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

Practical Guidelines for the Inspection and Repair of Hot Dip Galvanized Coatings http://www.ckit.co.za/secure/conveyor/troughed/corrosion-protection/practical-guidelines/practi...
Practical Guidelines for the Inspection and Repair of Hot Dip Galvanized Coatings
Information courtesy of: HOT DIP GALVANIZERS ASSOCIATION SOUTHERN AFRICA
Surface Conditions (SC)
Legend:
A - Accept R - Reject N - Negotiate C - Clean REP - Repair

RESPONSIBILITY: G - Galvanized D - Designer B - Builder/Fabricator S - Steel Type/Surface
Effect / Remedy A/R/N

SC Description Cause Example
/ Responsibility /C/REP
1 APPEARANCE OF SODIUM Although the recommended Maintain concentration of A
DICHROMATE. quantity of sodium dichromate is sodium dichromate at about
A small amount of sodium about 0,15 to 0,3%, 0,15 to 0,3%. G
dichromate is generally added to the occasionally when topping up,
quench water bath for passivation. more is added. This often results
in a dark yellow to brown colour
on the galvanized surface. The
darker colour will provide
enhanced initial corrosion
protection.
2 ASH DEPOSITS. Zinc oxide deposits coo take The coating is normally intact A/N
Ash deposits are grey, non-metallic place when the component is underneath the ash deposits.
deposits consisting of zinc oxide dipped or when it is removed Ash must be removed and the
that have been deposited no the hot from the both. coating thickness verified for
dip galvanized coating. conformance to the
specification requirements. REP
Remove ash from all liquid If
conveyance pipes. G necessary
1 of 11 06-Feb-17 9:22 PM
3 BARE SPOTS. There are several causes of bare spats. These include: A/R
Although excluded from ISO 1461, Overdrying. If the time between fluxing and hut dip galvanizing is
bare spots of about 5mm (2,2 x prolonged or the drying temperature is toe high, the barrier
2,2mm), due to small localised protection provided by the flux may be lost. This is indicated by a
flows, ore adequately protected by rusty appearance on the ungalvanized article, which can result in
the sacrificial properties of zinc and coating discontinuities after hot dip galvanizing. G
will have very little effect on the Excess Aluminium. A condition sometimes referred to as black.
service life of the coaling. Where spats may occur if the aluminium content of a bath becomes too
necessary, such spots may be high. No trouble should be experienced if flux concentration is
repaired using one of the specified correct and the aluminium content of the both is maintained
REP
repair methods. Gross uncoated
below approximately 0,007%. G If
areas ore a cause for rejection. See necessary
Further causes are:
Coating Repair Procedures.
Blowouts; flux deposits; stains and inclusions; mechanical
damage; touch marks; uncoated surfaces caused by - surface
contaminants, scale or sand; welds and weld spatter. See SC
No's 6, 16, 19, 30, 33, 34, 35 and 37
4 BLACK STEEL INSPECTION. Components should be checked Insufficient inspection prior to A/R
Inspection prior to hot dip for distortion caused during hot dip galvanizing can be the
galvanizing is extremely important. rolling or fabrication. Check for cause of dispute. G
appropriate vent, fill and
drainage holes: removal of weld
slag and spatter; venting of
overlapping surfaces; unsuitable
joining materials; temporary
identification markings;
clearance for moving ports and
potential distortion due to the
process.
5 BLASTING DAMAGE. Incurred nozzle pressure; nozzle A hot dip galvanized coating wi8 R
Sweep blasting, dune correctly, angle; sweeping distance; size be partially or fully destroyed by
substantially increases paint of abrasive and recycling of grit. excessive blasting. Refer to the
adhesion and final coating HDGASA Cede of Practice.
appearance hut done incorrectly can D/B
result in coating damage.
2 of 11 06-Feb-17 9:22 PM
6 BLOWOUTS. Pre-treatment chemicals Pre-heat item prior to A

Staining and coating defects around penetrating sealed overlap areas immersion in zinc both to dry
unsealed weld areas and vent holes. through the required vent holes out overlap area as much as
Similar to stains ceased by weeping. and escaping during immersion in possible. D/G C/REP
See SC 28. the molten zinc. This effect If
tends to damage the flux necessary
coating, causing localised
uncoated areas.
7 CLOGGED HOLES. Molten zinc has a high surface Make holes as large as possible. A
Zinc film clogging or partly bridging tension and will not easily drain Removal of molten zinc over
holes. from holes under 8mm in the bath and utilization of
diameter. vibrators will reduce the C
likelihood of clogging. D/G If
required
8 CLOGGED THREADS. Insufficient centrifuging or poor The correct centrifuging R

Threaded components or drainage of threaded equipment or post galvanizing
attachments have threads dogged attachments on withdrawal from thread cleaning by heating, wire
with zinc. the galvanizing bath. brushing or oversize tapping of
nuts, will generally remove
clogging. If necessary specify C/REP
delivery of bolts end nuts in
nutted up farm. G
9 DESIGN STRUCTURES IN Double dipping can sometimes Touch up and repair can be A
MODULAR LENGTHS AND be used to hot dip galvanize avoided, the cost of hut dip
OPTIMUM WIDTHS TO SUIT fabrications that are too long or galvanizing reduced and the
AVAILABLE BATH SIZES. wide far single immersion. If the overall quality improved, if the
fabrication exceeds the bath design of the component is
size, members in the fabrication restricted to the length, width C/REP
may require touching up. and depth 0f the galvanizing
bath. D/B
10 DISCOLOURING AFTER HOT DIP Materiel stored in contact with Once the cause has been A
GALVANIZING CAUSED BY rusty steel, or iron filings can removed the stains will
GRINDING OR OTHER cause surface rust staining. gradually disappear. B
RESIDUES. C
If
possible
3 of 11 06-Feb-17 9:22 PM
11 DISTORTION. The hot dip galvanizing process Use symmetrical designs; Use A/N
Distortion is the unwanted warping occurs ala molten zinc sections of similar thickness;
that occasionally becomes evident temperature of 450 dug C. This Stiffen unsupported thin wall
after hut dip galvanizing. is at the lower end of the stress sections; Use preformed
relieving temperature for treating members with the correct
steel. Thus, any inherent rolling minimum bend radii; Use
or welding stresses in the balanced or staggered welding
fabrication, are likely to be techniques; Make use of
released. This may result in a temporary braces on thin walled REP
dimensional change, i.e. sections such as troughs,
If
distortion. cylinders and angle frames.
Avoid quenching after possible
galvanizing. Components can
be straightened after hot dip
galvanizing. D/G
12 DRAINAGE SPIKES. The edge mast likely to have Drainage spikes are easily A/N
Spikes and teardrops of zinc often these spikes is the last to leave removed at the bath while still
appear along the edge of a the bath on withdrawal. This molten but with complex
component after hot dip galvanizing. applies particularly to complex fabrications, the solidified spikes
fabrications. will be removed by fettling by
the galvanizer prior to C/REP
inspection. G If
possible
13 DROSS. Gross dross deposit from the Dross consists of the same R/N
Dross particles are iron/zinc alloy bottom of the zinc both, trapped iron/zinc alloy as the coating, it Mechanically
crystals produced when hut dip in the corner of a fabrication. will provide the same corrosion remove if
galvanizing steel. These precipitate The dross incorporated in the protection as a normal hot dip possible, repair
to the bottom of the bath and are coating prevents drainage of the galvanized coating. G or regalvanize
removed by the galvanizer. zinc in the intermediate area and
a build up occurs. C/REP
If
necessary
14 DULL GREY OR MOTTLED This appearance indicates the Although not as aesthetically A
COATING APPEARANCE. presence of extensive iron/zinc pleasing as a coating with free
Dull grey or mottled coatings can allay phase growth, mused by zinc on the surface, a dull grey
appear as a dark grey circular steels with high reactive levels of coating provides similar or
patter, a localised dull patch or, may Silicon and Phosphorous in hotter corrosion protection.
extend over the entire surface of steels. D/S
the component.
4 of 11 06-Feb-17 9:22 PM
15 FLAKING OR DELAMINATION High phosphorous content Use a steel that has a R/N
OF COATING. (greater) than 0,03% causes phosphorous content of lower
No adhesion of zinc to steel surface. entire coating to delaminate than 0,03%. D/S
Thick, rough coating. from the steel.
16 FLUX DEPOSITS, STAINS AND Flux deposits or stains may Flux deposits or stains should A
INCLUSIONS. occur as a result of excessive be removed and the
Flux deposits or stains from the "dusting" with ammonium underl~4ng coaling measured
galvanizing process may adhere to chloride on withdrawal from the to determine whether it
the steel or become included in the molten zinc. Flux inclusions can conforms to the minimum
coating. Flux residues are black, occur when a surface flux requirements of the
brown, grey or blanket is applied to the zinc specification. G C/REP
yellowish non-metallic deposits surface (wet galvanizing). Flux
consisting mainly of ammonium blankets are normally only used If
chloride. for specialised processes, e.g. necessary
galvanizing of tubes and
fasteners.
17 DISCOLOURATION OF THE Inadequate repair of a damaged Make use of the correct repair R
PAINT COATING OVER HOT DIP surface on the hot dip galvanized materials and application
GALVANIZING AFTER coating prier to the application of procedures when touching up
EXPOSURE TO THE a paint coating. cut or welded hot dip galvanized
ENVIRONMENT. components. See Coating REP
Repair Procedures. B
18 COATING THICKNESS No matter how the zinc coating Specify hot dip galvanized R
PROVIDED ON FASTENERS USE is applied, the coating life is fasteners to ISO 1461, where
TO ASSEMBLE HOT DIP proportional to its thickness in a required. Alternatively overcoat
GALVANIZED STRUCTURES. given environment. Often fastener with an approved zinc
electroplated fasteners with rich point or epoxy. See Coating
insufficient coating thickness are Repair Procedures. D/B REP
incorrectly used in external If
environments. acceptable
19 MECHANICAL DAMAGE. The use of chains, wire ropes, Warning labels, highlighting a A
Mechanical handling or transport dragging or dropping of the thick coating and possible
damage may occur, particularly with component onto a hard surface, damage if manhandled, should
extremely thick coatings, which can cause mechanical damage. be attached by the galvanizer,
tend to be brittle in nature. This is particularly relevant with before the component is
thick brittle coatings. transported. The use of nylon REP
lifting slings is recommended. If
G/B necessary
5 of 11 06-Feb-17 9:22 PM
20 OXIDE LINES. Due to the shape and/ or No effect on corrosion A

Light aluminium oxide film lines on drainage conditions of some resistance. The overall
hot dip galvanized surface. components, the hoist crane has appearance becomes uniform in
stopped and started upon time. G
withdrawal of the items from the
molten zinc.
21 PIMPLES OR BLISTERS. Dross pimples result from The galvanizer should avoid A
Pimples or blisters formed during agitation of the dross layer at disturbing the dross layer at the
hot dip galvanizing are usually the bottom of the bath or from bottom of the bath by
associated with surface dragging material through the controlling immersion depths
imperfections such as dross dross layer. They appear as and dressing regularly. Since
inclusions. small, hard lumps on an dross pimples represent minor
otherwise normal galvanized disturbances in coating C
surface. Blisters may be formed uniformity, they do not affect If
by hydrogen, which is absorbed corrosion resistance. G necessary
daring pickling and diffused at
galvanizing temperatures.
22 REACTIVE AND NON-REACTIVE This difference in coating Select the same steel for A/N
STEELS, WELDED TOGETHER. thickness, is brought about by a fabricating a component. If
Variations in coating thicknesses can combination of a more reactive need be, accept a concession
arise when reactive and silicon killed steel, and/or high request by the galvanizer when
non-reactive steels are welded phosphorous resulting in a the thinner coating is possibly
together. Efforts to increase coating thicker coating and a less below specification. D/B
thickness on the less reactive steel reactive aluminium killed steel,
may result in an undesirably thick resulting in a coating thickness
and brittle coating on the most sometimes below that required
reactive steel. in the specifications. Should the
galvanizer be asked to
regalvanize in accordance with
the specification, the resultant
coating thickness on the reactive
steel will be excessively thick,
resulting in a brittle coating more
susceptible to damage.
23 REMOVAL OF ZINC COATING BY Excessive cleaning of the The affected areas usually only R
EXCESSIVE CLEANING. coating, particularly the edges, appear after the component is
Unless otherwise agreed, the by mechanical methods, can installed. Care should be
REP
galvanizer will limit cleaning of the result in uncoated areas. exercised by the galvanizer to
At the galvanizer
final coating by mechanical means avoid over cleaning. G/B or alternatively
to that required in the specification.
at site
6 of 11 06-Feb-17 9:22 PM
24 ROLLING DEFECTS IN STEEL. Steel may occasionally include Surface flaws in the base A
These defects maybe broadly laminations, laps, folds and material maybe removed by
classified as surface discontinuities in nonmetallic impurities, which local grinding after hot dip
the steel that have been elongated result in slivers rolled into the galvanizing followed by repair of
during rolling. metal surface. Defects of this the affected surface. Minor
type are sometimes detected surface defects will not REP
before or after pickling, but may adversely influence coating life. If
only become apparent after hot S necessary
dip galvanizing.
25 ROUGH COATINGS, CAUSED BY Rough surfaces, typical of The rougher surface will A
STEEL SURFACE CONDITIONS. coatings on corroded steel produce a thicker coating and
surfaces, can be hot dip result in a longer service life. S
galvanized satisfactorily. The
coating will, however, reflect the
texture of the 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 COATINGS, Rough, heavy coatings refer to The thicker coating produced A/R
CAUSED BY A ROUGH SURFACE hot dip galvanized components will provide greater corrosion
AND/OR THE CHEMICAL showing markedly rough protection. Except when the
COMPOSITION OF THE STEEL surfaces. This can include coating tends to flake off or
"TREE BARK EFFECT" coatings that have a generally delaminate see SC 15. S
rough surface and, in some
cases, groove type surface
configurations, "tree bark effect"
caused by variations in surface
steel analysis.
27 ROUGH HEAVY COATINGS Efficient centrifuging, will Provided the steal/casting R

CAUSED BY INSUFFICIENT generally remove excess zinc surface is reasonably smooth,
CENTRIFUGING. and provide a smooth and correctly centrifuged articles will
attractive exterior. provide an acceptable finish. G C/REP
If
acceptable
7 of 11 06-Feb-17 9:22 PM
28 STAINS CAUSED BY WEEPING. The salts from acid or flex that The stains can be easily A
have penetrated porous welding removed by means of bristle
or between contact surfaces brushing. Should the
during pickling can weep after component be destined for a
hot dip galvanizing and water corrosive area, the crevice
quenching, producing a stained should be sealed with a sealant C/REP
area. after cleaning. D/B If
necessary
29 TIGHTLY ADHERENT LUMPS OF Heavy walls and thick flanges The galvanizer should ensure all R
ZINC ON THE INSIDE OF HEAVY used in the manufacture of zinc hen been removed from
WALLED STEEL PIPING. piping can act as a heat sink the aside of the pipe by longer
when immersed in molten zinc. immersion times. G
This effect considerably
lengthens the immersion time.
Occasionally the galvanizer will
C/REP
remove the pipes before all the If
zinc has melted from the inside acceptable
of the pipe.
30 TOUCH MARKS. Articles entering the galvanizing Minimise contact between A

The zinc in the galvanizing bath baths should not be in tight components and jig
should have free access to all contact with each other. Jigging connections. (Loosen jigging
component surfaces or small wire should also be loosely wire). Small components can be
unmated or damaged areas can attached to eliminate wire centrifuged. G REP
result. marks. Where a component has
been resting on jigging or dipping If
equipment, an uncoated area en necessary
touch mark could appear. and
acceptable
31 TYPICAL SPANGLED HOT DIP Surface appearances may vary Small additions of aluminium to A
GALVANIZED COATING. according to the chemical the molten zinc, brightens the
A typical hot dip galvanized surface composition of the steel. Cooling coating. S/G
is shown in the example. The rate has a direct effect on the
surface is silver grey in colour and surface brightness and spangle
not necessary but often has a size. Easter cooling usually
spangled effect (zinc crystals) in a results in a brighter coating with
range of sizes. a smaller spangle size.
8 of 11 06-Feb-17 9:22 PM
32 UNEVEN DRAINAGE. This condition can occur over the Although not particularly A
Uneven drainage results in an entire surface Grin isolated attractive, this condition dons
uneven or lumpy area on which zinc areas. Uneven drainage also not adversely affect coating
build op has occurred. includes drips en the ends of performance. Protuberances C
ports, runs near halos. The and lumps, which interfere with If
cause is withdrawal speed too mating surfaces are necessary
high or low galvanizing unacceptable. G
temperature.
33 UNCOATED SURFACES CAUSED Residues, such as oil based Ensure all paint or grease is A/N/R
BY STEEL SURFACE paint, grease, oil or labels on the removed prior to hot dip
CONTAMINANTS OR steel surface or incorrectly galvanizing. Make usual suitable
ENTRAPPED AIR. positioned vent holes, can result marking pens for temporary
in localised ungalvanized areas in identification. Correctly position
an otherwise continuous adequately sized vent hubs. B
galvanized coating. Defects after REP
galvanizing can very in colour If
from grey black to brown while
no galvanized coating has been
necessary
formed.
34 UNGALVANIZED SURFACES Sand on cast iron or scale on the These ungalvanized areas may R/N
CAUSED BY SCALE OR SAND. steel surface is generally caused occur in a linear pattern on
by the process used to form or angles, channels or other rolled
roll the product. A localised products. They can also appear REP
ungalvanized area in an on cast iron products. S/G If
otherwise continuous coating
can occur if scale or sand from acceptable
the moulding or rolling is not
removed by acid pickling or
abrasive blasting.
35 UNGALVANIZED AREA IN THE A localised ungalvanized area Weld slag deposits should be R/N
VICINITY OF A WELD. near a weld can be caused by removed by the fabricator by
weld slug deposit, weld porosity means of abrasive blast
or weld undercut. Oxide deposits cleaning. The deposit can also
and residues from welding are be removed by proper chipping
resistant to normal pickling adds or wire brushing. Shielded arc
and mint be removed before the welding as opposed to slick REP
work is pickled and hot dip welding is preferred for If
galvanized. components which are to ho necessary
hot dip galvanized. B
9 of 11 06-Feb-17 9:22 PM
36 USE CONVENTIONAL FIXING Conventional drilling and bolting Coating repair can be done by A
METHODS SUCH AS BOLTS AND after hot dip galvanizing is zinc motel spraying urn zinc rich
NUTS, OR REPAIR DAMAGED preferred. Should welding or painter epoxy, providing the
COATINGS CAUSED BY noon-conventional method of product conforms to the
WELDING OR fixing be used, resulting in requirements of the
NON0-CONVENTIONAL FIXING damage to the coating, an specification. (See Coating REP
METHODS. approved repair method is Repair Procedures). D/B
necessary.
37 WELD SPATTER. Weld spatter is caused by weld Loosely adherent weld spatter A/N
Weld spatter is oxidised, normally pool explosions when improper should be removed prior to hot
spherical expelled weld metal, that is welding parameters are used, or dip galvanizing. Although not
fused or not onto the surrounding if the material is dirty or acceptable in terms of the
material during welding. contaminated. specification the presence of
tightly adherent weld spotter
after hot dip galvanizing will not
affect the corrosion resistant
properties of the coating. B
38 WET STORAGE STAIN OR WHITE Wet storage stain (zinc Wet storage stain ceases when A
RUST. hydroxide) is formed on freshly the cause is eliminated. If the
Wet storage stain or white rust as it galvanized surfaces whirls are in coating thickness at the
is commonly called, is a white close contact in presence of affected area is equal to, or
voluminous deposit that is moisture. Freshly galvanized greater than the minimum
occasionally found on the surface of coatings react with the required in the specification, it is
a freshly galvanized coating. environment until such time as a not a cause for rejection, other
stable zinc carbonate film is than for aesthetic reasons. The C
formed on the cooling surface. latter is subject to discussion If
with the end user. Customer is necessary
to exercise caution during
transport and storage. G/B
39 ZINC METAL SPRAYED REPAIR In order for zinc metal spraying Prepare surface for repair by A
APPLIED TO INADEQUATELY to adhere on application, the adequate blasting. Loosely
BLASTED SURFACES OR NOT damaged galvanized surface applied zinc metal sprayed
WIRE BRUSHED AFTER mast be adequately blasted. As coating at the perimeter of the
APPLICATION. it is difficult not to over spray, repair should ho removed by
excess zinc metal spray loosely wire brushing If net removed, C
adheres to the surrounding there is no compromise in the
coating. corrosion resistance. G/B
10 of 11 06-Feb-17 9:22 PM
40 ZING SPLATTER. When hot dip galvanizing an The loosely adherent zinc A
Splashes and flakes of loosely unusually deep fabrication by splashes are easily removed. An
adherent zinc, caused by moisture double dipping, moisture an the experienced galvanizer can
on the steal surface when hot dip surface of the steel contacts ensure the coating overlap on
galvanizing. with the molten zinc causing double end dipped surface, is
C
splashes of zinc to loosely not visible. G
adhere to the already hot dip
galvanized surface.
11 of 11 06-Feb-17 9:22 PM

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

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

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

Uploaded by

Copyright:

Available Formats

Practical Guidelines for the Inspection and Repair of Hot Dip Galvanized Coatings http://www.ckit.co.za/secure/conveyor/troughed/corrosion-protection/practical-guidelines/practi...

Information courtesy of: HOT DIP GALVANIZERS ASSOCIATION SOUTHERN AFRICA

Surface Conditions (SC)

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

Effect / Remedy A/R/N

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

8 CLOGGED THREADS. Insufficient centrifuging or poor The correct centrifuging R

20 OXIDE LINES. Due to the shape and/ or No effect on corrosion A

27 ROUGH HEAVY COATINGS Efficient centrifuging, will Provided the steal/casting R

30 TOUCH MARKS. Articles entering the galvanizing Minimise contact between A

You might also like