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© 2012 American Galvanizers Association. The material provided herein has been developed to provide accurate and authoritative information about
after-fabrication hot-dip galvanized steel. This material provides general information only and is not intended as a substitute for competent professional
examination and verification as to suitability and applicability. The information provided herein is not intended as a representation or warranty on the
part of the AGA. Anyone making use of this information assumes all liability arising from such use.
Communication among Design Engineer, Materials Suitable for Galvanizing
Architect, Fabricator, & Galvanizer
INTRODUCTION
Most iron-containing (ferrous) materials are suitable for hot-
Corrosion protection begins at the drawing board, and regardless dip galvanizing. Plain carbon steel (under 150 ksi/1100 MPa)
of what protection system is specified, it must be factored into and low alloy materials, hot-rolled steel, cold-rolled steel, cast steel,
the product’s design. Similarly, all corrosion protection systems ductile iron, cast iron, castings, stainless steel, and even weathering
require certain design details and proper planning to ensure steel can be and are galvanized for enhanced corrosion protection.
the highest quality coating. For hot-dip galvanizing, a total However, the material’s chemical composition influences the
immersion process in molten zinc, the design engineer will characteristics of the galvanized coating.
want to ensure all pieces are fabricated suitably for the process.
Most design principles necessary for success throughout the During galvanizing, the iron in the material reacts with the
galvanizing process are easily and readily followed, and in most molten zinc to form a series of zinc-iron alloy layers, which are
cases, ensure maximum corrosion protection. Incorporating covered by a layer of iron-free zinc. For most hot-rolled steels,
these design practices along with those listed in ASTM A385 the zinc-iron alloy portion of the coating will represent 50-70%
Practice for Providing High Quality Zinc Coatings (Hot-Dip), will of the total coating thickness, with the free zinc outer layer
not only produce optimum quality galvanized coatings, but also accounting for the balance (Figure 1).
help reduce costs and improve turnaround times.
Communication among...
Design
Fabricator/
Engineer/ Galvanizer
Detailer
Architect
3
to the utilization of other coating systems.
American Galvanizers Association
inclusions are not removed by chemical cleaning. Thorough Many coatings such as paint and lacquer cannot be removed
abrasive cleaning either by grit-blasting or a combination of grit from the steel with the chemical cleaning process used in the
and shot is the preferred and most effective method to clean the galvanizing facility. As perfectly cleaned steel is required for the
casting and remove foundry sand and impurities. Cleaning is metallurgical reaction to occur in the galvanizing kettle, these
traditionally performed before shipment to the galvanizer. contaminants need to be removed mechanically from the surface
prior to sending the fabrication to the galvanizer.
Sound, stress-free castings with good surface finishes will
produce high-quality galvanized coatings. The following The use of old along with new steel, or castings with rolled
design and preparation rules should be applied for castings steel in the same assembly, should be avoided (Figure 3). Where
to be galvanized: assemblies of cast iron, cast steel, malleable iron, or rolled steel are
unavoidable, the entire assembly should be thoroughly abrasive-
• Avoid sharp corners and deep recesses blasted prior to pickling to give the best chance for producing a
• Use large pattern numerals and generous radii to facilitate consistent galvanized coating appearance.
Atypical coatings produced from reactive steels exhibit
abrasive cleaning
different coating characteristics than a typical galvanized
coating such as: • Specify uniform wall sections. Non-uniform wall thickness in
certain casting designs may lead to distortion and/or cracking.
Appearance: The atypical galvanized coating may have Cracking results from stress developed as the temperature
of the casting is increased during galvanizing. Uniform wall Ductile iron pipe with
a matte gray appearance and/or rougher
sections and a balanced design lowers stress. machined flange
surface due to the absence of the free zinc
layer. The free zinc layer present on typical It is difficult to provide precise guidance in the area of steel
coatings imparts a shinier finish to selection without qualifying all steel grades commercially Combining Different Materials & Surface
a galvanized coating. available. However, these guidelines discussed will assist you
in selecting steels that provide good galvanized coatings. Varying surface conditions, different fabrication methods, or
Castings with
Adherence: Th
e zinc-iron alloy coating tends to be ferrous metals with special chemistries, when combined, make
mild carbon steel
thicker than a typical galvanized coating. • Levels of carbon less than 0.25%, phosphorus less than it difficult to produce coatings with uniform appearance. This
In the rare situation where the coating is 0.04%, or manganese less than 1.35% are beneficial is because different parameters for pickling (immersion time,
excessively thick, there is the possibility of solution concentrations, temperatures) and galvanizing (bath
diminished adhesion under external stress • Silicon levels less than 0.04% or between 0.15% - 0.22% temperatures, immersion time) are required for:
(thermal gradients, sharp impact). are desirable
• Coatings such as paint, lacquer, etc. on the steel Forged bolt with
Silicon may be present in many steels commonly galvanized machined threads
Reactive steels are still galvanized on a regular basis, and it is • Excessively rusted surfaces
important to note differences in appearance have no effect on even though it is not a part of the steel’s controlled
• Machined surfaces
the corrosion protection afforded by the galvanized coating. composition, because silicon is used in the steel deoxidation
process and is found in continuously cast steel. Both silicon • Cast steel
The performance of the coating is based on the thickness of
the zinc; therefore, often the duller (and thicker) coatings and phosphorous act as catalysts during the galvanizing • Malleable iron
produced by reactive steels last longer. Furthermore, all process, resulting in rapid growth of zinc-iron alloy layers. • Hot-rolled steel
galvanized coatings as they weather over time will develop a • Cold-rolled steel Machined surfaces
uniform matte gray appearance. Even when both elements are individually held to on pitted steel
desirable limits, the combined effect between them can • Cast iron, especially with sand inclusions
still produce an atypical coating of all or mostly zinc-iron • Pitted surfaces
alloy layers. When possible, your galvanizer should be • Steel containing excess carbon, phosphorus,
advised of the grade of steel selected in order to determine manganese, or silicon
Steel with different
whether specialized galvanizing techniques are suggested.
surface conditions
Castings
High-quality castings and forged parts are also commonly
and successfully galvanized. The quality of the galvanizing is
strongly influenced by the quality of the casting. As with all
steel to be galvanized, cleanliness is very important to achieve
completely galvanized cast iron or steel parts. However, Figure 3: Results will not be consistent with a combination of
conventional cleaning processes employed by galvanizers do these type of metals or finishes
not adequately clean castings because sand and other surface
Steel Casting Varying steel chemistries create visually different
5
coatings, as illustrated by this pipe assembly
American Galvanizers Association
Similarly, excessively rusted, pitted, or forged steels should your galvanizer early in the design process. Large assemblies are usually supported by chain
also not be used in combination with new or machined Almost any component can be galvanized slings or by lifting fixtures. Special jigs
surfaces because the difference in required pickling time by designing and fabricating in modules and racks are also commonly used to
for sulfuric acid pickling baths can cause over-pickling of suitable for available galvanizing simultaneously galvanize large numbers
the new or machined surfaces. Where this combination facilities. The average kettle length of similar items. Providing lifting
is unavoidable, a thorough abrasive blast cleaning of the in North America is 40 feet (13m), points where possible will reduce or
assembly (normally before any machining is done) provides and there are many kettles between eliminate chain or wire marks that
a more uniform galvanized coating. 50-60 feet (15.24 m - 18.28 m). can be left on an item when no
Kettle dimensions and contact lifting points are present. If no
If abrasive blast cleaning is used to prepare a surface for information for all member lifting points are provided, any
galvanizing, a coating thicker than normal will be produced galvanizers are available at marks, which are usually fully
for low silicon steel. Abrasive cleaning roughens the steel www.galvanizeit.org/galvanizers. galvanized, can be touched up
surface and increases its surface area, resulting in increased if desired for aesthetic reasons.
Hot-dip galvanizing cold-worked steel is very
reactivity with the molten zinc. Large structures designed in modules It is also good practice to discuss successful when following suggested guidelines
or sub-units to accommodate the the weight-handling capacity with
The best practice when combining different materials galvanizing kettle often provide the galvanizer to ensure capacity or
and surfaces is to galvanize separately and assemble after additional savings in manufacturing and the best places to put lifting points. Strain-Age Embrittlement
galvanizing. This will help facilitate efficient turnaround assembly because they simplify handling In addition to lifting points, large any structures and parts are fabricated using cold-rolled steel or
M
times in the process, eliminate over-pickling, and allow and transportation. The sub-units can be pipe sections, open-top tanks, and similar cold-working techniques. In some instances, severe cold-working
the pieces to be matched for appearance. Whether run connected after galvanizing by field-welding or structures may benefit from temporary bracing may lead to the steel becoming strain-age embrittled. While cold-
through the galvanizing process joined or separately, the bolting. Alternatively, if an item is too large for total to maintain their shape during handling. working increases the possibility of strain-age embrittlement, it
differences in appearance on assemblies containing steels immersion in the kettle, but more than half of the item will may not be evident until after galvanizing. This occurs because
with varying surface condition do not affect the corrosion fit into the kettle, the piece may be progressively dipped. Process Temperature/Heat aging is relatively slow at ambient temperatures, but more rapid at
protection. Furthermore, after aging in the environment, Progressive dipping is accomplished by dipping each end of the elevated temperature of the galvanizing bath.
all surfaces will exhibit a uniform matte gray appearance. the article sequentially to coat the entire item. Consult your During the hot-dip galvanizing process, steel is heated to
galvanizer before designing a piece for a progressive dip. approximately 830 F (443 C) for the galvanizing reaction Any form of cold-working reduces steel’s ductility. Operations
Size & Shape to occur. Every time steel is heated and cooled, stress is such as punching holes, notching, producing fillets of small
Considering size and shape, as well as weight, is also important added to the fabrication. Therefore, there are some design radii, shearing, or sharp bending (Figure 4) may lead to strain-
Another important consideration during the design process due to material handling techniques used in galvanizing plants. considerations to be aware of to help reduce any issues with age embrittlement of susceptible steels. Cold-worked steels less
is the size and shape of the fabrication. Because hot-dip The steel is moved through the process by the use of hoists and the heating of the galvanizing process. than 1/8-inch (3 mm) thick that are subsequently galvanized
galvanizing is a total immersion process, the design must overhead cranes. Small items, less than 30” (76 cm) in length, are unlikely to experience strain-age embrittlement. Since cold-
take into consideration the capacity of the galvanizing are frequently galvanized in perforated baskets. The baskets Mechanical Properties of Galvanized Steel working is the strongest contributing factor to the embrittlement
kettle; therefore, it is wise to verify kettle constraints with are then centrifuged or spun to remove excess zinc, delivering of galvanized steel, these tips (next page) are recommended to
smoother coatings. Fasteners, small brackets, and clips typify The hot-dip galvanizing process produces no significant
reduce the incidence of strain-age embrittlement.
work handled in baskets. changes in the mechanical properties of the structural steels
commonly galvanized throughout the world. The mechanical
properties of 19 structural steels from major industrial
countries were investigated before and after galvanizing in Preferred Design
a four-year research project of the BNF Metals Technology
Centre, UK, under the sponsorship of the International Lead
Zinc Research Organization (ILZRO). Steels conforming to
ASTM Standard Specifications A36 and A572 Grade 60 and
Canadian Standards Association (CSA) Specifications G 40.8
and G 40.12 were included in this study.
Trough
3.
3 Vent holes in end sections or in similar sections
Figure 12: Vent holes should be visible on the outside of 22 F
rom Figure 14, if H + W = 24” (61 cm) or
any pipe assembly to provide internal vent verification larger, the area of the hole, plus clips, should
must be 1/2-inch (13 mm) in diameter.
equal 25% of the area of the tube (H x W).
4.
4 Ends should be left completely open. Any Figure 14: Holes at either end of the rectangular tube
device used for erection in the field that prevents • I f H + W = less than 24” (61 cm) but trusses should be completely open
full openings on ends of horizontal rails and more than 16” (41 cm), the area of the
vertical legs should be galvanized separately and hole, plus clips, should equal 30% of
attached after galvanizing. the area of the tube.
2
of the pipe, but not less than 3/8-inch (10 mm) 1
11 in diameter. The two holes at each end and at Pipe Truss 3” (7.6 cm) & Larger ( Figure 15):
11 11 each intersection must be 180° apart and in
33 Vertical Sections
the proper location as shown.
11
Hole locations for the vertical members should be as
shown in examples A and B in Figure 15.
F
11 2.
2 Vent holes in end sections or in similar sections
33 33 must be 1/2-inch (13 mm) in diameter. 2
Each vertical member should have two holes at each end
3.
3 Ends should be left completely open. Any and 180° apart in line with the horizontal members as D CD C D C
33 device used for erection in the field that prevents indicated by the arrows. The size of the holes preferably
Figure 13: External vent holes should be visible on the full openings on ends of horizontal rails and should be equal and the combined area of the two holes 2
outside of pipe assemblies vertical legs should be galvanized separately and at either end of the verticals (Areas C and D or Areas E
attached after galvanizing. and F) should be at least 30% of the cross-sectional area.
completely open, with the same diameter as the round holes must equal 30% of the area of the I.D.
of the pole end of the tapered arm for 3” (7.6 cm)
section top and bottom. D and larger I.D.s. The opening must equal 45% of the
2.
2 This is an equal substitute if the full opening is
not allowed. area of the pole end of the tapered arm if the I.D. is
less than 3” (7.6 cm). 1 2
3.
3 This is an equal substitute if the full opening is
not allowed.
4. This is an equal substitute if the full opening is Internal gusset-plates and end-flanges should also be
B
4
Temperature of Use
Hot-dip galvanized steel provides uninterrupted corrosion
protection in a wide variety of temperatures. However,
some extreme temperatures can affect the coating. Cold
temperatures have little affect on the galvanized coating.
On the other hand, constant exposure to temperatures
above 390 F (200 C) will cause the coating to separate and
is not recommended. Short times at temperatures above
390 F do not effect the galvanized coating.
Poles with wet storage stain
22 23
Galvanized guard rail stored with wood
spacers to avoid wet storage stain American Galvanizers Association
American Society for Testing and Materials
Related Specifications
ASTM A36 Specification for Carbon Structural Steel
ASTM A123 Specification for Zinc (Hot-Dip Galvanized) Coatings on Iron and Steel Products
ASTM A143 Practice for Safeguarding against Embrittlement of Hot-Dip
Galvanized Structural Steel Products and Procedure for Detecting Embrittlement
ASTM A153 Specification for Zinc Coating (Hot-Dip) on Iron and Steel Hardware
ASTM A384 Practice for Safeguarding Against Warpage and Distortion During Hot-Dip Galvanizing of
Steel Assemblies
ASTM A385 Practice for Providing High-Quality Zinc Coatings (Hot-Dip)
ASTM A563 Specification for Carbon and Alloy Steel Nuts
ASTM A572 Specification for High-Strength Low-Alloy Columbium - Vanadium Structural Steel
ASTM A767 Specification for Zinc-Coated (Galvanized) Steel Bars for Concrete Reinforcement
ASTM A780 Practice for Repair of Damaged and Uncoated Areas of Hot-Dip Galvanized Coatings
ASTM B6 Specification for Zinc
ASTM D6386 Practice for Preparation of Zinc (Hot-Dip Galvanized) Coated Iron and Steel Product and
Hardware Surfaces for Painting
ASTM E376 Practice for Measuring Coating Thickness by Magnetic-Field or
Eddy-Current (Electromagnetic) Test Methods
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American Galvanizers Assocation
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