galvanize

Valmont Coatings is the market and technical leader in hot dip galvanizing. We are one of the largest custom galvanizers in North America, serving all steel fabrication markets from coast to coast. Valmont Coatings is a member of the American Galvanizers Association.

Galvanized to exceed your expectations.

Process and Sizing Guide For Hot Dip Galvanizing

Introduction The size of products that can be hot dip galvanized is determined by the size of the zinc kettles, the tanks in the cleaning line, the crane capacities, or the building structure clearances within a particular galvanizing plant. The most economical and highest quality galvanizing is achieved when steel products T h e L e a d i n g G a lv a n i z e r As a full-service coatings company, Valmont Coatings provides quality surface nishes that extend the service life and improve the appearance of metal products throughout the country. Our processes and transportation capacities are designed to efciently handle steel products of all shapes and sizes, for customers anywhere in the country. are sized to enable the entire product to be totally immersed in the molten zinc in a single dip. When needs dictate that the product to be galvanized must be longer or deeper than the galvanizers kettle, it can often be galvanized by means of the double dipping procedure. With this method, 50% or more of the surface of the product is immersed in the molten zinc. When the galvanizing of that portion is completed, the product is turned over and the remaining uncoated portion is lowered into the zinc and galvanized. This section will guide the prospective user of Valmont Coatings service to determine common size and weight limits for products that are single-or double-dipped within our plants. We urge fabricators, engineers and architects to consult with us if the product under consideration is slightly larger than the dimensions cited in this brochure. In some situations, depending upon the design of the product, certain special procedures can be used to satisfy greater requirements. At the beginning of the process, products are batched into bundles, trays or racks to be handled in the most effective manner through the cleaning line. At this stage, each product is examined to determine the presence of adequate details for venting and draining of uids during cleaning and galvanizing, and to assure that, when necessary, the product is provided with holes or lugs for lifting. If additional venting details or lifting holes/lugs are required, the customer is notied and arrangements are made to install them. After batching, the products are passed through the stages of the cleaning and galvanizing line, illustrated in Figure 1. This schematic applies to products whose coating must meet the requirements of ASTM Specication A 123. When parts are required to have excess zinc removed by centrifuging or brushing, the stages shown in Figure 2 are applicable. Products are galvanized in this manner to conform to the requirements of ASTM Specication A 153. Caustic The caustic tank contains heated water with caustic soda and detergent additives. Oils, soil and soluble paint markings are removed from products during immersion at this stage. Fa c i l i t i e s a n d P r o c e s s Valmont Coatings uses galvanizing kettles that typically are the following sizes: Rinse A tank containing plain water is used to remove residues of the caustic dip. Pickle A bath of heated dilute sulfuric acid solution removes rust and mill scale from the products. Rinse Another tank containing plain water is used to remove residues from pickling. Flux Zinc ammonium chloride in solution provides additional cleaning of the products being dipped. During galvanizing, the lm of ux on the products improves wetting between the steel and the molten zinc. Re-xturing Depending upon the product and/or type of batching used during cleaning, some products are re-xtured, or re-batched, for better processing through the molten zinc bath. Galvanizing The uxed, possibly re-xtured, product is taken to one of the zinc kettles. Each kettle is provided with a foamy, black blanket of zinc ammonium chloride ux which oats on the surface of the molten zinc. The products are lowered through the ux blanket en route to the molten zinc below and, in so doing, receive one nal cleaning. Products remain in the molten zinc until they reach the approximately +830F molten zinc temperature. Centrifuging or Brushing (For ASTM A 153 Only) When the perforated basket containing the product is removed from the molten zinc, it is transferred immediately to the centrifuge where excess zinc is spun away. 1

Products that are too large to be centrifuged, but are still in need of removal of excess zinc, are subjected to brushing of the critical areas before the zinc solidies. Quench After galvanizing and centrifuging or brushing (when applicable), the product is immersed in a plain water quench to retain as much bright zinc surface as possible and to reduce the time required for handling. Inspection Products are visually checked for coating integrity and measured to verify that coating thickness meets or exceeds ASTM Standards.

Size Limits Single Dip Lifting Capacity: 10,000 lbs.

Product length

Size Limits Double Dip Lifting Capacity: 10,000 lbs. 1. Double dip for height

2. Double dip for length

Size Limits Centrifuge Maximum product dimensions:

t length Produc
height

Rounds: 18 long x 4 diameter Plates: 6 x 6 x 1 thick Angles: 5 x 5 x 1/2 thick x 6 long Consult with Valmont Coatings if the product under consideration is slightly

Height

Product length

Height 26 or 52 kettle length Kettle length

larger than the dimensions given in this brochure. In some situations, depending on the design of the product, certain special procedures can be used to satisfy greater requirements.

26 Foot Kettle Maximum product dimensions: 25-8 long x 4-4 wide x 6-0 high. 52 Foot Kettle Maximum product dimensions: 51-6 long x 4-4 wide x 5-0 high.

Kettle length

Maximum product dimensions: 4 x 4 wide x length and height from table below:
Maximum length using all dip stages except caustic*

Note 1: Items 39 through 48 in height are too large for caustic double dipping and can only be processed if they are given SP-6 Commercial Blast before supplying to Valmont. *Products can be galvanized to the lengths given in this column when steel is cleaned to SP-6 Commercial Blast before supplying to Valmont. Such cleaning enables bypass of size restriction imposed at the caustic tank.

26 Foot Kettle Maximum product dimensions: 24-0 long x width and height, from this table:
Width Maximum height Height

Maximum length using all dip stages

Up to 6 +6 to 12

61-10 62-9

72-0 72-0 72-0 71-9 67-0 64-11 62-8 58-4

Up to 9 +9 to 12 +12 to 24 +24 to 52

12-0 11-7 10-5 10-4

+12 to 18 62-8 v+24 to 30 62-7 +30 to 36 62-6 +36 to 39 62-6 +39 to 42 See note 1 +42 to 48 See note 1

52 Foot Kettle Maximum product dimensions: 50-0 long x 4-4 wide x 10-0 high. 2

Limited by building structure clearance.

Figure 1: Process for ASTM A 123

Caustic Caustic

Rinse Rinse

Pickle Pickle

Rinse Rinse

Flux Solution Flux Solution

Zinc Bath Zinc Bath

Quench Quench

Inspection Inspection

FIGURE 2: Process for ASTM A 153

Caustic Caustic

Rinse Rinse

Pickle Pickle

Rinse Rinse

Flux Flux Solution Solution

Transfer Transfer toto Basket Basket

Zinc Zinc Bath Bath

Centrifuge Centrifuge (or (or Brush) Brush)

Quench Quench

Inspection Inspection

Principles 1. Product Is Oriented to Maximize Bath/Kettle Space

Product width

3. Final Vent Is at Position Immersed Last

5. Size, Style and Location of Openings Are Adequate

Dip direction
Vent Vent

Vent

Fill Fill

Good internal galvanizing depends on the ability of cleaning uids and molten zinc to surge through the hollow product from the entry to the exit point, without compressing any air into pockets in its path. In any Some examples are given to show how the principles are applied to tubular products but, since the type and conguration of products are so varied, we are relying on these principles, coupled with the fabricators knowledge of their own product, to enable them to determine where vents and drains are required. *Holes that are used to drain as a part is being removed from the bath have earlier served as llholes during the immersion of the part. For purposes of this brochure, use of the terms ll and drain should be taken to describe the same hole, depending upon how it is functioning at a particular stage of the process. 2. Initial Fill Location Is at Largest Available End Opening
Fill Bath width

Fill

Fabricators Guide to Pipe and Tube Galvanizing

Introduction and Purpose The galvanizing of products that are made from tube or pipe requires special attention by the fabricator and the galvanizer. Installation of suitably sized holes in strategic locations on the product is essential to assure the correct galvanizing of all internal surfaces. The holes, so placed in the product, serve several purposes, namely to: 1. Prevent pressure build up and rupture 4 of the product that could result from heating of enclosed air and moisture during partial or full immersion in the 840 F galvanizing bath. 2. Provide for the rapid entry of cleaning uids and molten zinc to overcome the natural buoyancy of hollow objects. 3. Enable air and galvanizers ux to escape from the last remaining upper corners of a product at the moment of total immersion. Elimination of air pockets allows cleaning uids and molten zinc to reach all surfaces to permit complete internal cleaning and coating. Evacuation of ux eliminates a potentially corrosive internal condition. 4. Eliminate the entrapment of pockets of zinc as the product is being withdrawn from the galvanizing bath. Properly sized and placed holes avoid large and costly volumes of zinc from solidifying in deep recesses. 5. Contribute to the safety of galvanizing plant personnel. The purpose of this brochure is to acquaint the fabricator with the principles that Valmont uses in determining how to position a work piece for lowering into the baths, and how this leads to a determination of where the vents and drains should be located. Holes, placed in products to fulll the functions listed, are referred to as vents and drains* in the galvanizing industry. Size and location of such holes are a frequent topic of conversation between a galvanizer and the fabricator. Conservative recommendations on the size and location of openings are given in ASTM A 385, Standard Practice for Providing High Quality Zinc Coatings (Hot-Dip). In order to select adequate, yet economical details for vents and drains, it is necessary to understand how the product will be oriented as it is being lowered into the baths. This is not something that a fabricator could reasonably know without prior guidance.

For secondary components, as for primary members, ll holes (F) need to be located as close as possible to the point on the member where the uids rst make contact during immersion. Similarly, vent holes (V) on secondary members need to be as close as possible to the point where the member is nally and completely immersed. Other Valmont Coatings recommendations relating to openings are as follows: Minimum Size of Openings Requirements for ll and vent opening size vary according to the size of tube or pipe being lled, and whether that tube or pipe is a primary or secondary component of the overall product. Fill and vent openings for primary members apply when these members have end closures of any kind. The following tables provide guidelines on sizes that Valmont Coatings generally considers to be minimum. Pipe and Round Tube
Minimum Fill and Vent Hole Diameter Pipe & Tube Primary Secondary Diameter Member Member

hollow product, the last exit point must be located at the place where the last portion of the hollow component submerges into the bath. 4. Lift Orientation Is Suited to Initial Fill, Final Vent Locations

Generally, products are set up for galvanizing so that their smallest dimension parallels the bath width. Several identical pieces can often be galvanized side by side at the same time, thereby utilizing most of the width of the cleaning bath or zinc kettle. It is with this orientation that the consideration of vent and drain openings begins.

Vent

In order to select adequate, yet economical details for vents and drains, it is necessary to understand how the product will be oriented as it is being lowered into the baths. This is not something that a fabricator could reasonably know without prior guidance.

As the work piece is being lowered into each of the baths, the natural tendency of the cleaning uid and molten zinc is to push upward through the product. To enhance this movement and to An opening at, or very near to, a lower end location of the product is selected as the initial entry opening to allow cleaning uids and molten zinc to ow into the interior. When a product has an opening at each of its two ends, and one of these openings is larger than the other, the larger opening will be chosen as the entry orice, provided that it can be situated near the bottom of the product when suspended by a crane. encourage a ow, especially along longitudinal components of the products, each work piece is arranged at a slight angle on the hoisting equipment as shown.

1-14 , 1-12 5/8 2 4 6 8 10 12 14 16 18 20 7/8 1-5/8 2-3/8 3-14 4 4-5/8 5-14 6 7 8

3/8 12 7/8 1-14 1-5/8 2 2-3/8 2-5/8 3 3 12 4

Square or Rectangular Tube Triangular corner cutouts, rather than round holes, are suggested for ll or vent openings in end closures on primary members made of square or rectangular tube. Round holes, however, remain suitable to be ll or vent openings in secondary members made from this type of tube. The following table lists square-inch units for minimum opening sizes in primary members, and hole diameters in inch units for minimum openings in secondary members.
Minimum Fill and Vent Hole Size Tube Cross Primary Secondary Section* Member Member (sq. in.) (sq. in.) (inches)

Lo cat i o n o f O p e n i n g s Openings are best located where they will help to ll, vent and drain the tubes most rapidly. Their location on individual components must be related to the listing direction of the overall assembly. (a) In Primary Members

(b) In Secondary Members

1/2 maximum

3/4 maximum

Lift

Lift

Perpendicular member

Angled member

Vent (Far end)

Fill (Near end)

2.25 4.0 9.0 16.0 25.0 36.0 49.0 6 64.0 81.0 100.0

0.6 1.0 1.25 2.75 4.5 5.5 8.0 11.0 13.0 15.0

12 5/8 5/8 1 1-14 1-3/8 1-5/8 1-7/8 2 2-14

Lift Lift

6. Product Filled Slowly, Gradually

Round single Square or rectangle single

Examples
Pipe Handrail
Dip direction 3/8 diameter Secondary vent 1/2 maximum 1/2 maximum

from End to End Slow immersion allows the bath and the product to adjust for their very different initial temperatures. Filling from end to end allows ux on the interior surfaces to be ushed out of the product. 7. Product Is Drained Through Original Fill Holes The sloped orientation of the work piece

Vent (Far end)

7
5/8 diameter Primary vent 1-1/2 Pipe handrail 1/2 maximum

Fill (Near end)

*Interior cross section, square or rectangular tube.

Round assembly Square or rectangle assembly

Quality of Opening The evenness of the edge of an opening plays a signicant part in helping Valmont Coatings achieve a good looking galvanized coating around it. Regular openings allow a smooth spill of molten zinc upon withdrawal from the bath. Irregular, ragged edge openings cause molten zinc to splatter as it pours and should be avoided.

on the lifting equipment facilitates drainage. Fu rt h e r A s s i s ta n c e Valmont Coatings will provide help to customers, upon request, to establish the size and location of vent and drain holes during the fabrication of an order. If Valmont Coatings technicians determine additional vent and drain fabrication is necessary once a product is in the Valmont plant, we will notify the customer, provide costs for appropriate modications and request permission to install or modify the holes.

1/2 maximum

3/8 diameter Secondary ll

3/8 diameter Primary ll 1/2 maximum 5/8 diameter Primary ll

3/8 diameter Secondary ll

3/8 diameter Secondary vent

Tubular Bracket
Two cutouts 1 x 1-1/4 (1.25 sq. in.) Primary vent 5/8 diameter Secondary vent
Dip direction

Good

Avoid
3-1/2 x 2-1/2 Tu be
be Tu /2 -1 2 x

1/2 2-

5/8 diameter Secondary ll Open end 3/4 maximum

The majority of items that are hot dip galvanized are suspended by wires attached at one or more pick-up points on each work piece.
Major Cross section dimension (Inches)

The graph is intended to provide only a very approximate guideline as to whether a product may be supported at a single pick-up point.
60 50 40 30 20 10 9 8 7

3. Choice of Top or Bottom Side Is Based on Openness Determination is made as to which of two sides of a product will be rst to be lowered into the bath. This is particularly signicant when the ends (in the case of one point pick-up) or the sides (in the case of two point pick-up) are not the same. Guidelines to help determine how a product will be hung, based upon its width, are provided in Principle No. 1. It must also be determined which remaining side will be the top, and which will be the bottom. For each submersion of non-symmetrical products, Valmont will choose the side that is most open to be the bottom.

Single Point Pick-Up In general, Valmont will suspend from a single corner pick-up point if: (1) the geometry of the product is reasonably streamlined along its length; (2) the product would give minimal drag through molten zinc as it was being moved along the length of the kettle; (3) the length and Generally, products are set up for galvanizing so that their smallest dimension parallels the bath width. Several identical pieces can often be galvanized side by side at the same time, thereby utilizing most of the width of the cleaning bath or zinc kettle. 2. Product Support Locations Depend on Size, Conguration and Number of Pieces per Lift Product is set up for galvanizing either by being placed into a rack, or by suspension from a harness of wires that is attached through a suitably placed hole at a corner location near to the end of the product. Rack Use of a rack is preferable when: (1) there are many identical pieces to be galvanized, such as warehouse stock angle; (2) these Principles 1. Product Is Oriented to Maximize Bath/Kettle Space
Product width

Fabricators Guide to Open Section Galvanizing

Introduction and Purpose Fabricated steel products that are to be galvanized should have details that would allow the galvanizers cleaning solutions and molten zinc to ow freely through the product at various stages throughout the hot dip galvanizing process. When such details are made, they eliminate the formation of air pockets during dipping. This helps to assure that the steel 8 is thoroughly cleaned and coated in all corners. Improperly cleaned areas of steel will not galvanize. Details that allow a clear path for the run-off of molten zinc when steel parts are being withdrawn from the galvanizers kettle result in a coating that is more evenly formed throughout the product. Proper details prevent unwanted zinc build-ups which, ultimately, add to the customers cost, look unsightly, and may interfere with the t-up of adjoining parts. To determine how to avoid pockets and traps when a product is being hot dip galvanized, the fabricator must rst understand how a product will be oriented as it is being lowered into and lifted from the baths. This is not something that a fabricator could reasonably be expected to know without guidance from the galvanizer. The purpose of this brochure is to acquaint the fabricator with the principles that Valmont Coatings uses to: (1) determine how to position a work piece for lowering into, and lifting from, the baths, and (2) how this leads to a determination of where vents and drains should be located. The focus of this section is on the fabrication details for products made of open-sided components. Examples are provided to show how the principles are applied to fabrications made of open-sided components. However, since the type and conguration of products are so varied, Valmont Coatings relies on these principles, coupled with the fabricators knowledge of their own product, to help them determine where vents and drains are required.

5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Product length (Feet)

major cross-section dimension of the product falls at or below the limits of the graph given below; and (4) if the minor cross-section dimension of the product is not greater than 7.
Examples of products suited to single point pick-up

Example: A product with a major crosssection dimension of 20 and a minor cross-section dimension of 7 and a length of 11 will be lifted from a single pick-up point. The required pick-up hold size is 3/8 diameter for items weighing less than 100 pounds, and 5/8 diameter for heavier items. Two Point Pick-Up Any product for which rack or single point pick-up is not practical is picked up from a wire harness through a hole in each of its two ends. The required pick-up hold size is 3/8 diameter for items weighing less than 200 pounds, and 5/8 diameter for heavier items.

9
Liquid surface

A table-like stand, for instance, would be lowered legs rst.

pieces are generally not more than 4 x 4 in cross-section; and (3) they are no more than 20 in length. Items galvanized in a rack do not need to be provided with a pick-up hold.
Product

The product is arranged on the lifting equipment so that it enters the bath at an angle. The angular orientation is used to encourage a ow of molten zinc to move progressively along each component of the product from one end to the other.
Side view of loaded rack

This provides a more uniform wetting action between the steel and the zinc, and better drainage upon withdrawal.

Bath width

4. Potential Air Pockets and Zinc Traps Are Identied Once it has been determined how a product is likely to be picked up and oriented, it is possible to identify places where air pockets could potentially form during submersion, and also where molten zinc could be prevented from draining during withdrawal. The illustrations provide examples of frequent problem areas and the proper methods to avoid them.
Detail needed: 1/2 diameter hole made at each corner prevents air pocket formation

Venting at structural panel point

Air pocket

Venting and draining of enclosure body

Detail needed: 1/2 diameter pick-up hole in ange, and as close as possible, also serves as a vent to prevent formation of an air pocket. See enlarged detail.

Fu rt h e r A s s i s ta n c e Valmont will provide help to customers, upon request, to establish the size and

Hanging wire

location of vent and drain holes during fabrication of an order.

Liquid surface Dip direction

Liquid surface Dip direction

If Valmont Coatings technicians determine additional vent and drain fabrication is necessary once a product is in the Valmont plant, we will notify the customer, provide costs for appropriate modications and request permission to install or modify the holes.

1/2 diameter pick-up / vent hole

Draining at structural panel point

2diameter hole for lling and draining at the lower right corner of the back wall

Trapped liquid

Venting and draining of a stand

Detail needed: 1/2 diameter hole made in the angle and downturned ange of top prevents air pocket formation. Holes need to be as close to the top corner as possible. Air pocket

10

Detail needed: 1/2 diameter hole made at each corner prevents a trap for galvanizing liquids

Withdrawal

Hanging wire typically four places

Liquid surface

Dip direction

11

Liquid surface
See note 1 Note 1: 1/4 gap. If no gap, provide 1/2 diameter hole in the end of the horizontal leg of brace angle. See note 1

See note 1

Venting at base of post

Air pocket Detail needed: 1/2 diameter hole made in each angle prevents a trap for galvanizing liquids. Holes need to be as close to the top surface of the shelf as possible. Alternative: 1/2 diameter holes in the top surface of the shelf as close to the corner as possible.

Detail needed: 1/2 diameter hole made in the leg of each angle prevents a trap for galvanizing liquids. Holes need to be as close to the corner of the angle and the base plate as possible.
Air pocket

Detail needed: 1/2 diameter hole made in the angle and downturned ange of the shelf prevents air pocket formation. Holes need to be as close to the inside corner of the shelf as possible. Alternative: 1/2 diameter holes in the top surface of the shelf as close to the corner as possible.

Hanging wire Air pocket

Shelf

Liquid surface Detail needed: 1/2 diameter hole made in a corner of the web, and as close to the plate as possible, prevents air pocket formation Dip direction Construction: Angle legs and braces; sheet or place top and shelf with brake formed anges.

After galvanizing, it would be necessary for the fabricator to remove the struts and repair the area where they had been joined to the plate. Valmont would be pleased to assist in establishing strut and end connection details based on each particular case. Cause and Prevention: Welding There are several actions the fabricator

Cause: Lack of Symmetry in Product The potential for warpage is greatly reduced when a product is symmetrical about its horizontal and vertical neutral axes. When a symmetrical section such as a simple I-beam is galvanized, thermal expansion forces above and below the neutral axis balance each other and leave the beam free of distortion. However, in the case of unsymmetrical sections, such as a wide ange beam with a rectangular structural tube welded to its top ange, a geometric imbalance has been created. The wall of the tube is considerably thinner than the ange of the beam. Consequently, the tube material will be thoroughly heated to the temperature of the galvanizing bath, while the bottom ange of the beam lags behind it in coming up to bath temperature. As a result, the tube material is expanding fast, but the cooler bottom ange is unable to keep pace. If such a beam were to be galvanized in the conguration shown, it would experience upward bowing distortion.

Beams would be bolted back-to-back using pie spacers to separate the beams to allow the anges to be cleaned and galvanized. The bolts would be removed after galvanizing when the sections have cooled. Spots where the spacers contacted the beam anges would be repaired with galvanizing repair material. Valmont would be pleased to assist in the determination of the number and size of bolts to use. Separation and touch up of the sections would be the customers responsibility unless other arrangements are made. (b) Fabricate and galvanize the I-beam and tube as separate loose pieces. Then, weld them together after galvanizing. Touch up welds with galvanizing repair material. (c) Redesign the section to make it symmetrical.

Control of Distortion in Galvanized Products

Introduction and Purpose This article describes major causes of distortion that become evident after hot dip galvanizing and suggests ways to reduce the risk. Considering the volume of products that are hot dip galvanized, the occurrence of distortion is quite infrequent. When it does happen, however, distortion is a serious concern to the fabricator and galvanizer 12 alike, involving extra costs and possibly delays to remedy the problem. An understanding of the causes of warpage during galvanizing can lead to measures that will eliminate or substantially reduce the problem. Causes and Prevention Overview In many instances, the potential for distortion has been put into the product before its arrival at the galvanizing plant. Distortion can be due to: residual stresses induced at the mill during rolling of structural sections or plate; residual stresses created by bending or welding; lack of symmetry in simple sections such as channels or in built up sections; a combination of thick and thin material in the same assembly; assemblies made so large that they require double dipping to be coated over their entire surface. Cause: Bending While a product may have the correct form in the as fabricated condition, stresses induced in the product during bending operations at the fabricating plant may be released when the product is galvanized. The galvanizing temperature, 820 to 870 F, is at the low end of the stress relieving temperature range. Consequently, stresses induced by bending may be released during galvanizing with a resultant change in shape or dimension of the fabricated product.
1/4 H

should take to minimize the potential for distortion due to the release of stresses in welds. Those actions are as follows: Consider the case of a plate section that has a curve rolled into it so that when several such sections are joined, they form a circle. As a result of galvanizing, the plate would relax to a greater radius than the dimension originally fabricated. avoid over welding; use as few weld passes as possible; place welds near the neutral axis; balance welds around the neutral axis; use backstep welding; make weld shrinkage forces work in the desired direction; balance shrinkage forces with opposing forces; use a well planned, balanced welding sequence; remove weld shrinkage forces during Prevention: Installation of temporary struts across the chord of the circle will enable the curved section to retain its form. The struts would be structural angles or channels bolted or welded into position. Their size will be proportional to the size and thickness of the plate section. The struts should be located at the quarter points of the height of the section as shown below. and after welding; reduce the welding time. More information on these points and much additional guidance on minimizing distortion in weldments is given in the brochure, Distortion . . . How to Minimize It With Sound Design Practices and Controlled Welding Procedures, Plus Proven Methods for Straightening Distorted Members, written by Omer W. Blodgett, P.E., and Duane K. Miller, P.E., and
1/4 H

Some causes of distortion can arise at the galvanizing plant. These can be due to: poorly selected pick-up points for handling product through the process; random laydown of product after galvanizing, especially of products leaning against each other or against other objects, that may establish a deformed set in the product during cooling. The remainder of this article details causes of distortion that can be controlled by the fabricator or the galvanizer and describes preventive measures that can be applied to each case.

Distortion in structural channels is typically a uniform bow in the weak direction with the toes of the channel pointing away from the radial center. This distortion can also be minimized by the back-to-back method.

13

Prevention: This problem can be prevented in any of three ways, depending upon economics and desire to maintain the integrity of the corrosion protection: (a) Galvanize the sections back-to-back if there are a number of identical pieces on the order that allow this to be an option.

published by Lincoln Electric Company. Valmont will be pleased to furnish a complimentary copy upon request.

Cause: Thick and Thin Material in Assembly Thin material in an assembly expands faster than thicker materials nearby because it takes less time to be fully heated to the galvanizing temperature. Distortion will take place in thin material when thicker material restrains it from free expansion. Consider the case of a steel sheet or plate placed on a structural frame and securely attached by welds around its perimeter. Imagine that the sheet or plate is only half as thick as the material in the frame. The sheet soon reaches the galvanizing temperature of about 850 F and its maximum potential expansion. The frame, being thicker, is still cooler and has not yet had the opportunity to expand as much as the sheet. Since the sheet cannot push its growth outwards at the edges because of the welds, its increase in size results in one or more buckles in the sheet surface.

Prevention: Two approaches can be taken to avoid this condition. (a) Galvanize the sheet and frame separately and join them after galvanizing. (b) Use the same thickness of material for frame and sheet. Cause: Size of Assembly Requires Double Dip The potential for warpage increases when an item is so large that the galvanizer must dip one portion at a time in order to fully coat it.

Simple pipes and poles do not experience distortion from double dipping, probably because of their symmetry and simplicity of design. Whenever possible, it is preferable to size a product so that it can be totally immersed in a single dip. Even though a product is small enough to be immersed in a single dip, it is important that ll and drain holes be large enough to enable the part to be immersed and withdrawn rapidly to avoid differential expansion.

Cause: Poorly Selected Pick-up Points When a long, slender product is picked up at both ends for transport through the galvanizing process, a potential is created for the product to become bowed.

Drainage opening should be placed and sized according to recommendations in the articles of Fabricators Guide to Pipe and Tube Galvanizing and Fabricators Guide to Open Section Galvanizing to minimize containment of excess zinc. Cause: Poor Laydown After Galvanizing Permanent deformation may occur when a batch of hot galvanized

Prevention: In both cases, this type of problem can be reduced by arranging the parts after galvanizing as straight and as free from external forces as possible during cooling. When a product has acquired an unexpected bow during galvanizing, setting it down while hot and applying weights to restore the part to straightness during cooling may be helpful. Fu rt h e r A s s i s ta n c e Upon request, Valmont will provide help to customers about countermeasures to distortion during the fabrication of an order.

When the hot, galvanized product is being withdrawn from the zinc bath, some of the deection caused by the products own empty weight can be permanently set into the product. The yield strength of mild steel can be temporarily reduced during immersion in the zinc bath. The problem

products is laid down haphazardly and exed out of shape during cooling.

The portion immersed in the zinc is subjected to much higher temperature and greater thermal expansion than the portion projecting from the kettle, especially during

A structural member set down on its side on blocks that are too far apart can easily sag in its weak direction under its own weight. If it is set down that way while still hot, it may permanently retain some portion of that distortion. 15

is compounded in slender products that have inadequate drainage openings that allow a substantial weight of molten zinc to be retained and delayed from leaving the product during withdrawal. Prevention: Long, slender products should be equipped with lifting lugs located at the quarter points of the length of the product to overcome the possibility of experiencing this kind of distortion.
1/4 L

14

the rst dip. The differential heating and expansion between the two portions can cause distortion that will not be removed when the remainder of the product is placed into the molten zinc.

Section A-A

Distortion due to restrained expansion.

Section A-A

Considering the volume of products that are hot dip galvanized, the occurrence of distortion is quite infrequent. When it does happen, however, distortion is a serious concern to the fabricator and galvanizer alike, involving extra costs and possibly delays to remedy the problem.

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Pa rt 2 P r o d u c t s 2.01 Steel Materials A. Structural shapes, plates and bars that are to be galvanized shall be manufactured from steel conforming to ASTM A 36 or A 572 except that silicon (Si) content shall be in the range of 0 to 0.04% or 0.15 to 0.20%, and phosphorus (P) content in the range of 0 to 0.02%. Steel with chemistry conforming to the formula Si + 2.5P 0.09 is also acceptable. Mill certicates 1.03 Submittals The original and two copies of Certicates of Compliance shall be forwarded to the Architect/Engineer. 1.04 Handling, Transport and Storage Galvanized articles shall be loaded and stored as follows to prevent the formation of wet storage stain: (a) The material shall be loaded in such a manner that continuous drainage B. Certication 1.02 Quality Assurance A.Relevant Standards: American Society for Testing and Materials (ASTM) A 53 Pipe, Steel, Black and Hot-Dipped Zinc Coated Welded and Seamless A 123 Zinc (Hot-Dip Galvanized) Coatings on Iron and Steel Products A 143 Safeguarding Against Embrittlement of Hot-Dip Galvanized Structural Steel Products and Procedure for Detecting Embrittlement A 153 Zinc Coating (Hot-Dip) on Iron and Steel Hardware A 325 High Strength Bolts for Structural Steel Joints C. Inspection and Tests Inspections, tests and samples shall conform with ASTM A 123 or A 153 as applicable. Inspections and tests shall include the following: 1. visual examination of samples or nished products, as appropriate; 2. tests to determine thickness or weight of zinc coating per square foot of metal surface; 3. adhesion. When requested by the purchaser/ designer, a Certicate of Compliance shall be provided stating that the galvanizing complies with ASTM Specications and Standards and all other applicable requirements specied herein. could occur. (b) In storage, the articles shall be raised from the ground and, if necessary, separated with strip spacers to provide free access of air to most parts of the surface. They shall also be inclined in a manner which will give continuous drainage. Under no circumstances shall galvanized steel be allowed to rest on cinders or clinkers; nor shall it be stored on wet soil or decaying vegetation. shall be furnished. Note: Hot dip galvanized coatings result from metallurgical reactions between molten zinc and steel. Galvanized coatings formed on steel of normal reactivity have a two-part composite structure. One part, a layer of iron-zinc alloy formed during galvanizing, metallurgically bonds the coating to the underlying steel. The other part of the coating is an outer layer of uniform appearance that has a chemical composition similar to the zinc in the galvanizing bath. Certain percentages of silicon and phosphorus in the chemistry of some steels increase the reactivity between the steel and molten zinc during galvanizing and produce coatings of a different structure and appearance. Galvanized coatings on steels with increased reactivity, due to the silicon and/or phosphorus levels, may be matte grey, mixed shades of grey, or include localized outbursts of grey colored ironzinc alloy in otherwise bright surfaces. In some instances, steels with increased reactivity produce galvanized coatings that are very thick and consequently brittle. Galvanized coatings on the steel chemistries suggested in these guidelines should have acceptable adhesion and be substantially free from iron-zinc alloy outbursts. However, the coatings will tend to be thicker on steels having higher levels of silicon. For steels with silicon content in the range of 0.15 to 0.20%, phosphorus

may increase the steel reactivity, but the galvanized coating should not show substantial iron-zinc alloy outbursting. B. Steel for fasteners shall conform to the following ASTM specications for each category: General
Category Carbon Steel High Strength Tower Bolts Bolt Material A 307 Gr. A or B A 325 Type 1 or 2 A 394 A 563 Gr. DH or, A 194 Gr. 2H A 563 Gr. A Nut Material A 563 Gr. A

Unsuitable marking paints shall be avoided, and consultation by the fabricator with the galvanizer about the removal of grease, oil, paint and other deleterious material shall be undertaken prior to fabrication. Surface contaminants and coatings which would not be removable by the normal chemical cleaning process in the galvanizing operation shall be removed by the fabricator using blast cleaning or some other method. 2.04 Surface Preparation Steel shall be prepared utilizing a caustic bath, acid pickle and ux. Where appropriate, the steel can be blast cleaned and uxed. 2.05 Galvanizing A. Steel members, fabrications, and assemblies shall be galvanized after fabrication by the hot dip process in accordance with ASTM A 123. B. Bolts, nuts and washers, and iron and steel hardware components shall be galvanized in accordance with ASTM A 153. Nuts and bolts shall be supplied in accordance with ASTM A 194, A 307, A 325, A 394 or A 563, as applicable. Products shall be safeguarded against steel embrittlement in conformance with ASTM A 143. All articles to be galvanized shall be handled in such a manner as to avoid any mechanical damage and to minimize distortion. When the galvanizer detects design features which may lead to difculties during galvanizing, he shall point them out to the fabricator and arrange for modications to be made prior to dipping. The composition of metal in the galvanizing bath shall not be less than 98% zinc. 17

Suggested Guidelines for Hot Dip Galvanizing

Pa rt 1 G e n e ra l 1.01 Scope These guidelines cover the galvanized coating applied to general steel articles, structural sections, fabricated steel assemblies and threaded fasteners. Note: These guidelines do not apply to the galvanized coating on semi-nished products such as wire, tube or sheet galvanized 16 in specialized or automatic plants. A 384 Safeguarding Against Warpage and Distortion During Hot-Dip Galvanizing of Steel Assemblies A 385 Providing Quality Zinc Coatings (Hot-Dip) A 563 Carbon and Alloy Steel Nuts A 780 Repair of Damaged Hot-Dip Galvanized Coatings B 6 Zinc (Slab Zinc)

C. Steel for sheet metal articles shall conform to ASTM A 569 or A 570. D. Steel for pipe or tubing shall conform to ASTM A 53 or A 595 Gr. A or B. Note: Avoid use of steels with an ultimate tensile strength greater than 150 ksi. 2.02 Zinc for Galvanizing Zinc for galvanizing shall conform to ASTM B 6. 2.03 Fabrication Fabrication practice for products to be galvanized shall be in accordance with the applicable clauses of ASTM A 143, A 384 and A 385. Care shall be taken to avoid fabrication techniques that could cause distortion or embrittlement of the steel during galvanizing. Before fabrication proceeds, the Architect/Engineer shall be notied of potential warpage problems which may require modication in design. All welding slag and burrs shall be removed prior to delivery to the galvanizer. Holes and/or lifting lugs to facilitate handling during the galvanizing process shall be provided at positions as agreed between the designer, fabricator and galvanizer.

2.06 Coating Requirements A. Thickness/Weight: The thickness or weight of the galvanized coating shall conform with paragraph 5.1 of ASTM A 123 or Table 1 of ASTM A 153, as appropriate. B. Surface Finsh: The galvanized 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 the coated article. The integrity of the coating shall be determined by visual inspection, coating thickness measurements, and adhesion testing. Where slip factors are required to enable friction grip bolting, these shall be obtained after galvanizing by suitable treatment of the faying surfaces in accordance with the latest edition of the Specication for Structural Joints Using ASTM A 325 or A 490 18 Bolts as approved by the Research Council on Structural Connections of the Engineering Foundation. C. Adhesion: The galvanized coating shall be sufciently adherent to withstand normal handling during transport and erection.

Pa rt 3 E x e c u t i o n 3.01 Welding Where galvanized steel is to be welded, adequate ventilation shall be provided. If adequate ventilation is not available, supplementary air circulation shall be provided. In conned spaces, a respirator shall be used. Welding shall be performed in accordance with the American Welding Society publication D19.0-72, Welding Zinc Coated Steel. All uncoated weld areas shall be touched up. A. Galvstop Service Successful welding of galvanized steel requires pre-planned, plain, uncoated areas conforming to fabrication requirements. Valmonts Galvstop service is an adaptable method to provide specic uncoated areas of any size, shape or location. Extra preparation work is not required. Requirements must be provided. Note: Galvstop is only applicable on external surfaces and accessible internal surfaces.
Individual areas, or all surfaces for special length, at end of section Entire top of ange, or any localized area

3.02 Touch Up and Repair A. Mechanical Damage Areas damaged by welding, ame cutting, or during handling, transport or erection shall be repaired by one of the following methods whenever the damage exceeds 3/16 in width on at surfaces, or 1/10 on cut ends: (1) Cold Galvanizing Compound Surfaces to be reconditioned with zinc-rich paint shall be clean, dry, and free of oil grease and corrosion products. Areas to be repaired shall be power disc sanded to bright metal. To ensure that a smooth reconditioned coating can be effected, surface preparation shall extend into the undamaged galvanized coating. Touch-up paint shall be an organic, cold galvanizing compound having a minimum of 65% zinc dust in the dry lm. The paint shall be spray-or brushapplied in multiple coats until a dry lm thickness of 4 mils minimum has been achieved. A nish coat of aluminum paint shall be applied to provide a color blend with the surrounding galvanizing. Coating thickness shall be veried by measurements with a magnetic or electromagnetic gauge.

(2)

Zinc Based Solder Surfaces to be reconditioned with zinc based solder shall be clean, dry, and free of oil, grease and corrosion products. Areas to be repaired shall be wire brushed and given a thin layer of acidic paste ux. Heat shall be applied slowly and broadly close to, but not directly onto, the area to be repaired. The zinc-based solder rod shall be rubbed onto the heated metal until the rod begins to melt. A exible blade or wire brush shall be used to spread the melt over the area to be covered. The zinc based solder shall be applied to a minimum thickness equivalent to that of the undamaged coating. Coating thickness shall be veried by measurements with a magnetic or electromagnetic gauge.

B. Wet Storage Stain Any wet storage stain shall be removed by the galvanizer if formed and discovered prior to leaving the galvanizers plant, unless late pick-up or acceptance of delivery has necessitated the material being stored in unfavorable conditions. In any event, wet storage stain shall be removed before installation to prevent premature failure of the coating. Wet storage stain shall be removed as fol lows: (1) (2) The objects shall be arranged so that their surfaces dry rapidly. Remove light deposits with a stiff bristle (not wire) brush. Heavier deposits are to be removed by brushing with an acidic-based metal cleaner. The surfaces cleaned shall be thoroughly rinsed with water. (3) A coating thickness check must be made in the affected areas to ensure that the zinc coating remaining after the removal of wet storage stain is sufcient to meet or exceed the requirements of the specication. 19

(3)

Metallizing Surfaces to be reconditioned with zinc metal spray shall be clean, dry, and free of oil, grease and corrosion products. The area to be repaired shall be grit blasted to white metal, followed by zinc metal spraying to a coating thickness equivalent to that of the undamaged coating, and seal coated using an aluminum vinyl paint.

End cross section, when required

Any localized area

Notes

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