
approximately 200 grams of ash which must be able
to escape through the venting holes.
The location of the vent holes will be determined by:
- the shape of the fabrication
- the angle at which it is suspended for galvanizing.

If the air pockets are large enough, the steel item may
have sufficient boyancy to float on the surface of the
molten zinc.With hollow sections, a general rule is that
if the section contains more than 15% of its internal
volume as air because of inadequate venting, the item
will not sink in the zinc.

BASIC VENTING RULES

1. No vent hole should be less than 8 mm in diameter
2. Preferred minimum vent hole size is 12 mm.
3. Vent holes should not be located in the centre of end plates and connections.
4. Vent holes should be located at the edges of hollow sections oriented in the same plane as the fabrication.
5. Large hollow vessels require 1250 mm2 of vent hole area for each cubic metre of enclosed volume. This is
equivalent to a 40 mm diameter hole for every cubic metre of volume.
6. Hollow sections (pipe, RHS and SHS) require minimum vent holes equivalent to 25% of the sections'
diagonal cross section, made up of single or multiple vent holes. The preferred design option is to leave the
ends of hollow sections completely open.
7. Hollow sections that are connected require external vent holes as close to the connection as possible. If
internal vent holes are used, they should be the same size as the internal diameter of the connecting section.
8. Large seal welded overlapping surfaces will require venting if the enclosed area may contain condensation or
allow process chemicals to enter the overlap during the galvanizing process. Overlaps exceeding 40,000 mm2
should be vented with a 10 mm vent hole. Overlaps under 10,000 mm2 generally do not require venting.
Intermediate sized overlaps should be judged on the basis of weld integrity and residual welding heat in the
joint to ensure total dryness at time of sealing. Longer or larger overlapping areas require spaced holes for
progressive venting. Very large overlapping areas should be avoided as an undesirable design for galvanizing.

SAFETY NOTE:

Water or process solutions may enter hollow sections during fabrication or

during the galvanizing process. When the item is heated to 450 degrees C
C, water is converted to steam
and undergoes an expansion of approximately 1750 times its original volume. Pressures in the order of
50 MPa can be produced.

Adequate hole sizes in sealed hollow sections in the correct locations ensures galvanizing quality.

THE PRINCIPLES OF DRAINING

When an item is immersed in process solutions or molten zinc, the liquids have to flow freely into and out of
the item. The viscosity of molten zinc and its density are important factors in designing adequate drainage into
fabrications.
When the item is immersed, good galvanizing practice requires that it is lowered into the galvanizing bath at
a steady rate. If drain holes are too small, the zinc will not flow fast enough and the item may become buoyant
which may result in the item floating off the dipping equipment, rolling over or otherwise being subjected to
erratic immersion.
When a hollow vessel or section is withdrawn from the galvanizing bath, the zinc must be able to flow freely
from it. Molten zinc has a density of 6620 kg/m3 and excessive dead weight may be applied to the item or the
lifting equipment is molten zinc is retained in the item.
With thin walled vessels such as tanks, this can result in mechanical distortion of the item.

Good detail design provides adequate

natural drainage without requiring holes

Closed pipes require at least two diametrically opposed vent and

drain holes aligned with the lifting points.

The size of drain holes

The size of drain holes will be
determined by:
- the enclosed volume of zinc in the
fabrication
- the detail design of the fabrication
(size, shape)
The location of the drain holes will
be determined by:
- the shape of the item
- the angle of suspension during
galvanizing

Vessels with large internal volume requires large drain holes. This tank
contains over 10 tonnes of molten zinc when immersed

BASIC DRAINING RULES

1.
2.
3.
4.
5.
6.

7.

No drain hole should be less than 10 mm in diameter

Preferred minimum drain hole size is 25 mm.
Drain holes should not be located in the centre of end plates and connections.
Drain holes should be located at the edges of hollow sections oriented in the same plane as the
fabrication.
Large hollow vessels require 10,000 mm2 of drain hole area for each cubic metre of enclosed volume.
Hollow sections (pipe, RHS and SHS) require minimum drain holes equivalent to 25% of the sections'
cross sectional measurement, made up of single or multiple drain holes. The preferred design option is
to leave the ends of hollow sections completely open.
Hollow sections that are connected require external drain holes as close to the connection as possible.
Internal venting is also recommended to ensure that pretreatment chemicals and zinc can flow freely and
steam generated from liquids remaining inside can be efficiently vented.

Channel frames require at least four and preferably

eight vent/drain holes using conventional design

By using outward facing channels, no special

venting or draining provisions are required

NOTE: Water or process solutions enter hollow sections during fabrication or during the galvanizing
process. If the drain holes are not located at the lowest point in the fabrication;
- process chemicals will be trapped internally and cause an explosion hazard when immersed in the molten
zinc.
- zinc will be trapped internally and will freeze in the undrained area. This may interfere with assembly, it
will add to the weight of the item in service and it is a waste of zinc which adds to the cost of galvanizing.

Vent and drain holes must be located as close to the high and low points of the hollow section as
possible to prevent air locks, entrapment of pretreatment chamicals and zinc puddling

THE PRINCIPLES OF A
VOIDING DIST
OR
TION
AV
DISTOR
ORTION
When steel sections or fabrications are immersed in
molten zinc, their temperature is raised to that of the
molten zinc which is typically 455oC. The rate at
which the steel will reach this temperature across its
entire surface will depend on;
- the thickness of the individual sections making
up the item.
- the total mass of the item.
- the dimension of the item.
At galvanizing temperatures, there is no change to
steel's metallurgical microstructure and the
galvanizing process is not hot enough to have any
heat treating effects on the mechanical properties of
the steel after galvanizing.

However, at galvanizing temperatures, the yield strength

of steel is lowered by approximately 50%. If the adjacent
steel is not at the same temperature and any stresses
exist, the weaker area will be subject to movement by
the stronger area. There is a responsibility on the
designer, the fabricator and the galvanizer to co-operate
in ensuring that distortion risks are minimised or
eliminated.

The pattern of distortion in this 3 mm floorplate is clearly the result of the welding technique used.
Attatching the channels with fasteners after galvanizing would significantly reduce the risk of distorting

Basic design rules

1. Design to use uniform thickness sections throughout
the fabrication.
2. Ensure welding and assembly techniques minimise
stresses in components making up the item.
3. Ensure that venting and draining are adequate. This
will allow the item to be immersed in and withdrawn
from the molten zinc as quickly as possible.

4. Ensure that the structural design of the item is

sufficient to support its own weight at 50% of the
steel's specified yield strength. Consider temporary
bracing if potential to yeild exists.
5. Avoid using large areas of thin (under 8 mm) flat
plate.
6. Guillotine cut plate is preferred to oxy cut plate.

GAL
VANIZING RULES T
O A
VOID DIST
OR
TION
GALV
TO
AV
DISTOR
ORTION
1. Immerse the item as quickly as possible.
2. Keep the molten metal line as short as possible on the item.
3. Withdraw the work from the galvanizing bath as quickly and as steadily as possible
4. Air cool distortion prone items. Support the item during cooling on level supports. Do not water quench.

Classification of distor
tion pr
one items
distortion
prone

1. Low risk. All hot rolled structural sections,

fabrications containing angles, channels and
universal hot rolled sections, tube and RHS
sections and fabrications, ribbed or corrugated
plate sections, grating, heavy plate (over 16 mm).

2. Medium risk. Light section roll formed products, long light walled conduit and tubing, fabrications containing assymetrical weldments or steel
of significantly different thickness, medium plate,
some double dipped items (8-16 mm).

3. High risk. Thin sheet and plate (under

under 8 mm
depending on shape and area), floorplate, deep web
plate girders, platforms containing floorplate, long
channel sections with multiple weldments (cleats)
on one side of web.

BASIC RULES - DESIGN FOR GAL

VANIZING
GALV

Gussets and stiffeners should be cropped prior to

assembly for good drainage.

End plates should have vent/drain holes

in the corner(s) of the connecting angle, channel
or beam.

Outward facing angles and channels in fabri

cated frames reduce venting and drainage
problems.

Terminating bracing short of adjacent flanges

will allow free flow of zinc through the
connection and eliminate pockets in service.

BASIC DESIGN RULES (CONT)

- Consult the galvanizer; understanding how a fabrication

will be oriented during galvanizing may simplify detailing.

- Avoid connection sections of significantly different

thickness in other than short lengths.
This angle bracing is welded toe to toe to the
- Bracing angles on trusses and gantries should be connected main members, eliminating the need for any
special venting and draining requirements. It also
by welding on the toes and not the flats. This facilitates
eliminates pockets and horizontal surfaces that
drainage, eliminates overlapping surfaces and eliminates
allow contaminants to accumulate in service.

horizontal surfaces in service for better durability.

- Terminating bracing short of adjacent flanges will allow

free flow of zinc through the connection and eliminate
pockets in service.
- Seal weld seams and joints

- Do not mix materials such as mild steel and stainless

steel in fabrications.

.
Designing for optimum bath dimensions allows
large fabrications to be easily galvanized.

- Avoid severe cold working of steel - punching holes in

thick sections, tight radius bending or rebending to
eliminate risk of embrittlement.
- Consider the dimensions of the design in relation to
galvanizing bath size. Cost and quality benefits arise from
co-ordinating item dimensions with galvanizing bath
dimensions.

- Avoid large overlapping areas (e.g. welded back-to-back

channels). Overlapping surfaces that are seal welded may
require venting if there is a risk of moisture entering or
being trapped in the overlap.

Two-dimensional items can be handled and

transported more economically than threedimensional fabrications.

- Consider the overall on-site costs of fabrications rather

than first cost. Two dimensional items can be galvanized
and transported more economically than three dimen
sional fabrications.
- Consider the orientation of the component is service. Good
design for galvanizing will generally improve overall
anti-corrosion performance through improved drainage.

- Moving parts require a design clearance of 2mm

to accommodate the galvanized coating.
10

Hinges and moving parts require adequate

clearance to accommodate the galvanized coating
on all surfaces.

FACT
ORS AFFECTING GAL
VANIZING QUALITY AND SER
VICE
ACTORS
GALV
SERVICE
There are a number of factors in the nature of steelwork presented for galvanizing that impact on the galvanizers ability to provide a quality product and service. These are:
1. Surface condition of the steel: rusty
eviously galvanized.
rusty,, painted, pr
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
fabrications to be galvanized should be avoided.
2. T
ype of pr
oduct; castings, old wr
ought ir
onType
product;
wrought
ironwork, brazed, solder
ed
or
riveted
assemblies.
soldered
Old wrought ironwork may be porous and allow
moisture into voids in the castings. Abrasive blasting
is the preferred method of surface preparation for this
material to minimise immersion in process chemicals.
Soldered items must not be galvanized. The solder will
melt out at galvanizing temperatures .

Steel and iron castings must be sound and free of

moulding sand. Any sand that is burned onto the surface
will prevent the galvanized coating from forming.
Brazed components can be galvanized. The brazing
will take on the appearance of a conventional
galvanized coating after processing.
Rivetted components containing aluminium pop rivets
should not be processed. The aluminium will rapidly
dissolve in both the caustic tank through sodium
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.

11

FACT
ORS AFFECTING GAL
VANIZING QUALITY AND SER
VICE (CONT
.)
ACTORS
GALV
SERVICE
(CONT.)
3. Steel metallurgy
The galvanized coating is formed by the steel reacting with the zinc at galvanizing temperature. The metallurgy 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, phosphorous, 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. Ir
on. 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) thickness 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
ous. Phosphorous (P) is a very reactive residual element in structural steels that does not present a
Phosphorous.
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.

12

FACT
ORS AFFECTING GAL
VANIZING QUALITY AND SER
VICE (CONT
.)
ACTORS
GALV
SERVICE
(CONT.)
4. Surface Pr
ofile
Profile
The rate of reaction between steel and zinc is also affected by the surface profile. Very smooth surfaces
such as those found on cold rolled sheet and tube products will have a relatively low rate of reaction and may
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.

Heavy gauge wire used in pool and fence panels may

also produce uneven galvanized coatings , typically in
a spiral pattern, caused by surface stresses induced in
the steel during straightening.

While badly rusted steel can be easily

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

5. W
eld quality
Weld

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.

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.

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 .
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
process.

Weld spatter will be galvanized as well as the steel and

should be removed if appearance is a requirement.

13

5. W
eld 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.
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
required.

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.

New welding technology significantly redices

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
allowed pretreatment chemicals to penetrate the
joint. These chemicals leach out after galvanizing a
stain the coating.

Slag left on welds wil interere with the

pretreatment process and will prevent the
galvanized coating from forming.

14

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
zinc at sufficient an angle will give rise to heavy
zinc buildups and drainage spikes.

Industrial Galvanizers larger structural galvanizing

plants can process beams around 20 metres in length by
double dipping.

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.

15

THREADED PAR
TS
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

oversize to provide clearance for the hot dip
galvanized coating.

Threaded assemblies can be

cleaned by heating and wire
brushing after galvanizing.

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

Minimum Over
tapping of FemaleThr
eads.*
Overtapping
FemaleThreads.*

12 mm and smaller
Over 12 mm to 25 mm
Over 25 mm

0.4 mm
0.53 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.
16

Manufacturers of threaded parts recognize that

special procedures must be followed in their plants
where certain items are to be galvanized. Following
are some examples:
1. Low carbon bars are recommended since high carbon
or high silicon causes a heavier, rougher galvanized
coating on the threads.

3. Sharp manufacturing tools are mandatory. Ragged

and torn threads open up in the pickling and
galvanizing processes. Worn tools also increase bolt
diameters. Frequent checking is necessary on long
runs.
4. Standard sized threads are cut on the bolt, while
standard sized nuts are retapped oversize after
galvanizing.

2. Hot formed heading or bending requires cleaning

at the manufacturing plant to remove scale before
threading. Otherwise, over-pickling of threads will
result during scale removal.

MOVING P
AR
TS
PAR
ARTS
When a galvanized assembly incorporates moving parts
(such as drop-handles, shackles and shafts), a radial
clearance of not less than 1.6 mm must be allowed to
ensure full freedom of movement after the addition of
zinc during galvanizing.
Designs should provide additional clearance for moving
parts to allow for the pickup of zinc during galvanizing.
It is recommended that, whenever possible, work be
designed so that hinges can be bolted to frames, covers,
bodies, and the like after galvanizing.

Before galvanizing, any adjacent edges should be

ground to give at least 0.8 mm clearance. The pin
holes can be cleared of excess zinc at time of assembly.
After hinges are galvanized, it is recommended that
an undersized pin be used to compensate for the zinc
picked up during the galvanizing process. If desired,
the pin holes in the hinges may be reamed 0.8 mm
after galvanizing to permit the use of regular size
pins.

Hinges should be galvanized separately and assembled

after galvanizing. All hinges to be galvanized should
be of the loose pin type.

17

MARKING FOR IDENTIFICATION

Identification markings on fabricated items should be
carefully prepared before galvanizing, so they will be
legible after galvanizing.
Do not use paint to apply addresses, shipping
instructions, and job numbers on items to be galvanized.
Oil based paints and crayon marks are not removed by
the pickling acids. This results in extra work and extra
charges by the galvanizer to properly prepare the steel
for galvanizing.
For temporary identification, use heavily embossed
metal tags wired to the work or a water soluble marker
such as Dymark PB80 should be specified. For
permanent identification use heavily embossed, punched
or welded lettering.

Where permanent identification is needed there are suitable alternatives for marking steel fabrications to be
hot dip galvanized. Each will enable items to be rapidly identified after galvanizing and at the assembly
site. The three marking alternatives are:
1 Fixing a deep stamped steel tag (minimum thick ness - 2.5 mm) to the fabrication by seal-welded
directly to the item to be galvanized.
2. Stamping the surface of the item using die cut deep
stencils or series of center punch marks. These marks
should be placed in a standard position on each of
the members. They should be a minimum of 12 mm
high and 0.80 mm deep to ensure readability after
galvanizing. This method should not be used to mark
fracture critical members.

REPAIR OF DAMAGED GALVANIZED SURFACES

Where significant coating damage has occurred to the
galvanized coating through cutting, welding or impact,
there are a number of methods of repair that are intended
to provide a repaired area of equivalent performance to
the undamaged coating. The three main repair materials
are:
1. Zinc rich paints
2. Zinc metal spray
3. Zinc alloy repairs sticks.
Zinc rich paints used for repairing damaged hot dip
galvanized coatings should conform to AS2204 (Zincrich organic priming paint). High quality two-pack
epoxy zinc rich paints, applied to the damaged area to a
ons
minimum dry film coating thickness of 100 micr
microns
are most commonly used. Single pack epoxy zincs are
also suitable for galvanizing repair applications.
Zinc metal spray will provide a metallic repair coating
of equal performance to the hot dip galvanized coating.
18

Zinc metal spray is not well suited to the repair of small

areas and must be applied to a Class 3 (AS 1624.4)
abrasive blasted surface.
Zinc alloy repair sticks are best suited for repairing
weld areas in the downhand position while they are
still hot, as the surface needs to be heated to the melting
temperature of the zinc alloy for application.

WET ST
ORAGE ST
AIN PREVENTION
STORAGE
STAIN
When steel is freshly galvanized, the surface of the
zinc is succeptible to reaction with rainwater and dew
on prolonged exposure in poorly ventilated conditions.
The stable oxidising carbonate films that form on the
surface of the zinc require the presence of carbon
dioxide for their formation. Galvanized steel that is
stacked or nested in wet conditions will inhibit the
formation of these stable films.
Wet storage stain or `white rust' occurs under these
conditions. Considerable coating damage may occur
with prolonged exposure to wet, poorly ventilated
environments.

2. Heavy staining
Brush off bulky oxidation products with a wire brush
or stainless steel pot scourer. Treat the affected surface
with a solution of 5% sodium dichromate, 0.1%
sulphuric acid, brushing with a stiff nylon bristle brush
for 30 seconds before thorough rinsing of the surface.
If the surface has been dulled and still has sufficient
galvanized coating present; to restore a bright finish,
apply a small amount of aluminium paint to a cloth
pad and rub over the surface to blend the damaged
area with the adjoining galvanized coating.

Normal galvanizing practice is to quench the

galvanized steel in a very weak solution of sodium
dichromate to passivate the zinc surface during the
early stages of atmospheric exposure.
Other post treatments such as oil, wax or polymer
coatings can be applied for applications that are
considered to have a high risk of wet storage staining.
Stacking of galvanized work in storage to provide
good ventilation and drainage will ensure that white
rusting problems are eliminated.

These freshly galvanized sections show the

reaction of rainwater on areas of the coating that
have been buffed. The buffing removes the
passivation film and exposes pure zinc to
oxidation until new passivation films form.

Removal of 'white rust' stain.

1. Light staining
The corrosion products formed when white strorage
staining occurs are bulky and powdery when dry.
Light white rust films that have stabilised will quickly
weather off in service and have little effect on the
performance of the galvanized coating.

This guardrail bullnose section has been badly

affected by white rust through being stored in a
pack for a long period after exposure to rainy
weather shortly after galvanizing.

3. Severe staining
If severe staining has occurred to the extent that most
of the galvanized coating has been removed, it is
desirable to treat the affected area as damaged. The
surface should be prepared by buffing or wire brushing
and repaired with a high quality two-pack epoxy zinc
rich paint, applied to the damaged area to a minimum
dry film coating thickness of 100 microns. If extensive
severe white storage staining has occurrs, regalvanizing
of the item may be required.
19

PAINTING GALVANIZED STEEL

Galvanized steel surfaces are painted easily and

satisfactorily using established and proven paint systems
ranging from simple self-priming finishes to complex
systems suitable for the most demanding service
requirements. Powder coatings over galvanized steel
also offer advantages in architectural applications.

*NOTE: Diesel fumes falling onto surfaces from truck

exhausts are a major cause of surface contamination.
Clean galvanized work being transported to painting
facilities should be covered in transit.

Paint systems for galvanized steel

Many specialised paint systems require pretreatment

of the galvanized surface to obtain adequate long
term adhesion and optimum paint performance.
Manufacturers instructions should be followed
exactly from product data sheets.

Different procedures and paint types are necessary from

those used in painting uncoated steel. Two factors are
critical to the satisfactory performance of paint coatings
applied over galvanized coatings:

Pretreatment systems for galvanized steel

Mechanical preparation using abrasive blasting

techniques should be done using the following
parameters:

1. Initial adhesion
2. Long term adhesion
Initial adhesion of the paint system is achieved by use
of a recommended pretreatment primer or self priming
finish on an uncontaminated surface, which provides a
base for subsequent coatings.
Long term adhesion depends on compatibility of the
pretreatment primer or finish coats with the galvanized
coating. Use of incompatible paint systems, or direct
application of unsuitable finishes without the correct
primer or pretreatment will result in premature paint
failure.
Preparation of galvanized steel surfaces for painting

blast pressure 40 psi (280 MPa) maximum

abrasive grade 0.2-0.5 mm - ilmenite
blasting angle - 45 degree angle to surface
distance from surface 300-400 mm
nozzle type - minimum 10 mm venturi

This will ensure that the blasting causes minimum

damage to the galvanized coating and removes no
more than 10 microns of the coating
Chemical etching: of galvanized surfaces prior to
painting is not recommended because of inconsistency of application and entrapment of corrosive
residues.

As in all painting operations, the surface to be painted

should be thoroughly clean, free from grease and oil,
and dry. Galvanized steel surfaces are clean and oil free
as manufactured but should they become contaminated
during transport*, storage or fabrication the following
cleaning methods should be used:
1. Non-oily soils and dirt should be removed by brush
ing or scrubbing. Detergent washing, followed by
thorough clean water rinsing is satisfactory, provided
the detergent is of the non-ionic type. Other types
should be avoided as their residues may interfere
with paint adhesion.
2. Grease and oil may also be removed by swabbing
generously with a suitable hydrocabon solvent such
as white spirit or mineral turpentine, using several
clean swabs on each area.
3. Thoroughly dry areas which have been cleaned.
20

Painting over galvanizing provides one of the

best steel protection systems available with 50
year coating life achievable with properly
specified coatings.

Weathering: Leaving galvanized surfaces to weather

as a pretreatment for painting is not recommended.
While weathering will establish stable carbonate films
on the surface, atmospheric contaminants will also
accumulate.
Chemical conversion pr
etr
eatments: A range of
pretr
etreatments:
chemical conversion treatments is available which
convert the galvanized surface to an insoluble complex
to provide good adhesion for subsequent paint finish.
Phosphate tr
eatments: Many specialised phosphating
treatments:
systems are available for use with galvanized steel.
Phosphate conversion coatings give excellent,
permanent adhesion to suitable paints and are ideal for
the preparation of galvanized steel surfaces.
Cold phosphating: Treatments such as Prep Galv and
Lithoform No 2 are suited to on-site applications. Their
use will generally upgrade the performance of suitable
paint systems on galvanizing, improving initial adhesion
when used before etch primers. The instructions of the
phosphating treatment manufacturer must be followed
exactly.
Chromate treatments: The use of chromate treatments
on galvanized steel before painting may interfere with
paint adhesion if no other pre-treatment is undertaken
prior to application.

Specialised primers for galvanized steel

Several primer types may be applied directly to
galvanized steel without pretreatment other than
cleaning and degreasing. These include specific
formulations of the following types:
1. Modified acrylic water-borne primers
2. Certain water borne self priming finishes
3. Etch primers
Modified acrylic water-borne primers: Specialised primers suitable for direct application to galvanized steel without preparation other than
degreasing, include Taubmans Duraquaprime and
Rust Proof Etch Primer, and Dulux Galvanized Iron
Primer.
Water-borne self priming finishes: Many waterborne self priming finishes of the 100% acrylic type
give excellent performance on new galvanized steel
and are ideal for decorative and protective coatings on
new galvanized steel used for exterior walls, guttering
and roofing. Gloss and matt finishes are available. Twocoat application direct to new clean galvanized steel
surfaces will ensure a minimum of 10 years service
without loss of adhesion.
21

Maintenance painting is normally carried out using

the same type of water-borne finish. Water-borne finishes designed specifically for galvanized surfaces may
be top coated with oil or synthetic vehicle systems.
Etch primers
Single pack or two-pack etch primers or wash primers
are ideal for priming galvanized steel surfaces. Thin
ons should
coatings, typically no more then 12-15 micr
microns
be applied, preferably by spray and strictly in accordance with the manufacturers' instructions

produce a high quality powder coating on hot dip

galvanizing.
Galvanized steel intended for powder coating is best
not chromate quenched. For normal exposure
conditions, the freshly galvanized steel surface is zinc
phosphate or iron phosphate pretreated, and then powder
coated. For heavy duty applications where maximum
adhesion, salt spray resistance and durability is required,
zinc phosphate pretreatment is recommended.

Finish coats for galvanized steel

Selection of paint systems including pretreatments,
primers and finish coats should be made from manufacturer's recommendations depending on the type of
galvanized steel surface and the demands of subsequent
exposure and service.Advice as to suitability of particular finishes for specific products and environments
is available from paint manufacturers.
Powder coating galvanized steel
The polyester powder coating of galvanized steel greatly
enhances the durability of galvanized coatings under
atmosheric exposure conditions. A wide range of colours
and finishes is available. Powder coating should be
performed soon after galvanizing, preferable within 12
hours and work be kept dry in the period prior to
coating. Special preheating teatment combined with
special grades of polyester powder is required to

Industrial Galvanizers installed a purpose built

powder coating facility in conjunction with its
Newcastle (NSW) operations to apply high
performance polyester powder coatings to hot dip
galvanized products like these pool fence panels.

Polyester powder coating over hot dip galvanizing provides a high performance architectural finish that can stand up
to UV exposure and wear. Pedestrian railings like this have been in service for nearly 10 years without maintenance.

22

GALVANIZING GLOSSAR
Y
GLOSSARY
Acid pickling: Hydrochloric acid is used to remove rust and mill scale from steel prior to galvanizing.
Alloy layers: The hot dip galvanized coating consists of a series of alloy layers of zinc-iron alloys, coated with
a layer of zinc. The alloy layers enhance the abrasion resistance and allow thicker coating to be applied.
Ash: Zinc oxidation products formed from the molten zincs reaction to air and the flux on the steel surface float
on the baths surface and is skimmed off as zinc ash which can then be processed to recover zinc metal and
compounds.
Bare spots: Defects in the galvanized coating due to inadequate cleaning prior to galvanizing.
Beam work: Dipping beams are used in the galvanizing process to support items suspended from the beam from
hooks or wire to minimise the non-productive steel entering the bath .
Brush blasting: Light abrasive blasting to prepare galvanized surfaces for painting. Mild abrasives such as
illmenite are required at low nozzle pressures (40 psi) to prevent damage to the galvanizing.
Centrifuge work: Small parts are galvanized by spinning or centrifuging in a bucket to throw off excess zinc. Used
for fasteners, washers, chain, brackets and bolts.
Cathodic protection: Zinc is more electrochemically reactive than steel and will corrode preferentially of steel is
exposed through the galvanized coating through cutting or damage.
Caustic degreasing: All work to be galvanized is first treated in a hot caustic bath to remove grease, oil, some types
of paint and organic material so that the steel can be pickled . Acid will not remove rust and oxides if organic
contamination is present on the surface.
Chain work: Large, long or awkward items dipped by suspending them on chains are classified as chain work in the
galvanizing process.
Clockwise fr
om top: 1. Alloy layers are shown in this micrograph of a galvanized coating on high silicon steel. 2.
from
Ash forms on the surface of the galvanizing bath and is skimmed off periodically. 3. Bare spots occur when
pretreatment is inadequate or air locks prevent the molten zinc contacting the stee; the cause of this particular defect.
4. Chain work is work that is too large to fit onti jigs or beams and is handles through the galvanizing process on
chains as individual items.

23

GAL
VANIZING GLOSSAR
Y (CONT
.)
GALV
GLOSSARY
(CONT.)
Chromate treatment: After steel is galvanized, it is quenched in water containing a small amount of sodium
dichromate which passivates the new zinc surface and prevents early oxidation of the surface.

Coating thickness: hot dip galvanized coatings are

thicker on heavier sections like these lighting
columns which have 200 micron coatings applied.

Double dipping allows large and complex

fabrications to be satisfactorily galvanized.

Coating thickness: The hot dip galvanized coating thickness is determined by the metallurgy , surface condition
and section thickness of the steel. Australian Standard AS1650-1989 defines minimum coating thickness
standards for hot dip galvanizing.
Continuous galvanizing: Sheet, wire and some tube sections are continuously galvanized. The coating formed is
relatively thin and soft.
Corrosion rate: The corrosion rate of galvanized coatings is predictable so the life of the coating can be accurately
estimated in any known environment.
Double-dipping: Long or wide fabrications or sections can be galvanized by dipping each end or side sequentially.
Dross: Steel reacting with the zinc in the galvanizing bath forms dross which is a zinc-iron crystal that is heavier
than zinc and has a higher melting point. Dross must be periodically removed from the bottom of the galvanizing
bath to maintain operating depth.
Draining: All items to be galvanized must allow zinc to flow off or out of the items during galvanizing.
Duplex coating: When galvanized coatings are painted, duplex coating systems are formed which have durability
higher than that of the sum of the coatings used separately.
Electroplating: Thin zinc coating are applied by electroplating. Used for coating small parts and fasteners with
a smooth, bright coating but are unsuitable for exterior exposure.
Embrittlement: Embrittlement can be induced in some steel items during galvanizing due to excessive cold
working (strain ageing) or acid pickling (hydrogen embrittlement) of high strength steel.

Dross is a mushy zinc-iron alloy that forms during the

galvanizing process and must be periodically removed
from the galvanizing bath.

24

Electoplating (centre) is characteristically bright

and shiny compared to hot dip galvanized coatings
(l and r). Electroplated coatings are very thin and
are unsuitable for exterior applications.

GAL
VANIZING GLOSSAR
Y (CONT
.)
GALV
GLOSSARY
(CONT.)
Etch primers: Some galvanized coating primers
contain acid etching components to condition the zinc
surface for painting. These primers require careful
application to be successful.
Fluxing: Prior to entering the galvanizing bath and
after caustic degreasing and acid pickling, steel is
fluxed in a hot zinc ammonium chloride solution to
condition the surface for galvanizing.
Galvanizing: Coating steel by immersing it in molten
zinc either as a batch or continuous process.
Grey coatings: Certain types of steel can produce
dull grey galvanized coating. These coatings have no
free zinc on their surface and tend to be thicker and
less impact resistant than shiny coatings.
Hardness of galvanized coatings: The zinc
component of the galvanized coating is about half the
hardness of 250 grade steel. The alloy layers in a hot
dip coating are about twice as hard as 250 grade
steel.
Hydrogen embrittlement: Steel over 1000 mPa
yield strength may be prone to embrittlement from
hydrogen entering the steel crystals from acid
pickling.
Inclusions: Hot dip galvanized coatings may have
inclusions in the coating formed by dross crystals
floating in the molten zinc. They have no effect on the
coatings durability.
Jig: A steel frame which supports work during the
galvanizing process. Special jigs are designed for
specific products to optimise quality and productivity.
Magnetic testing: Galvanized coating thickness is
measured by magnetic flux instruments which
measure the distance from the surface of the coating
to the surface of the steel.
Metallising: Zinc wire or powder is melted in an oxyacetylene flame and sprayed onto a Class 3 Blast
steel surface. Metallising is a recommended repair
method for large damaged or uncoated areas of a
galvanized item.
Moving parts: The hot dip galvanized coating
thickness on small parts is typically around 100
microns. Clearances on moving parts should
accommodate this thickness on both surfaces plus an
allowance for irregularities in the coating.
Normalising: The galvanizing temperature (455
455
degrees C
C) is not high enough to effect the strength or
temper of steel but will have stress relieving effect in
welded items.
Passivation: Galvanizing is passivated by quenching
in a weak sodium dichromate solution to prevent
early oxidation of the zinc surface if exposed to dew
or rainwater.

Grey coatings are caused by metallurgical

differences in the steel which increases the rate
of reaction between zinc and steel during
galvanizing. The are most commonly arise on
plate products like these brackets.

Jigs are used in galvanizing to support

work through the process. This jig is used
for galvanizing flat bar to minimise touch
marks and distortion during galvanizing.

Magnetic thickness guages are used

universally for the measurement of
galvanized coatings and provide accurate and
reproducible results

25

GAL
VANIZING GLOSSAR
Y (CONT
.)
GALV
GLOSSARY
(CONT.)
Phosphorous: Steels containing high levels of
phosphorous (in conjunction with silicon) are very
reactive with molten zinc and will form thick, grey
coatings.
Powder coating: Polyester powder coating over
galvanizing is done by phosphate pretreating the
galvanizing then electrostatically applying polyester
powder and then fusing it in an oven.
Repairs: Damage to galvanized coatings can be
repaired with recommended zinc rich paint touch up
systems , with zinc repair sticks or by zinc metal
spraying.
Runs: When molten zinc drains off items as the work
emerges from the zinc bath, the zinc may freeze on the
surface to form runs or drainage spikes.
Silicon steel: Some steels with high levels of silicon are
very reactive with molten zinc and can form very thick
coating many times thicker than a standard coating.
The coatings thus formed are duller and more
susceptible to mechanical damage but will provide
extremely long service life.
Strain ageing: Severely cold-worked steel may
become brittle during galvanizing as a result of the heat
of the process accelerating the stress effects of the cold
work.
Venting: All hollow section must be correctly vented
to allow air and steam to escape during immersion in
the molten zinc. Items must allow zinc to flow in and air
to flow out to ensure that the item will sink in the zinc
and that molten zinc can contact all surfaces during
immersion.
Welding: Welding of galvanized steel requires correct
ventilation and the use of correct welding electrodes
and techniques.
White rust or wet storage stain: When steel is
freshly galvanized, the zinc is free of any protective
oxide film. If pure water (dew or rain) is in prolonged
contact with the zinc in this condition, the zinc will
react with the water to for zinc hydroxide; a bulky white
oxide deposit. Passivation after galvanizing along with
good ventilation and drainage will prevent white
storage staining.
Zinc carbonate film: This oxide film provides zincs
excellent atmospheric corrosion resistance and as this
coating thickens with weathering, the galvanizing
develops its characteristic soft grey appearance.

Runs are caused by molten zinc freezing as it drains

off the steel. These drainage spikes are removed
during dressing and inspection after galvanizing.

Welding of galvanized steel requires the use of

appropriate ventilation and the correct electrodes.
Repairs of welds is best done as soon as possible
after completion of welding.

White rust:Hot dip galvanized product such as

guard rail should be stacked to allow rainwater to
drain out as storage of nested product in wet
conditions will accelerate white rust problems.

26

EMBRITTLEMENT AND GAL

VANIZING
GALV
With mild steels that are produced by conventional
methods, hot dip galvanizing has no significant effect
on their properties or performance other than enhancing
the steel's durability and providing a low level of stress
relief from fabrication stresses through the items being
heated to the galvanizing temperature.
With some types of steels and with some fabrication
techniques which involve severe cold working of the
steel prior to galvanizing, embrittlement problems can
arise that can result in the performance of the item in
service being affected.
There are three significant types of steel embrittlement
that can be associated with the hot dip galvanizing
process. These are:
- liquid metal embrittlement
- hydrogen embrittlement

The hot dip galvanizing processes throughout Australia

use hydrochloric acid at ambient temperature almost
exclusively for pickling prior to galvanizing. Acid
concentration is typically 10-15% HCl
The majority of steel hot dip galvanized is generally in
the range of 200-450 MPa so is not subject to hydrogen
embrittlement problems. Higher strength steels such
as the quenched and tempered Bisalloy steels are
appearing in the structural area and special
consideration must be given to these types of steels if
they are required to be hot dip galvanized.
Avoiding hydr
ogen embrittlement
hydrogen
The requirement to galvanize high strength steels is a
very small one in comparison to the volume of lower
strength product that is routinely processed through
galvanizing plants. High strength steels can be
galvanized satisfactorily provided the necessary
precautions are taken in the galvanizing process.

- strain age embrittlement

Liquid metal embrittlement: Liquid metal
embrittlement is caused by the attack of the molten metal
(zinc in the case of galvanizing) on susceptible steels.
The most common liquid metal embrittlement problems
associated with hot dip galvanizing are with stainless
steel. Attaching stainless steel fittings to mild steel items
prior to galvanizing should be avoided for this reason
as the molten zinc may affect the mechanical properties
of the stainless steel.
Hydr
ogen embrittlement. When atomic hydrogen
Hydrogen
diffuses into the structure of susceptible metal such as
high strength steel, some mechanical properties can be
seriously impaired. Sustained tensile stress can thus
lead to failure. Dynamic and static laboratory testing
can detect losses of tensile or torsional ductility.
Hydrogen embrittlement is caused by the presence of
hydrogen atoms within the crystal lattice structure of a
metal or alloy. In the galvanizing process, hydrogen
may be absorbed in the steel during the pickling process
through contact with the hydrogen ions present in the
hydrochloric acid.

The recommended method of processing high strength

steels for galvanizing is to eliminate the acid pickling
process and use mechanical cleaning methods for
preparation of the surface prior to hot dip galvanizing.
Abrasive blast cleaning to Class 2 1/2 immediately
prior to galvanizing will ensure that the steel is
adequately cleaned and that a satisfactory hot dip
galvanized coating will be produced.
Australian Standard AS 1214-1973
1214-1973, Appendix C
states the following with respect to hydrogen
embrittlement of high strength bolts, which are the most
commonly encountered high strength steel requiring
to be galvanized.

Where additional sqfeguard is sought (eg. For bolts

of Grade 10.9 or higher cleaned by acid pickling),
Fasteners should be baked at a temperature of 200
C, for a time found on the
degrees C + 10 degrees C
basis qf experience to be adequate (for guidance, a
time of 30 minutes before galvanizing, or 4 hours
immediately after galvanizing, might prove
satisfatory).

Steels with a tensile strength in the order of 1000 MPa

or higher or with an equivalent surface hardness of 30
Rockwell C or higher are considered to be most
susceptible to hydrogen embrittlement.
27

EMBRITTLEMENT AND GAL

VANIZING (CONT
.)
GALV
(CONT.)
Strain Age Embrittlement
Strain ageing is associated with strain that results from
plastic deformation which is more commonly known
as cold working. Steel is an alloy of iron and carbon
and contains other alloying elements which provide it
with specific performance characteristics.

embrittlement can be induced in any severely cold

worked steel by heating and the tendency to
embrittlement by strain ageing will always be present
and its manifestation will simply be a matter of time.
Avoiding
voiding strain age embrittlement

Severe cold working of steel causes the migration of

carbon atoms in the iron crystals and the segregation
of these atoms at dislocations in the steel causes a
reduction in ductility of the steel.

To avoid the risk of strain ege embrittlement, the

following design criteria should be followed:

The ageing process is a function of temperature and

time and occurs very slowly at ambient temperature
but very rapidly at the 450-460oC temperatures of the
galvanizing process. Severe cold working of steel can
be caused by hole punching in thicker sections, tight
radius bending or rebending.
It should be noted that it is not the hot dip galvanizing
that is the cause of accelerating the strain ageing of the
steel, but the heat of the process, so strain age

use bend radii at least 3 x section

thickness;

hot bend if bend radii under 3 x

section thickness is rrequir
equir
ed;
equired;

anneal at 650-815C prior to galvanizing;

ream punched holes to rremove

emove sever
ely cold
severely
worked material fr
om
surface
prior
to
from
galvanizing.

GENERAL INFORMA
TION ON GAL
VANIZED COA
TINGS
INFORMATION
GALV
COATINGS
This information has been pr
ovided to assist in the selection of zinc coated pr
oducts and materials for
provided
products
use in conjunction with hot dip galvanized pr
oducts.
products.

COA
TING CHARACTERISTICS OF GAL
VANIZED COA
TINGS.
COATING
GALV
COATINGS.

Most galvanized coatings involving the immersion of

steel in molten zinc are made up of a series of zinc-iron
alloy layers that are formed through the reaction of the
ees centigrade.
zinc with the steel at 450 degr
degrees
-

The alloy layers are generally covered by a layer

of free zinc.
The alloy layers have a characteristic pale grey
appearance while the free zinc is shiny when first
galvanized.

Some galvanized coatings will have a spangled

appearance due to trace elements in the zinc coating.
The combination of alloy layers and free zinc and their
proportion in the coating are important in determining
the flexibility and durability of the coating.

The free zinc is relatively soft (about 70 Diamond

Hardness). The alloy layers range in
Pyramid Hardness
hardness up to 240 DPN in the thicker Delta layers
on
which contain 7 to 12% ir
iron
on. This is considerably
harder than 250 Grade steel, which is typically 160
DPN.
The continuously galvanized coatings have very thin
alloy layers and are thus capable of being heavily
deformed without delamination of the coating but the
coating is not nearly as abrasion resistant as hot dip
galvanizing.
The general galvanized coatings, with their thicker alloy
layers, are not as flexible but have a much higher
5X that of continuously
abrasion resistance (5X
galvanized coatings) and are also typically 4-5 times
as thick .
28

GAL
VANIZED COA
TING METHODS
GALV
COATING
There are a number of methods of applying zinc coatings and each will determine the coating s thickness
and its ultimate durabilty in a specific environments

2. MECHANICAL PLA
TING involves tumbling the
PLATING
items to be coated in zinc powder with glass beads and
special reducing agents to bond the zinc particles to the
steel surface.

The most commonly encountered types of zinc coatings are:

Coating characteristics: The mechanical plating

processis used to apply zinc or alloy coatings to fasteners
and small parts. The zinc particles are in lamellar form
and durability equivalent to hot dip coatings can be
achieved in a uniform coating that is particularly suited
to threaded fasteners and hardened TEK type screws
that are unsuitable for hot dip galvanizing. These
ons thick.
coatings are typically 15 - 20 micr
microns

1. Zinc electr
oplating
electroplating
2. Mechanical plating
3. Sherardising
4. Continuously galvanized sheet
5. Continuously galvanized wir
wiree
6. Galvanized pipe and tube
7. General or hot dip galvanizing
8. Zinc metal spraying

3. SHERARDIZING involves heating the articles to

be coated in zinc powder to approximately 400oC at
which temperature diffusion bonding of the zinc with
the steel occurs.

A brief description of each application process and the

characteristics of the coating formed is as follows:
1. ZINC ELECTROPLA
TING involves immersion
ELECTROPLATING
of the items to be coated in a solution containing zinc
ions and applying an electric current to uniformly coat
the surface.

Coating characteristics: Sherardised coatings are

diffusion coatings whose thickness can be varied
ons and whose
considerably up to over 300 micr
microns
constituents can be modified by adding other metal or
inorganic compounds to the zinc powder. The
sherardized coatings are almost entirely made up of ironzinc alloy phases. The long cycle times for the process
make application costly. It is now rarely used.

Coating characteristics: Zinc electroplated coatings

are bright coatings that are thin - typically around 5-10
micr
ons and are not suitable for exterior use where
microns
durability is required. Heavy chromate coatings are frequently applied to zinc platings to improve their durability, especially for fastener applications. The coating
is all pure zinc and lacks the hard alloy layers of the
hot dipped coatings.

4. CONTINUOUS STRIP GAL

VANIZING involves
GALV
passing coil steel through a bath of molten zinc in a
controlled reducing atmosphere at high speed (180 m/
min)
min).
Coating characteristics: The zinc coating thickness is
closely controlled in the manufacturing process by air
wiping of the sheet as it emerges from the galvanizing
bath. The coating thickness varies from an average of
7 micr
ons on ZI00 sheet to 42 micr
ons on the heaviest
microns
microns
Z600 sheet
sheet. The coating has a very thin zinc-iron alloy
layer which gives it its flexibility for pressing and
forming.
5. CONTINUOUSL
Y GAL
VANIZED WIRE is
CONTINUOUSLY
GALV
produced by passing cleaned steel wire through a lead/
zinc bath at high speed ( 180 m/min).
Coating characteristics: Similar to those of
continuously galvanized sheet. Coating thickness varies
depending on the diameter and coating grade of the wire
ons in the thinnest standard gauge to 43
from 3 micr
microns
micr
ons in the thickest (8 mm) heavy galvanized grade.
microns
29

GAL
VANIZED COA
TING METHODS (CONT
.)
GALV
COATING
(CONT.)

6. GAL
VANIZED PIPE AND TUBE is produced by
GALV
two methods; one is semi-continuous where stock
lengths of tube are cleaned and passed continuously
ee
through a bath of molten zinc at 450 degr
degree
ees centigrade.
The other method is continuous where strip is formed
into tube from coil and the tube then passed through a
ees centigrade. This
bath of molten zinc at 450 degr
degrees
second method coats the exterior of the tube only.
Coating characteristics: The semi-continuously
applied coating is a conventional galvanized coating
ons
having a coating thickness typically around 65 micr
microns
which consists largely of zinc-iron alloy layers as the
free zinc layer is largely removed through air wiping
during the process. The continuous tube galvanizing
process produces a bright coating which is almost all
free zinc with very thin aloy layers, giving the product
good forming properties. Coating thickness is typically
12-25 micr
ons on the exterior of the tube only.
microns

Most larger diameter pipe products are batch hot

dip galvanized. Smalller sections are galvanized
in semi-continuous or continuous processes.

7. GENERAL OR HOT DIP GALVANIZING

involves preparing work by acid pickling in batches or
on jigs and then dipping the work into a bath of molten
zinc.
Coating characteristics: The typical general galvanized
ons to over 300 micr
ons
coating ranges from 65 micr
microns
microns
depending on the steel analysis, thickness of material
and immersion time in the galvanizing bath. Typical
coating thickness on most general galvanized products
ons.
is 80-100 micr
microns.
8. ZINC MET
AL SPRA
METAL
SPRAYING
YING requires the steel
surface to be cleaned to a Class 3 level and then zinc
wire or zinc powder is sprayed onto the surface with an
oxy-acetylene or plasma flame gun.

Many building products are manufactured from

contunuously galvanized sheet steel. While this
facilitates manufacture, light zinc coatings (typically
20 microns) and exposed steel at cut edges reduce
durability to less than 1/3 that of hot dip galvanized
components.

Coating characteristics: Zinc metal spraying produces

a relatively porous coating that is able to be applied in
ons
any desired thickness but is typically 75-200 micr
microns
ons.
It is used where the size or shape of the article make it
unsuitable for hot dip galvanizing. The availability of
larger galvanizing baths has resulted in it being little
used for other than repairs to galvanized coatings.
General or hot dip galvanizing is largely applied
after fabrication and the immersion process ensures
that all internal and external surfaces are heavily
coated with zinc.

30

FRICTION-GRIP BOL
TING GAL
VANIZED STEEL
BOLTING
GALV

Bolting of steel structures is well suited for use with

hot dip galvanized coatings. Apart from the need to
ensure that the bolts used are hot dip galvanized to the
same standard as the structural steel, designers are
provided with various Australian standards associated
with bolting, including AS1214 - 'Hot dip galvanized
coatings on threaded fasteners', AS 1252 - `High
strength steel bolts with associated nuts and washers.',
AS 1559 - `Fasteners -bolts, nuts and washers for tower
111 - 'ISO metric commercial bolts
construction.', AS 111
112 - `ISO metric hexagon nuts...'
and screws' and AS 111
and AS4100 - `Steel structures'.

Industrial Galvanizers has undertaken extensive test

work in association with the University of Newcastle's
TUNRA research organisation to establish parameters
for post treatment of hot dip galvanized structural
steelwork that will ensure that the coefficient of friction
will meet or exceed 0.35.

Australian Standard 4100 - `Steel structures' assumes

a slip factor of 0.35 for clean as-rolled steel surfaces
with tightly adherent mill scale. In friction-type bolted
joints, all loads in the plane of the joint are transferred
by friction between the mating surfaces. The load can
be transmitted by a friction type joint is dependent on
the clamping force applied by the bolts and the slip
factor of the mating surfaces.

The test work undertaken by TUNRA established that

two techniques will produce coefficients of friction on
hot dip galvanized surfaces exceeding the 0.35
minimum.

AS 4100 permits the use of applied finishes to

connecting surfaces of friction type joints provided that
the slip factor used in design calculations is based on
test evidence.

Where friction grip bolting of structures is required,

consultation with Industrial Galvanizers will allow the
required quality assurance procedures to be
implemented to ensure that design requirements are
satisfied.

These are:
1. Buffing the connecting surfaces during final
inspection to roughen the surfaces.
2. Galvanizing at higher temperature or deferring
quenching to produce fully alloyed `grey' coatings.
Steel metallurgy and section thickness will impact
on the effectiveness of this technique.

A large number of structures such as this have been been friction grip bolted satisfactorily after galvanizing.
Controlled galvanizing techniques combined with post galvanizing treatment of the connecting surfaces by
the galvanizer ensures that coefficients of friction in excess of 0.35 are obtained at the galvanized connections.

31

CORROSION RA
TES OF GAL
VANIZED COA
TINGS
RATES
GALV
COATINGS
In most environments, the corrosion rate of of
galvanized (and zinc) coatings is proportional to its
thickness.
When selecting components to be used in conjunction
with hot dip galvanized coatings, it is essential to
ensure that their coating thickness is equivalent to that
of hot dip galvanizing.
All pre-galvanized products have much thinner zinc
coatings than their hot dip galvanized equivalents. The
following basic rules should be applied:
1. Do NOT use zinc plated fasteners for heavy duty
applications.
2 Specify hot dip galvanized purlins and girts in hot
dip galvanized structures. Z300 galvanized coatings
on roll-formed structural sections are typically only
20 microns in thickness and have exposed steel at
cut edges. Coating life is typically 20% that of
equivalent section hot dip galvanized products.
3. Do NOT use continuously coated tube and sections
for heavy duty applications. These coatings are
typically 12 - 25 microns in thickness and the hollow
sections are not internally coated.

In non-atmospheric exposures (contact with chemicals,

buried in soil, immersion in potable and ground waters),
the corrosion rate of zinc will depend on the following
factors:
1. pH of the liquid (galvanized/zinc coatings perform
best in the pH range from 6-10
6-10)
2. Time of wetness ( prolonged periods of wetness with
rainwater or condensation will increase
corrosion rate by 2X or more).
3. Contact with electrochemically incompatible metals
(copper, brass, stainless steel) will result in very high
zinc corrosion rates.
4. Splash zone exposure in both marine and fresh water
prevents the formation of stabilizing oxide films and
will result in higher zinc corrosion rates.
NOTE: For any specific environment, the suitability
of hot dip galvanizing can be quickly determined through
a site audit of environmental and chemical exposure
conditions, and evaluation of process water quality.

GAL
VANIZED COA
TING CORROSION RA
TES IN A
TMOSPHERIC ENVIRONMENTS
GALV
COATING
RATES
ATMOSPHERIC
Atmospheric Environment

Corrosion rate range - microns per year

Rural - dry, 600 mm annual rainfall or lower Residential - non-industrial, over 600 mm annual rainfall Tropical - over 1000 mm annual rainfall, high average humidity Industrial - External Industrial - Internal (fumes, vapour, steam) Coastal - 100 to 500 metres from ocean surf Marine - oceanfront / surfside -

32

1-2 microns
2-3 microns
5-8 microns
3-5 microns
5-8 microns
5-8 microns
8-15 microns

SURF
ACE AREA T
ABLES
SURFACE
TABLES

While hot dip galvanizing is usually priced in dollars per tonne, it is desirable to also convert this to
dollars per square metre to allow comparison with alternative coatings.
In addition, the conversion to square metres allows accurate estimation of weight increase through
the addition of the hot dip galvanized coating. The surface area per tonne can also be calculated
using the following formula:
Surface ar
ea per tonne
area

________ 255________
Section thickness in mm

Mass per square metre of steel can be calculated using the following formula:
Mass per squar
squaree metr
metree (kg/m2)

Section
thickness
mm

Mass/m 2
kg/m2

1 mm
2 mm
3 mm
4 mm
5 mm
6 mm
8 mm
10 mm
12 mm
15 mm
20 mm
25 mm

Surface ar
ea/tonne
area/tonne
m2/tonne

255
127
64
85
51
42
32
25
21
17
13
10

7.85
15.70
23.55
31.40
39.25
47.10
62.80
78.50
94.20
1117.75
17.75
157.00
196.25

section thickness in mm x 7.85.

Min coating thickness

micr
ons -per AS 1650*
microns

Mass incr
ease
increase
%**

45 micr
ons (320 g/m2)
microns
55 micr
ons (390 g/m2)
microns
55 micr
ons (390 g/m2)
microns
70 micr
ons (500 g/m2)
microns
70 micr
ons (500 g/m2)
microns
70 micr
ons (500 g/m2)
microns
85 micr
ons (600 g/m2)
microns
85 micr
ons (600 g/m2)
microns
85 micr
ons (600 g/m2)
microns
85 micr
ons (600 g/m2)
microns
85 micr
ons (600 g/m2)
microns
85 micr
ons (600 g/m2)
microns

4.10%
2.85%
1.65%.
1.59%
1.25%.
1.05%
0.95%
0.75%.
0.65%
0.50%
0.40%
0.30%

* Hot rolled steel sections and heavier steel sections will generate galvanized coatings considerably
thicker than required by the AS 1650 Standard. To convert coating thickness in microns to equivalent
coating mass in grams per square metre (g/m2), use the following formula:
Coating mass (g/m2)
Coating thickness (micr
ons)
(microns)

=
=

Coating thickness in micr

ons x 7.05
microns
Coating mass (g/m 2) x 0.14

** Actual zinc pickup after galvanizing will depend on average coating thickness and section design.
Poor drainage, zinc entrapment and large horizontal surfaces will result in higher zinc pickup.
NOTE: Actual zinc usage in hot dip galvanizing is significantly higher than physical zinc pickup.
Zinc usage in hot dip galvanizing is typically 5-7% of the mass of steel dipped because of zinc consumed
on jigs and in generating zinc ash and zinc dross in the galvanizing process.

33

INSPECTION OF GAL
VANIZED PRODUCTS
GALV
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,, less smooth coating is obtained on job galvanized articles compared with continuously galvanized sheet or wire.
2.
A thicker
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)

GAL
VANIZED COA
TING APPEARANCE
GALV
COATING
AND DEFECTS
There are a number of common types of defects arising
from the hot dip galvanizing process. An explanation
of the causes of defects and variations in appearance
follows:
1. Ungalvanized weld ar
eas. Coating misses on weld
areas.
areas are caused by the presence of welding slag on the
welds. All welding slag must be removed by the
fabricator prior to despatch to the galvanizer. These
areas require repair.

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.

INSPECTION OF GAL
VANIZED PRODUCTS (CONT
.)
GALV
(CONT.)
3. Dull gray or mottled coatings. Reactive steels will
generate thicker galvanized coatings that are duller than
standard coatings. These coatings have longer life
because of their greater thickness and their appearance
is a function of steel metallurgy and generally beyond
the control of the galvanizer.
4. Dr
oss pimples/inclusions. Dross is formed in the
Dross
galvanizing process in the form or zinc-iron crystals
on
(approx 95% zinc - 5% ir
iron
on) with a higher melting
point that the metal in the zinc bath. Dross trapped in
the galvanized coating may give the coating a rough or
gritty appearance. The presence of dross inclusions in
the coatings is not detrimetal to the coating's
performance as the corrosion resistance of zinc dross
is identical to that of the galvanized coating
5. White storage staining. After galvanizing, items
stored or stacked in wet, poorly ventilated conditions
will react with atmospheric moisture to form bulky
white zinc hydroxide deposits on the surface of the
galvanized coating.

6. Ash staining. Zinc ash is formed in the galvanizing

process as the work is immersed in the zinc. The ash
formed is skimmed off the surface of the molten zinc
prior to withdrawing the work from the galvanizing
bath. Sometimes, ash is trapped inside inaccessible
areas and sticks to the outside of the coating as the
work exits the bath. Ash may leave a dull surface
appearance or a light brown stain after removal. It does
not affect the performance of the galvanized coating.
7. Striations and general surface irr
egularities.
irregularities.
Ridges and lines thicker than the adjacent galvanized
coating are caused by different rates of reaction of the
zinc with the steel surface due to stress areas on the
steel surface or the presence of weld areas or weld metal
with modified metallurgy to the parent metal. This
phenomenon is most commonly encounted on pipe and
tube products.Coating performance is unaffected
8. Runs, drainage spikes and puddling. These defects
are unavoidable in the hot dip galvanizing of general
items and are acceptable as long as they do not interfere
with the assembly of the function of the item or present
a safety hazard in handling or service.
9. Bar
Baree patches. Uncoated areas on the surface of
galvanized work are due to poor surface preparation;
inadequate pretreatment in degreasing, pickling and prefluxing. These areas must be repaired using a
recommended repair method or the item regalvanized
if the defect is of sufficient size.

Dross pimples are formed when dross crystals

present in the molten zinc are caught up in the
coating, giving the surface a grity appearance.(lower
section). The textures and striated galvanized
surface on the upper steel component is caused by
the surface metallurgy of the steel producing
differing micro reactive zones on the surface.

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.

Chain marks are unavoidable when galvanizing large

items. These defects are normally buffed off during
dressing and inspection

35

Galvanizing appearance and defects (cont)

10. Rust staining. Uncoated steel in contact
with galvanized coatings will accelerate corrosion of
the coating and stain the coating brown in the area of
contact. This can be removed by wire brushing.

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.

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.

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.

Industrial Galvanizers Services

Industrial Galvanizers Corporation has a network of
hot dip galvanizing operations throughout Australia and
in South East Asia and the USA.
The group processes over 100,000 tonnes of steel
annually and offers a range of specialised services
associated with the efficient provision of hot dip
galvanized coatings to steel.
Some of the groups hot dip galvanizing capabilities
include:
-

24 hour turnaround on negotiated contract

galvanizing.

Heavy lift galvanizing (exceeding 20 tonnes) in

specific plants.

Large bath sizes in most major centres to

accommodate long or wide fabrications

Project management capabilities to co-ordinate

steel to construction site.

Design assistance in detailing project steelwork

to facilitate galvanizing and reduce coating time
and cost.
36

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.

INDUSTRIAL GAL
VANIZERS CAP
ABILITIES
GALV
CAPABILITIES
The galvanizing plants within the Industrial Galvanizers
Group galvanizers a wide variety of fabricated
steelwork. These examples illustrate the capabilities
within the group.

With the world's largest galvanizing bath

in Newcsatle, NSW, very large items can be
galvanized within the IG Group.

Galvanizing Industries, Industrial Galvanizers

Melbourne Vic plant can galvanize sections over
22 metres in length .

Stadium lighting tower segments, manufactured

by Riverton Engineering in Perth , WA were able
to be galvanized in NSW and Qld plant to supply
a Qld project.

All of Industrial Galvanizers plants have a large

customer base providing a wide variety of
products. Accurate work tracking systems are
in place to account for this diversity of products.

Above: This marine lead light tower was hot dip

galvanized and painted with Industrial Galvanizers
administering the application of the total coating system.
Left: Industrial Galvanizers pioneered the hot dip
galvanizing of railway bridge beams, each
weighing over 9 tonnes

37

GAL
VANIC CORROSION
GALV
While hot dip galvanized coatings provide envelope
protection for steel, the zinc in the coating will also
protect the steel cathodically if the coating is
damaged and the bare steel exposed.

should be avoided where electolyte forming

moisture is likely to be present.

The rate of consumption of the galvanized coating

will depend on the size of the cathode (the bare
steel) and the size of the anode) the galvanized
coating). It is essential that exposure of galvanized
coatings to cathodic metals and materials be
minimised to prevent accelerated corrosion of the
galvanized coating.
The following table lists metals in order of their
relative reactivity with each other and when
considering coatings and materials for maximim
durabality, contact between dissimilar metals

GENERAL INFORMA
TION ABOUT ZINC AND STEEL
INFORMATION

Steel

Zinc
Atomic weight
olled
Density
- rrolled
- cast
- liquid
Melting point
Boiling point
Thermal conductivity

65.37
7192 kg/m3
6804 kg/m3
6620 kg/m3
419.5oC
907oC
113 W/m.K

38

Atomic weight
55.85
Density
7850 kg/m3
Melting point
1540 oC
Boiling point
2900 oC
Thermal conductivity 57 W/m.K

PERTINENT GALVANIZING STANDARDS

Standards

Australia

AS 1650
AS 1214
AS 1250
AS 1394
AS 1074
AS 1397

Standards

Hot Dip Galvanized Coatings on Ferrous Articles

Hot Dip Galvanized Coatings on Threaded Fasteners
SAA Steel Structures Code
Round Steel Wires for Ropes
Steel Tubes and Tubulars
Steel Sheet and Strip - Hot-dipped Zinc Coated and Alimimnium/zinc
Coated Steel
Guide to the Protection of Iron and Steel in Atmospheric Environments
Methods of Test for Metallic and Related Coatings - Magnetic Method

AS 2312
AS 2331.1.3

New Zealand Standards

BS 729*
BS 443*
Ministry of Works
Ministry of Works
*

British

American
A90
A123
A143

A153
A325
A384
A385
A394
A780
B6
E376

Canadian
G164-M

Hot Dip Galvanized Coatings on Iron and Steel Articles

Galvanized Coatings on Wire
MOW CD306 Specification for Hot Dip Galvanizing on Structural
Steel Work.
MOW CD307 Specification for Protection of Structural Steel Work

Standards
Society

for

Testing

and

Material

Test Methods for Weight of Coatings on Zinc Coated (Galvanized) Iron or

Steel Articles
Zinc (Hot Dip Galvanized) Coatings on Iron and Steel Products
Recommended Practice for Safeguarding Against Embrittlement of Hot Dip
Galvanized Structural Steel Products and Procedure for Detecting
Embrittlement
Zinc Coating (Hot Dip) on Iron and Steel Hardware
High-Strength Bolts for Structural Steel Joints, including Suitable Nuts and
Plain Hardened Washers
Recommended Practice for Safeguarding Against Warpage and Distortion
During Hot Dip Galvanizing of Steel Assemblies
Recommended Practice for Providing High Quality Zinc Coatings (Hot Dip)
on Assembled Products
Galvanized Steel Transmission Tower Bolts and Nuts
Practice for Repair of Damaged Hot-Dip Galvanized Coatings
Zinc Metal (Slab Zinc)
Recommended Practice for Measuring Coating Thickness by Magnetic-Field
or Eddy-Current (Electromagnetic) Test Methods
Standards

Association

Hot Dip Galvanizing of Irregularly Shaped Articles.

39