S E A S H O R E G A LVA N I Z I N G FA C T O R Y

An ISO 9001 Company

(HOT-DIP GALVANIZING)

ALKHOR INDUSTRIAL AREA

P.O. BOX 60100, ALKHOR, QATAR.

TEL: 4722843/4722844 FAX: 4720564

PROCEDURE FOR
HOT-DIP GALVANIZING
HDG:PQ-001-REV.0
 HOT DIP GALVANIZING PROCEDURE

1. INTRODUCTION

1.1 Hot Dip Galvanizing is the process of coating Iron & Steel components with Zinc for
protection against corrosion, by dipping the components in Molten Zinc at a
temperature of 455 + 50 C.

2. RECEIVING INCOMING MATERIALS

2.1 Materials received for Galvanizing shall be inspected as follows:-

(i) Quantity

(ii) Components shall be checked for damage, if any.

(iii) Dimensions and shape shall be checked to ensure for suitability of the bath.

(iv) Provision for venting and draining as per applicable specification .

(v) Distortion at galvanizing temperature.

2.2 The above inspection check points which are based on specifications shall be
discussed with the customer wherever applicable. Materials which are not
dimensionally suitable shall be segregated. Customer’s approval will be obtained
prior to creating any holes on closed structures for venting and draining.

2.3 The Material Receipt-cum- Inspection Report shall be raised incorporating all the
customers’ requirements, the description of materials, quantity, specification and
commercial terms.

2.4 The materials shall be tagged customer wise for identification.

3. SHOT BLASTING:

3.1 The steel components shall be subjected to mechanical de-scaling process to remove
the Mill scales and rust to obtain a clean surface for Galvanizing by Shot Blasting
using steel shots S-330.The surface will be cleaned so that there is no mill scale and
rust remaining on the surface.

Page 2 of 7
4. PREPARATION

4.1 The materials are shifted to wiring area as per production schedule.

4.2 Vent, Drain and Wiring holes if required are cut by Gas/Drill with the consent of the
customer

3.4 The materials are then wired or stacked on to Jigs / Frames taking into account

the size, shape, section, vent and drain holes, position of wiring points etc.

4.3 The Jigs or Frames are then shifted to pickling area with the help of overhead cranes.

5. PICKLING

5.1 Dipping in a solution of Hydrochloric Acid (Hcl) added with acid inhibitor to remove
rust, impurities etc from steel surface. Acid concentration will be approximately 8-
18%.

5.2 Dipping time depends on surface condition of steel.

5.3 Materials are inspected visually for cleanliness after pickling.

5.4 Materials that do not meet specified cleanliness criteria are repeatedly pickled until
they are found to be clean for further processing.

5.5 Solutions are tested for concentration and pH once in 10 days and records are
maintained.

6. RINSING:

6.1 The pickled components are then rinsed in water until free of Acid.

6.2 The process is carried out by alternating the rinsing between two tanks provided for
this purpose.

6.3 pH of rinsing water is tested once in 5 days.

7. FLUXING:
7.1 After rinsing the materials are immersed in a Flux bath
7.2 This process is done to wet the steel surface and prevent oxidation before Galvanizing
and assist Galvanizing process, to have a uniform coating.

Page 3 of 7
 7.3 Visual inspection is carried out on the components to ensure complete cleanliness
after fluxing.

8. DRYING:

8.1 The materials are dried by spreading over a heating platform. Purpose of drying is to
remove the moisture content from the steel and also to facilitate the flux to form a
thin film over the steel articles and to pre heat the materials before dipping.

8.2 The steel articles are re-arranged in the Jigs or frames according to size or shape, and
suitability for dipping etc.

9. DIPPING:

ZINC BATH SIZE

7mtr Long x 0.8mtr Wide x 1.2mtr Depth
9.1 Zinc Bath size is 7mtr Long x 0.8mtr Wide x 1.2mtr Depth.

9.2 The zinc bath is maintained at a Temperature of 455 + 50 C.

9.3 The surface of Zinc bath is skimmed to remove flux residues or ash prior to
immersing the articles.

9.4 The articles are slowly dipped into the bath at an inclination, until fully immersed.

9.5 Depending on the thickness of sections, coating requirements, the articles remain
immersed in the bath.

9.6 The articles are then swung and agitated.

9.7 The zinc bath surface is skimmed and the articles are slowly withdrawn at an
inclination to allow free drainage of excess zinc. Unsolidified excess zinc is removed
by scrapers.

10. QUENCHING / COOLING:

10.1 Steel components which may not undergo any distortion are quenched in water by
gradually immersing in a quenching bath, and those which may suffer distortion are
allowed to cool naturally.

10.2 Cooled materials are removed from Jigs or Frames and are then removed to recovery
area.

Page 4 of 7
11. RECOVERY AND FINAL INSPECTION:

11.1 Excess Zinc, Lumps, Spikes etc. are removed from the materials by filing.

11.2 Wire marks if any are smoothened by a light grinding action by using a sander
and touch up is done on the affected area with a suitable zinc rich primer.

11.3 Zinc Coating thickness is tested for each lot of materials received,and identified
by a work order number, using a calibrated Elcometer and the readings are
recorded based on each work order number.

11.4 Conformity certificate is issued if requested by customer.

12. LOADING AND DESPATCH:

12.1 Finished goods are transferred to yard for despatching.

12.2 Materials are arranged and stacked in the yard in such a manner to avoid any

Damage and also to facilitate easy loading.

12.3 Materials are loaded to customers transport and dispatch documents are made .

12.4 Invoicing will be based on actual physical weight./no of pcs of the materials as the
case may be after galvanizing.

13. PRODUCTION CAPACITY OF SGF:

13.1 The estimated production capacity is to the tune of 20-25 Tons per day.

13.2 The maximum size of the job which can be dipped (by double dipping process)
will be Length-11 Mtrs, provided the overall diameter or height/width is 250mm.
(With Prior Consultation)

ATTACHMENTS

 ISO accreditation certificates.

Page 5 of 7
 TYPICAL GALVANIZING PROCESS – FLOW CHART

Material
Receiving &
Inspection

Shot Blasting

Acid Pickling

Not Acceptable Re-pickling Done

Visual

Inspection
Acceptabl
e
Water Rinsing

Fluxing

Drying

Molten Zinc Dipping

Natural Cooling Cooling by

Quenching

QC Inspection, Rejected
Materials are Re-Processed
Finishing

Final Inspection

Stacking

Certificate of
Conformity if Required

Dispatch

Page 6 of 7