Sample Galvanizing Procedure +ITP

G. K.
WIRE INDUSTRIES LLC

P.O.Box - 32820 , RAS AL KHAIMAH , United Arab Emirates
RAK - Tel.(9717) 2447970 , FAX.( 9717) 2447515
Head Office, Dubai - Tel.(9714) 8872904 , Fax.(9714) 8816250
E-mail : gabions@emirates.net.ae

PROCEDURE FOR SURFACE PREPARATION
AND HOT DIP GALVANIZING ON FABRICATED
STEEL ITEMS

PROJECT: EPC CPF Phase-1 al BADRA OIL FIELD
CLIENT: Unger Steel Middle East FZE / PETROFAC
P.O NO.: 2013030011
LOCATION: UAE
SUPPLIER: G.K.Wire Industries LLC
DOCUMENT NUMBER: LME- FCP-199-004

REV. ISSUE DATE PURPOSE OF ISSUE PREPARED APPROVED
01 05-09-2012 Customer Specific N.B.Joshi Dhananjay Joshi
02 05-09-2012 Customer Specific N.B.Joshi Dhananjay Joshi

G. K. WIRE INDUSTRIES LLC
RAK - Tel.(9717) 2447970 , FAX.( 9717) 2447515

REVISION HISTORY:

REV DATE DESCRIPTION PREPARED BY APPROVED BY
00 05.09.2012 Customer Specific N.B.Joshi Dhananjay Joshi

.

DEFINITIONS :

Project: EPC CPF Phase-1 al BADRA OIL FIELD

Contractor: PETROFAC / Unger Steel Middle East FZE

Galvanizer: G.K.Wire Industries LLC

RAK - Tel.(9717) 2447970 , FAX.( 9717) 2447515

TABLE OF CONTENTS
2. REFERENCE DOCUMENTS
articles
ple Salt)
( Hot dip Galvanizing ) of steel items
nching process
& Grinding of galvanized Items
k. Inspection
l. Adhesion
m. Repair

1. SCOPE

3. RESPONSIBILITIES
4. PROCEDURE

a. Blasting & Cleaning the surface of steel
b. Degreasing
c. Water Rinse
d. Pickling ( HCL Acid cleaning process )
e. Water Rinsing Process
f. Flux coating process :( Zinc Ammonium Chloride Tri
g. Drying of Articles
h. Zinc coating
i. Water Que
j. Cleaning

RAK - Tel.(9717) 2447970 , FAX.( 9717) 2447515

1. SCOPE
This Process procedure intends to have the clear guidelines for Hot Dip Galvanizing of fabricated Steel
products as per Order specification & Standard code specification requirements applicable to G.K.Wire
2.
on & test method.
related Rust
grades and products preparation grades of uncoated substrates and of steel substrates after
s coatings.
ification for Zinc (Hot-Dip Galvanized) Coatings on Iron and Steel
Products
2013-200-CS-SP-002 Engineering Specification to structural steel work

4.

Industries LLC.
REFERENCE DOCUMENTS
1. BS EN ISO 1461:2009 Hot Dip galvanized coatings on fabricated iron & steel articles-
Specificati
2. ISO8501-1 - Preparation of steel substrates before application of paints and
overall removal of previou
3. ASTM A 123-Standard Spec
4. GB088-
3. RESPONSIBILITI ES
Production Engineer / QC Inspector
PROCEDURE
Preparation for Galvanizing Materials:

a. The Production Engineer decides on the article suspension method either tying or placing them in
suitable fixture taking into consideration the following points,
Articles shape, size, weight & Identification of member number.
Position of venting & drainage holes ( if required )
IG-6.7) if required, shall be drilled as per Job
material requirements. Dia 8 mm to 15 mm as required, if required depending upon shape and size.
rated balance & weight of items recorded in
logbook.
Availability of tying points
b. Vent holes & drainage holes (As per ASTM A385, F
c. Pre-weighing - Articles are weighed on the calib
d. All articles to be galvanized shall be handled in such a manner as to avoid any mechanical damage
and to minimize distortion due to mechanical force.

1) Blasting & Cleaning the surface of steel articles :

a. Articles are blasted with Automatic shot blasting method by using steel shots S-170 grade or other
grades. Used steel shots / scales are collected in drums & refilled with new shots & used shots are
disposed off to authorized dump yard.
ds required according to surface condition of articles.
r White Blast Metal.( SA 2-1/2 grade blasting surface finish (as per
r the contaminant
each article is tilted & shot particles shall be removed from inside portion of each
shaking each other.
b. Articles are blasted to ensure that the surface is entirely free of rust and other visible contaminants.
The shift foreman determines the no. of roun
c. Blasted articles are inspected visually by the Quality control engineer & items shall be shot blasted
to a surface cleanliness of Nea
SSPC,SP10)
d. Any incomplete blasted areas are assessed by QC Inspector to determine whethe
can be removed during the pickling process.
e. After blasting
article by

RAK - Tel.(9717) 2447970 , FAX.( 9717) 2447515

f.
g. ion, venting
drainage.
2 Degreasing
2.2 to 2.5mm dia. Black annealed wire pieces are used for tying the articles to the frames. The
batch articles are spaced along the frame to ensure no contact with each other.
The frames are attached to cranes & the wired articles are checked for uniform distribut
&

)

remove organic contaminants including dirt,
ater based paint markings, grease and oil. Degreased objects are visual inspected for removal of
fted and tilted to drain all solution from articles.

Articles are dipped in batches in degreasing tank to
w
impurities on the surface. Articles are li
3) Water Rinse

After cleaning articles are rinsed in water by immersing in Water bath.
Again articles are lifted and tilted to drain the water.

4) Pickling ( HCL Acid cleaning process )

a. After degreasing, articles are immersed for approx. 2 to 5 minutes in the pickling solution
uring fresh start of acid bath.
the articles for cleanliness after
hieved. Quality
ined & submitted to local Authority for approval. After approval from
ized surface, Black surface, Black spots, pH value 2-3, Iron content (Fe)
150gms/lit. max., HCL concentration % > Complete replacement of old acid from bath.
Acid strength shall be checked every 15 days interval at in-house laboratory & samples are
analyzed for Acid concentration & Iron content. Acid pH shall be checked everyday with pH paper
at the beginning of the shift.
The finished materials are bundled & packed as per job requirements & dispatch note is issued. If
direct delivery is arranged for finished materials then loading requisition note is issued against the

depending upon the size, type, shape and surface condition of the articles. Pickling is performed to
remove mill scales and /or surface rust.
b. Pickling solution comprising of commercial grade HCL acid (33%) diluted with water to
approximately 15% strength d
c. In regular use the shift foreman / QC Inspector visually inspects
pickling process.
d. On rejection articles are repeatedly pickled until the above conditions are achieved.
e. In regular use depending upon the quality of pickled galvanized materials the fresh acid + water in
2: 1 ratio respectively is added directly into the acid bath until the required pH is ac
of Pickled galvanized materials > Heavy coating thickness, Zinc flaking or peeling / chipping of zinc
> Replenished the acid bath.
f. HCL Concentration > Min.17 - 18% & Required pH Value > Min. 7
g. If the acid is found weaker for process then it is collected in containers which are neutralized to
7pH by adding caustic soda & samples are sent to an independent laboratory for analysis. Test
analysis certificate to be obta
Local Authority, this neutralized acid is disposed off to approve dump yard location.
h. Following Criteria is used for changing the complete acid from bath : Weaker Acid strength >
Blisters on galvan
i.
j.
loaded materials.

RAK - Tel.(9717) 2447970 , FAX.( 9717) 2447515

5) Water Rinsing Process :

a. Pickled articles are dipped into the rinsing bath completely & suspended over the bath until water
no longer pours off.
(pH <3).
b. Samples from rinsing water bath checked with pH paper every 7 days for determining the pH value,
results are recorded. Fresh water shall be added when water becomes too acidic

6) Flux coating process :( Zinc Ammonium Chloride Triple Salt)

a. Rinsed articles immersed in the flux bath for a minimum of two minutes, withdrawn & suspended
above the bath until flux is no longer runs off. Flux coating is performed to remove / dissolve
oxides of iron, which had formed after pickling also flux coating acts as anti oxidation coating on
esh start of Flux bath.
. Density of flux is maintained 22 30 Baume & flux bath temperature is maintained 70 80 C.
e Flux bath solution density is measured with Hydrometer at every 4 Hrs. intervals
& decided how much flux concentration or water is needed to restore the flux to the required
ux bath until the required relative density of
ality of Galvanized materials, every six month flux bath solution is checked
visually for flux bath solution quality, strength & if the solution is found weaker then it is disposed
t.

the surface.
b. Flux solution comprising of Galva flux - STC-III + Flux additives - STC prepared at 2 : 1 ratio
respectively mixed with fresh water in flux bath during fr
c
d. In regular use, th
density in the bath. Accordingly fresh solution of flux (100 kg. Galva flux STC-III + 30 kg. Flux
additives STC) is added with water directly into the fl
min. 22 30 Baume is achieved.
e. Depending upon the qu
off through Local Authority Environmental departmen
7) Drying of Articles :

a. The fluxed article frames are suspended in the oven & preheated to assist flux drying. The oven
temperature is maintained min. 110C to max. 120C.
b. The suspended article frames are detached from the 1
st
crane & attached to the 2nd crane for next
galvanizing operation.

8) Zinc coating ( Hot dip Galvanizing ) of steel items :

a. During fresh start of Zinc bath, 99.995% pure Zinc is added in the tank. An average molten zinc
bath temperature of 445C 5C is maintained.
b. Suspended articles are slowly dipped at an inclined position until fully immersed in the molten zinc
bath.
c. Depending upon the size, type & thickness of the section, the articles remains immersed until
violent reaction have ceased & white smoke disappears. The articles are swung & agitated to assist
disappearing of white smoke the articles are slowly withdrawn from bath at inclined
position to allow the free drainage of excess zinc & avoid lumps. Un-solidified excess zinc is
removed by scrapers from the surface of suspended articles.
6 from top) is maintained by adding fresh 99.995% pure
zinc slabs (24-26kg. each), depending upon the size & quantity of galvanized articles every day.
wetting.
d. The zinc bath surface is skimmed & zinc ash removed by scrapers.
e. After complete
f. In regular use, the level of zinc (max.
These fresh zinc slabs are preheated by keeping near the molten zinc before adding into the molten
bath.

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g. Zinc ash is removed from bath every day & collected into drums, Zinc dross is removed from bath
on weekly basis. Both the wastages are weighed prior to dispose off to scrap dealers & records are
maintained.

9) Water Quenching process :
a. The Hot dip Galvanized articles are quenched in cooled running water bath by immersing gradually
g onto the concrete floor. The quenching suitability
frames / fixtures & moved to cleaning

in a manner which will enable the steam to escape safely The articles which may suffer distortion
during quenching are cooled naturally by lowerin
is determined by the Supervisor by assessing the article shape & size.
b. Cooled & quenched articles are removed from the suspended
operation.
10) Cleaning & Grinding of galvanized Items :
a. The tie wires (if any) are cut & removed from galvanized articles & surfaces are visually inspected.
l zinc deposits are removed from both ends of holes location by hammering the punch rod
spots (if any observed) are cleaned & sprayed with
hall be removed by hammering or send to Fabrication
ss
Zinc coating thickness for the steel thickness 3mm to above 6mm
in on calibrated balance & galvanized materials weight is
11)
The good galvanized materials are further cleaned with smooth grinding & excess lumps / flow
marks / excess zinc deposits are removed from the surface.
b. Additiona
& all hole edges are to be removed by grinding.
c. Tie wire markings & small pointed galvanized
zinc rich paint- As per BS 2569 minimum two coating layer.
d. Distortion due to heat (warpages / bends) s
department for removing with hydraulic jacking system.
e. Each batch of galvanized materials is inspected as per sampling plan for Coating thickne
(Magnetic method), the mean
shall be minimum 70m to 100m.
f. Finished materials are weighed aga
calculated. Accordingly daily production report is prepared along with weighing records sheets.
Inspection:
a. The integrity of the coating shall be determined by visual inspection and coating
thickness measurement as per BS 1461:2009
ndards of galvanizing. The final weight of galvanized coating shall be as
per BS 1461:2009. Table-3,4
12.
b. Inspection shall be witnessed at the galvanizer works by the customer QC Inspector and client
designated third party Inspector if required.
c. Where coating thickness measurement is not feasible the coating weight shall be determined as
noted the referenced sta
Adhesion : The test is to be carried out by the customer. G.K.Wire will provide test sample of the
material for his testing, if required.
nner tending to
) shell be
he coated article.
c) The galvanized coating shall be sufficient by adherent to withstand normal handling during
transport and erection.
same
a) The adhesion of the zinc coating to the surface of the base metal shall be determined by cutting or
prying with the point of a stout knife, applied with considerable pressure in a ma
remove a portion of the coating , otherwise a cross-hatch test (according to ISO 16276
followed.
b) The galvanizing coating shall be continuous adherent as smooth and evenly distributed as possible
and free from any defect that is detrimental to the stated end use of t

RAK - Tel.(9717) 2447970 , FAX.( 9717) 2447515

13. Repair:
a. If any black surface or blistered surface and peel off surface observed then these items are re-
galvanized by complete process and remedial action are recorded in log book.
b. Renovation of damaged zinc coating shall be followed as per BS 1461:2009 Para 6.3
c. Renovation shall be by thermal zinc spraying as per ISO 2063, or by a suitable zinc- rich paint
as per BS 2569. Where the zinc dust pigment conforms to ISO 3549 within the practical limits
of such systems, or by suitable zinc flake or zinc paste products.

RAK - Tel.(9717) 2447970 , FAX.( 9717) 2447515

HOT DI P GALVANIZNG COATING CERTIFICATE

RAK - Tel.(9717) 2447970 , FAX.( 9717) 2447515

July 2012 Revision 1 Page 1 of 5

INSPECTION AND TEST PLAN
HOT DIP GALVANIZING

PROJECT: EPC CPF Phase -1 al BADRA OIL FIELD
CLIENT: Unger Steel Middle East FZE
P.O NO.:
LOCATION: UAE
SUPPLIER: LINK MIDDLE EAST LIMITED
Document No: GKWI-ITP-001

Rev. Issue date Purpose of issue Prepared Approved
0 Issued for Review Ronald Dsa

.

RAK - Tel.(9717) 2447970 , FAX.( 9717) 2447515


TABLE OF CONTENTS
1. SCOPE ............................................................................................................................................................. 3
2. DEFINITION...................................................................................................................................................... 3
3. REFERENCE CODE......................................................................................................................................... 3
4. INSPECTION AND TEST PLAN........................................................................................................................ 3
4.1 INSPECTION & TEST PLAN- RECEIVING INSPECTION OF RAW MATERIALS FOR FENCE AND GATES... 4

RAK - Tel.(9717) 2447970 , FAX.( 9717) 2447515


1. SCOPE
The scope of this Inspection and Test Plan is to establish the requirements of Fabricated Steel
Steel as per Specification and procedures.
2. DEFI NI TION
Contractor - : Unger Steel Middle East FZE/Petrofac
Supplier : G.K Wire Industries

3. REFERENCE CODE

ASTM A123 :
ISO BS EN 1461

4. I NSPECTI ON AND TEST PLAN

RAK - Tel.(9717) 2447970 , FAX.( 9717) 2447515

Document No GKWI-ITP-001 : July 2012 Revision 0 Page 4 of 5
4. 1 I NSPECTI ON & TEST PLAN- RECEI VI NG I NSPECTI ON OF RAW MATERI ALS FOR FENCE AND GATES
LEGEND
C- Check Point Inspection by LME , H - Hold Point CLIENT must attend, W - Witness Point - CLIENT must be informed but if not in attendance work can proceed, R -
Review Point - Documents relevant to inspection shall be reviewed, QC Quality Control Inspector,USME Unger Steel Middle east, PIL- Petrofac
A
C
T
I
V
I
T
Y

WORK ACTIVITY
QUALITY CHARACTERISTIC
TO BE VERIFIED
PROCEDURE
REFERENCE/CODE/
STANDARD
ACCEPTANCE CRITERIA /
VALUE
PERFORMED
BY
G
K
W
I

U
S
M
E

P
I
L

QUALITY VERIFICATION
RECORD
1 Receiving of
fabricated
Structures, Pipes,
accessories
Completion of fabrication
Qty, Surface condition
damages and defects
Internal Procedure, GB088-
2013030011-CV-J04-001
Operation completion as
per drawing, specification
Qty as per Order
Free from damages and
Any defects

Quality
Control
Engineer
Production
Engineer

C R R Visual Inspection Report

2 Surface preparation
Blasting, Pickling,
Flux coating
Surface free from Rust, Mill
Scales and Loose Burrs, Oil,
paint, Corrosion Marks

2013030011-CV-J04-001 Blasting to a surface
cleanliness of near White
Blast Metal ( SA 2 -
grade blasting finish)
Clean Surface with flux
coat
Quality
Control
Engineer

C W R Visual Inspection Report
RAK - Tel.(9717) 2447970 , FAX.( 9717) 2447515

Document No GKWI-ITP-001 : July 2012 Revision 0 Page 5 of 5
LEGEND
C- Check Point Inspection by LME , H - Hold Point CLIENT must attend, W - Witness Point - CLIENT must be informed but if not in attendance work can proceed, R -
Review Point - Documents relevant to inspection shall be reviewed, QC Quality Control Inspector,USME Unger Steel Middle east, PIL- Petrofac
A
C
T
I
V
I
T
Y

WORK ACTIVITY
QUALITY CHARACTERISTIC
TO BE VERIFIED
PROCEDURE
REFERENCE/CODE/
STANDARD
ACCEPTANCE CRITERIA /
VALUE
PERFORMED
BY
G
K
W
I

U
S
M
E

P
I
L

QUALITY VERIFICATION
RECORD
3 Hot Dip Galvanizing Zinc coating thickness, Zinc
adhesion, visuals,
Instrument calibration
verification
2013030011-CV-J04-001
ASTM A 123
ISO BS EN 1461
Average Zinc Coating as
per specification
No Peel off.
No lumps
Quality
Control
Engineer

C H H Hot Dip Galvanizing
Certificate
4 Final Inspection,
Identification,
Packing
Zinc coating finish
Individual / Batch
Identifications marks
Packing as per
requirements
2013030011-CV-J04-001
Customer specifications
Zinc coating as per
specification, no defects
Identification as per Job
numbers
Rigid packing to avoid
damages
Quality
Control
Engineer

C H W Pre despatch Inspection
Report

Sample Galvanizing Procedure +ITP

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WIRE INDUSTRIES LLC

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