Galvanizing Defects Rectifications

Galvanizing Defect & Repair Methods
Legend: A- Accept R-Reject N- Negotiate C- Clean REP- Repair
Responsibility: G- Galvanized D- Designer B- Builder / Fabricator S- Steel Type / Surface
Prepared By:
M.Sreedhar Patnaik
In charge-Process & QA
Visakha Steel Allieds
S.No. Description Cause Effect / Remedy / A/R/N/C/
Responsibility REP
1 APPEARANCE OF Although the recommended quantity Maintain concentration of
SODIUM of sodium dichromate is about 0.15 Sodium dichromate at about A
DICHROMATE. to 0.3 %, occasionally when topping 0.15 to 0.30 %.
A small amount of up, more is added. This often results G
sodium dichromate in a dark yellow to brown colour on
is generally added the galvanized surface. The darker
to the quench water colour will provide enhanced initial
bath for passivation. corrosion protection.
2 ASH DEPOSITS. Zinc oxide deposits cool take place The coating is normally intact A/N
Ash deposits are when the component is dipped or underneath the ash deposits.
grey, non-metallic when it is removed from the bath. Ash must be removed and the
deposits consisting coating thickness verified for
of zinc oxide that conformance to the
have been deposited specification requirements. REP
on the hot dip Remove ash from all liquid If
galvanized coating. conveyance pipes necessary
S.No. Description Cause A/R/N/C/

REP
3 BARE SPOTS. There are several causes of bare spots. A/R

Although excluded These include:
from ISo 1461, bare Over drying. If the time between fluxing and hot dip galvanizing is
spots of about 5mm prolonged or the drying temperature is toe high, the barrier protection
(2.2 x 2.2mm), due provided by the flux may be lost. This is indicated by a rusty
to small localized appearance on the ungalvanized article, which can result in coating
flows, ore discontinuities after hot dip galvanizing. G
adequately
protected by the Excess Aluminium. A condition some times referred to as black spots
sacrificial properties may occur if the aluminium content of a bath becomes too high. No
of zinc and will trouble should be experienced if flux concentration is correct and the
have very little aluminium content of the bath is maintained below approximately
Prepared By:
effect on the service 0.007%. G
M.Sreedhar Patnaik REP
life of the coaling.
In charge-Process & QA If necessary
Where necessary, Further causes are:
such spots may be Blowouts: flux deposits: stains and inclusions; mechanical damage;
repaired using one touch marks; uncoated surfaces caused by surface contaminants, scale
of the specified or sand; welds and weld spatter.
S.No. Description Cause Effect / Remedy / A/R/N/

Responsibility C / REP
4 BLACK STEEL Components should be checked for Insufficient inspection prior to A/R
INSPECTION. distortion caused during rolling or hot dip galvanizing can be the
Inspection prior to hot fabrication. Check for appropriate causes of dispute. G
dip galvanizing is vent, fill and drainage holes;
extremely important. removal of weld slag and spatter;
venting of overlapping surfaces;
temporary identification markings;
clearance for moving ports and
potential distortion due to the
process.
Incurred nozzle pressure; nozzle

5. BLASTING angle; sweeping distance; size of A hot dip galvanized coating
DAMAGE. abrasive and recycling of grit. wi8 be partially or fully R
Sweep blasting, done destroyed by excessive blasting.
correctly, Refer to the HDGASA Cede of
substantially increases practice.
paint adhesion and D/B
final coating
appearance hut done
incorrectly can result
in coating damage.
Prepared By:
M.Sreedhar Patnaik

6 BLOWOUTS. Pre-treatment chemicals Pre-heat item prior to immersion A

Staining and coating penetrating sealed overlap areas in zinc bath to dry out overlap
defects around through the required vent holes and area as much as possible.
unsealed weld areas escaping during immersion in the
and vent holes, molten zinc. This effect tends to D/G
similar to stains damage the flux coating, causing
ceased by weeping. localized uncoated areas. C/ REP
If
Necessary
Molten zinc has a high surface Make holes as large as possible.

7 CLOGGED HOLES. tension and will not easily drain Removal of molten zinc over the
Zinc film clogging or from holes under 8mm in diameter. bath and utilization of vibrators
partly bridging holes. will reduce the likelihood of A
clogging.
D/G
C
If
Required
Prepared By:
M.Sreedhar Patnaik

8. CLOGGED Insufficient centrifuging or poor The correct centrifuging R

THREADS. drainage of threaded attachments equipment or post galvanizing
Threaded components on withdrawal from the galvanizing thread cleaning by heating, wire
or attachments have bath. brushing or oversize tapping of
threads dogged with nuts, will generally remove
zinc. clogging. If necessary specify C / REP
delivery of bolts and nuts in
nutted up farm.
G
DESIGN
9. STRUCTURES IN Double dipping can sometimes be Touch up and repair can be A
MODULAR used to hot dip galvanize avoided, the cost of hot dip
LENGTHS AND fabrications that are too long or galvanizing reduced and the
OPTIMUM WIDTHS wide far single immersion. If the overall quality improved, if the
TO SUIT fabrication exceeds the bath size, design of the component is
AVAILABLE BATH members in the fabrication may restricted to the length, width C / REP
SIZES. require touching up. and depth of the galvanizing
bath.
D/B
DISCOLOURING
10. AFTER HOT DIP Material stored in contact with Once the cause has been A
GALVANIZING rusty steel, or iron filings can cause removed the stain will gradually
CAUSED BY surface rust staining. disappear.
GRINDING OR B C
OTHER RESIDUES. If
Possible
Prepared By:
M.Sreedhar Patnaik

11. DISTORTION. The hot dip galvanizing process Use symmetrical designs; Use A/N
Distortion is the occurs all molten zinc temperature sections of similar thickness;
unwanted warping of 450deg C. This is at the lower Stiffen un supported thin will
that occasionally end of the stress relieving sections; Use performed
becomes evident after temperature for treating steel. Thus, members with the correct
hot dip galvanizing. any inherent rolling or welding minimum bend radii; Use
stresses in the fabrication, are likely balanced or staggered welding REP
to be released. This may result in a techniques; Make use of If
dimensional change, i.e. distortion. temporary braces on thin walled possible
sections such as troughs,
cylinders and angle frames.
Avoid quenching after
galvanizing. Components can be
straightened after hot dip
galvanizing.
D/G
The edge most likely to have these A/N
12. DRAINAGE spikes is the last to leave the bath Drainage spikes are easily
SPIKES. on withdrawal. This applies removed at the bath while still
Spikes and teardrops particularly to complex molten but with complex
of zinc often appear fabrications. fabrications, the solidified C / REP
along the edge of a spikes will be removed by IF
component after hot fettling by the galvanizer prior Possible
dip galvanizing. to inspection. G
Prepared By:
M.Sreedhar Patnaik
S.No. Description Cause Effect / Remedy / A/R/N/C/
Responsibility REP
13. DROSS. Gross Dross deposit from the Dross consists of the same R/N
Dross particles are bottom of the zinc bath, trapped in iron/zinc alloy as the coating, it Mechanically
iron/zinc alloy the corner of a fabrication. The will provide the same corrosion remove if
crystals produced dross incorporated in the coating protection as a normal hot dip possible,
when hot dip prevents drainage of the zinc in the galvanized coating. G repair or re-
galvanizing steel. intermediate area and a build up galvanize
These precipitation to occurs.
the bottom of the bath C/REP
and are removed by IF
the galvanizer. necessary
14. DULL GREY OR This appearance indicates the Although not as aesthetically
MOTTLED presence of extensive iron/zinc pleasing as a coating with free
COATING alloy phase growth mused by steels zinc on the surface, a dull grey A
APPEARANCE. with high reactive levels of silicon coating provides similar or
Dull grey or mottled and phosphorous in steels. hotter corrosion protection.
coatings can appear as D/S
a dark grey circular
patter, a localized dull
patch or, may extend
over the entire surface
of the component
FLAKING OR
15. DELAMINATION High phosphorous content (greater Use a steel that has a
OF COATING. than 0.03% causes entire coating to phosphorous content of lower R/N
No adhesion of zinc delaminate from the steel. than 0.03%
to steel surface. D/S
Thick, rough coating.
Prepared By:
M.Sreedhar Patnaik
FLUX DEPOSITS,
Visakha STAINS
16. Steel Allieds
AND Flux deposits or stains may occur Flux deposits or stains should be
INCLUSION. as a result of excessive “dusting” removed and the underl~4ng
Flux deposits or stains with ammonium chloride on coating measured to determine A

17. DISCOLOURATION Inadequate repair of a damaged Make use of the correct repair
OF THE PAINT surface on the hot dip galvanized materials and application R
COATING OVER coating prier to the application of a procedures when touching up
HOT DIP paint coating. cut or welded hot dip galvanized
GALVANIGING components,
AFTER EXPOSURE REP
TO THE B
ENVIRONMENT.
18. COATING No matter how the zinc coating is Specify hot dip galvanized R
THICKNESS applied, the coating life is fasteners to ISO 1461, where
PROVIDED ON proportional to its thickness in a required. Alternatively overcoat
FASTENERS USE given environment. Often fastener with an approved zinc
TO ASSEMBLE electroplated fasteners with rich point or epoxy.
HOT DIP insufficient coating thickness are
GALVANIZED incorrectly used in external D/B
STRUCTURES environments. C / REP
If
acceptable
Prepared By:
M.Sreedhar Patnaik

19. MECHANICAL The use of chains, wire ropes, Warming labels, highlighting a A
DAMAGE. dragging or dropping of the thick coating and possible
Mechanical handling component onto a hard surface, can damage if manhandled, should
or transport damage cause mechanical damage. This is be attached by the galvanizer,
may occur, particularly relevant with thick before the component is REP
particularly with brittle coatings. transported. The use of nylon If
extremely thick lifting slings is recommended. necessary
coatings, which tend G/B
to be brittle in nature.
20. OXIDE LINES. Due to the shape and / or drainage No effect on corrosion A
Light aluminium conditions of some components, resistance. The overall
oxide film lines on the hoist crane has stopped and appearance becomes uniform in
hot dip galvanized started upon withdrawal of the time. G
surface. items from the molten zinc.
Prepared By:
M.Sreedhar Patnaik

21. PIMPLES OR Dross pimples result from agitation of The galvanizer should avoid A
BLISTERS. the dross layer at the bottom of the bath disturbing the dross layer at the
Pimples or blisters or from dragging material through the bottom of the bath by
formed during hot dip dross layer. They appear as small, hard controlling immersion depths
galvanizing are lumps on an otherwise normal and dressing regularly. Since C
usually associated galvanized surface. Blisters may be dross pimples represent minor If
with surface formed by hydrogen, which is absorbed disturbances in coating necessary
imperfections such as daring pickling and diffused at uniformity, they do not affect
dross inclusions. galvanizing temperatures. corrosion resistance.
G
22. REACTIVE AND This difference in coating thickness, is

NON-REACTIVE brought about by a combination of a
STEELS WELDED more reactive silicon killed steel,
TOGETHER. and/or high phosphorous resulting in a
Variations in coating thicker coating and a less reactive
thickness can arise aluminium killed steel, resulting in a
when reactive and coating thickness sometimes below
non-reactive steels are that required in the specifications.
welded together. should the galvanizer be asked to re-
Efforts to increase galvanize in accordance with the
coating thickness on specification, the resultant coating
the less reactive steel thickness on the reactive steel will be
may result in an excessively thick, resulting in a brittle
undesirably thick and coating more susceptible to damage
brittle coating on the
most reactive steel.
Prepared By:
M.Sreedhar Patnaik
Prepared By:
M.Sreedhar Patnaik

23. REMOVAL OF Excessive cleaning of the coating, The affected areas usually only R
ZINC COATING BY particularly the edges, by mechanical appear after the component is
EXCESSIVE methods, can result in uncoated areas. installed. Care should be
CLEANING. exercised by the galvanizer to
Unless otherwise avoid over cleaning. REP
agreed, the galvanizer G/B At the
will limit cleaning of galvanizer or
the final coating by alternatively
mechanical means to at site
that required in the
specification.
A
24. ROLLING DEFECTS Steel may occasionally include Surface flaws in the base
IN STEEL. laminations, laps, folds and material may be removed by
These defects maybe nonmetallic impurities, which result in local grinding after hot dip
broadly classified as silvers rolled into the metal surface. galvanizing followed by repair
surface discontinuities Defects of this type are sometimes of the affected surface. Minor
in the steel that have detected before or after pickling, but surface defects will not REP
been elongated during may only become apparent after hot adversely influence coating life. If
rolling. dip galvanizing. S necessary
Prepared By:
M.Sreedhar Patnaik
Prepared By:
M.Sreedhar Patnaik
S.No. Desciption Cause Effect / Remedy / A/R/N/

25. ROUGH Rough surfaces, typical of coatings on The rougher surface will A
COATINGS, corroded steel surfaces, can be hot dip produce a thicker coating and
CAUSED BY STEEL galvanized satisfactorily. The coating result in a longer service life.
SURFACE will, however, reflect the texture of the S
CONDITIONS. substrate. Other causes of rough
surfaces include uneven cold working,
over pickling, a high galvanizing
temperature and / or extended
immersion in the molten zinc.
26. ROUGH HEAVY Rough, heavy coatings refer to hot dip A/R
COATINGS, galvanized components showing
CAUSED BY A markedly rough surfaces. This can
ROUGH SURFACE include coatings that have a generally
AND / OR THE rough surface and, in some cases,
CHEMICAL groove type surface configurations,
COMPOSITION OF “tree bark effect” caused by variations
THE STEEL “TREE in surface steel analysis.
BARK EFFECT”
Prepared By:
M.Sreedhar Patnaik
Prepared By:
M.Sreedhar Patnaik

27. ROUGH HEAVY Efficient centrifuging, will generally Provided the steel/casting R
COATINGS remove excess zinc and provide a surface is reasonably smooth,
CAUSED BY smooth and attractive exterior. correctly centrifuged articles
INSUFFICIENT will provide an acceptable
CENTRIFUGING finish, C / REP
G If
acceptable
28. STAINS CAUSED The Salts from acid or flex that have The stain can be easily removed A
BY WEEPING penetrated porous welding or between by means of bristle brushing.
contact surfaces during pickling can Should the component be
weep after hot dip galvanizing and destined for a corrosive area, the
water quenching, producing a stained crevice should be sealed with a
C / REP
area. sealant after cleaning.
If
D/B
necessary
29. TIGHTLY Heavy walls and thick flanges used in The galvanizer should ensure all R
ADHERENT LUMPS the manufacture of piping can act as a zinc hen been removed from the
OF ZINC ON THE heat sink when immersed in molten aside of the pipe by longer
INSIDE OF HEAVY zinc. This effect considerably lengthens immersion times.
WALLED STEEL the immersion time. Occasionally the G C / REP
PIPING. galvanizer will remove the pipes before If
all the zinc has melted from the inside acceptable
of the pipe.
Prepared By:
M.Sreedhar Patnaik
Prepared By:
M.Sreedhar Patnaik

30 TOUCH MARKS. Articles entering the galvanizing baths Minimize contact between A
The zinc in the should not be in tight contact with each components and jig connections.
galvanizing bath other. Jigging wire should also be (Loosen jigging wire). Small
should have free loosely attached to eliminate wire components can be centrifuged.
access to all marks. Where a component has been REP
component surfaces resting on jigging or dipping G If necessary
or small unmated or equipment, an uncoated area and touch and
damaged areas can mark could appear. acceptable
result.
Small additions of aluminium to
31 TYPICAL Surface appearances may very the molten zinc, brightness the A
SPANGLED HOT according to the chemical composition coating.
DIP GALVANIZED of the steel. Cooling rate has a direct
COATING. A typical effect on the surface brightness and S/G
hot dip galvanized spangle size. Easter cooling usually
surface is shown in results in a brighter coating with a
the example. The smaller spangle size.
surface is silver grey
in color and not
necessary but often
has a spangled effect
(Zinc Crystals) in a
range of sizes.
Prepared By:
M.Sreedhar Patnaik
Prepared By:
M.Sreedhar Patnaik

32. UNEVEN The condition can occur over the entire Although not particularly A
DRAINAGE. Uneven surface grin isolated areas. Uneven attractive, this condition dons
drainage results in an drainage also includes drips and the not adversely affect coating
uneven or lumpy area ends of pots, runs near halos. The cause performance. Protuberances and
on which zinc build is withdrawal speed too high or low lumps, which interfere with C
up has occurred. galvanizing temperature. mating surfaces are If
unacceptable. necessary
G
A/N/R
33. UNCOATED Residues, such as oil based paint, Ensure all paint or grease is
SURFACES grease, oil or labels on the steel surface removed prior to hot dip
CAUSED BY STEEL or incorrectly positioned vent holes, galvanizing. Make usual suitable
SURFACE can result in localized un-galvanized marking pens for temporary
CONTAMINANTS areas in an otherwise continuous identification. Correctly position
OR ENTRAPPED galvanized coating. Defects after adequately sized vent hubs.
AIR. galvanizing can very in color from grey B
black to brown while no galvanized REP
coating has been formed. If
necessary
Prepared By:
M.Sreedhar Patnaik
Prepared By:
M.Sreedhar Patnaik

34. UNGALVANIZED Sand on cast iron or scale on the steel These un-galvanized areas may R/N
SURFACES surface is generally caused by the occur in a linear pattern on
CAUSED BY process used to form or roll the angles, channels or other rolled
SCALE OR SAND. product. A localized un-galvanized products. They can also appear
area in an otherwise continuous coating on cast iron products. REP
can occur if scale or sand from the S/G If
moulding or rolling is not removed by acceptable
acid pickling or abrasive blasting.
35. UNGALVANIZED A localized un-galvanized area near a Weld slag deposits should be R/N
AREA IN THE weld can be caused by weld slug removed by the fabricator by
VICINITY OF A deposit, weld porosity or weld means of abrasive blast
WELD. undercut. Oxide deposits and residues cleaning. The deposit can also
from welding area resistant to normal be removed by proper chipping
pickling adds and mint be removed or wire brushing. Shielded arc
before the work is pickled and hot dip welding as opposed to slick
galvanized. welding is preferred for REP
components which are to ho hot If
dip galvanized. necessary
B
Prepared By:
M.Sreedhar Patnaik
Prepared By:
M.Sreedhar Patnaik

36. USE Conventional drilling and bolting after Coating repair can be done by A
CONVENTIONAL hot dip galvanizing is preferred. Should zinc metal spraying, zinc rich
FIXING METHODS welding or noon conventional method painter epoxy, providing the
SUCH AS BOLTS of fixing be used, resulting in damage product conforms to the
AND NUTS, OR to the coating, an approved repair requirements of the REP
REPAIR DAMAGED method is necessary. specification.
COATINGS
CAUSED BY D/B
WELDING OR NON
CONVENTIONAL
FIXING METHODS.
WELD SPATTER.
37. Weld spatter is Weld spatter is caused by weld pool Loosely adherent weld spatter A/N
oxidized, normally explosions when improper welding should be removed prior to hot
spherical expelled parameters are used, or if the material dip galvanizing. Although not
weld metal, that is is dirty or contaminated. acceptable in terms of the
fused or not onto the specification the presence of
surrounding material tightly adherent weld spatter
during welding. after hot dip galvanizing will not
affect the corrosion resistant
properties of the coating.
B
Prepared By:
M.Sreedhar Patnaik
Prepared By:
M.Sreedhar Patnaik

38.. WET STORAGE Wet storage stain (Zinc hydroxide) is Wet storage stain ceases when A
STAIN OR WHITE formed on freshly galvanized surfaces the cause is eliminated. If the
RUST. which are in closed contact in presence coating thickness at the affected
Wet storage stain or of moisture. Freshly galvanized area is equal to, or greater than
white rust as it is coatings react with the environment the minimum required in the C
commonly called, is a until such time as a stable zinc specification, it is not a cause If
white voluminous carbonate film is formed on the for rejection, other than for necessary
deposit that is cooling surface. aesthetic reasons. The latter is
occasionally found on subject to discussion with the
the surface of a end user. Customer during
freshly galvanized transport and storage.
coating. G/B
A
39. ZINC METAL In order for zinc metal spraying to Prepare surface for repair by
SPRAYED REPAIR adhere on application, the damaged adequate blasting. Loosely
APPLIED TO surface must be adequately blasted. As applied zinc metal sprayed
INADEQUATELY it is difficult not to over spray, excess coating at the perimeter of the
BLASTED zinc metal. Spray loosely adheres to the repair should removed by wire
SURFACES OR NOT surrounding coating. brushing if net removed, there is
WIRE BRUSHED no compromise in the corrosion C
AFTER resistance,
APPLICATION. G/B
Prepared By:
M.Sreedhar Patnaik
Prepared By:
M.Sreedhar Patnaik

40. ZING SPLATTER. When hot dip galvanizing an unusually The loosely adherent zinc A
Splashes and flakes of deep fabrication by double dipping , splashes are easily removed.
loosely adherent /zinc, moisture an the surface of the steel An experienced galvanizer can
caused by moisture on contacts with the molten zinc causing ensure the coating overlap on
the steel surface when splashes of zinc to loosely adhere hot double end dipped surface. Is C
hot dip galvanizing dip galvanized surface. not visible.
G
Prepared By:
M.Sreedhar Patnaik

Galvanizing Defects Rectifications

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Galvanizing Defects Rectifications

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Galvanizing Defect & Repair Methods

Galvanizing Defect & Repair Methods

Legend: A- Accept R-Reject N- Negotiate C- Clean REP- Repair

Responsibility: G- Galvanized D- Designer B- Builder / Fabricator S- Steel Type / Surface

S.No. Description Cause A/R/N/C/

3 BARE SPOTS. There are several causes of bare spots. A/R

S.No. Description Cause Effect / Remedy / A/R/N/

Incurred nozzle pressure; nozzle

S.No. Description Cause Effect / Remedy / A/R/N/

6 BLOWOUTS. Pre-treatment chemicals Pre-heat item prior to immersion A

Molten zinc has a high surface Make holes as large as possible.

S.No. Description Cause Effect / Remedy / A/R/N/

8. CLOGGED Insufficient centrifuging or poor The correct centrifuging R

S.No. Description Cause Effect / Remedy / A/R/N/

S.No. Description Cause Effect / Remedy / A/R/N/

S.No. Description Cause Effect / Remedy / A/R/N/

S.No. Description Cause Effect / Remedy / A/R/N/

22. REACTIVE AND This difference in coating thickness, is

S.No. Description Cause Effect / Remedy / A/R/N/

S.No. Desciption Cause Effect / Remedy / A/R/N/

S.No. Desciption Cause Effect / Remedy / A/R/N/

S.No. Desciption Cause Effect / Remedy / A/R/N/

S.No. Desciption Cause Effect / Remedy / A/R/N/

S.No. Desciption Cause Effect / Remedy / A/R/N/

S.No. Desciption Cause Effect / Remedy / A/R/N/

S.No. Desciption Cause Effect / Remedy / A/R/N/

S.No. Desciption Cause Effect / Remedy / A/R/N/

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