Galvanizing Defects

Ash Deposit

CAUSES REMEDY

The coating is normally intact underneath the ash deposits.

Zinc oxide deposits cool take place when the component is
Ash must be removed and the coating thickness verified for
dipped or when it is removed from the bath..
conformance to the specification requirements.
 Bare Spots

CAUSES REMEDY

Such spots may be repaired using one of the specified repair

Over Drying, Excess Aluminium, Flux deposits, Stains and
methods as per standard requirements. Gross uncoated
Inclusions, Touch Marks, Surface Contaminants
areas are a cause for rejection.
 Drainage Spikes

CAUSES REMEDY

The edge most likely to have these spikes is the last to leave The solidified spikes will be removed by fettling by the
the bath on withdrawal galvanizer prior to inspection.
 Dross

CAUSES REMEDY

Precipitation to the bottom of the bath are removed by the

Dross particles are iron/zinc alloy crystals produced when hot
galvanizer Frequently and it must be cleaned where
dip galvanizing steel
appearance wise not acceptable.
 Dull Grey or Mottled Coating

CAUSES REMEDY

This appearance indicates the presence of extensive iron/zinc Although not as aesthetically pleasing as a coating with free
alloy phase growth mused by steels with high reactive levels of zinc on the surface, a dull grey coating provides similar or
silicon and phosphorous in steels. hotter corrosion protection.
 Oxide Lines

CAUSES REMEDY

No effect on corrosion resistance. The overall appearance

Light aluminium oxide film lines on hot dip galvanized surface.
becomes uniform in time.
 Pimples or Blisters

CAUSES REMEDY
The galvanizer should avoid disturbing the dross layer at the
bottom of the bath by controlling immersion depths and
Pimples or blisters formed during hot dip galvanizing are usually
dressing regularly. Since dross pimples represent minor
associated with surface imperfections such as dross inclusions.
disturbances in coating uniformity, they do not affect
corrosion resistance.
 Rough Coating

CAUSES REMEDY

The rougher surface will produce a thicker coating and

ROUGH COATINGS, CAUSED BY STEEL SURFACE CONDITIONS.
result in a longer service life.
 Strains Caused by Weeping

CAUSES REMEDY
The stain can be easily removed by means of bristle
The Salts from acid or flex that have penetrated porous welding
brushing. Should the component be destined for a corrosive
or between contact surfaces during pickling can weep after hot
area, the crevice should be sealed with a sealant after
dip galvanizing and water quenching, producing a stained area.
cleaning.
 Touch Marks

CAUSES REMEDY
The zinc in the galvanizing bath should have free access to all
Minimize contact between components and jig connections.
component surfaces or small unmated or damaged areas can
(Loosen jigging wire). Small components can be centrifuged.
result.
 Spangled Coating

CAUSES REMEDY

Surface appearances may very according to the chemical Small additions of Aluminium to the molten zinc, brightness
composition of the steel. the coating.
 Uneven Drainage

CAUSES REMEDY
Although not particularly attractive, this condition dons not
The cause is withdrawal speed too high or low galvanizing adversely affect coating performance. Protuberances and
temperature. lumps, which interfere with mating surfaces are
unacceptable.
 Wet Storage Strain or White Rust

CAUSES REMEDY
Wet storage stain (Zinc hydroxide) is formed on freshly It is not a cause for rejection, other than for aesthetic
galvanized surfaces which are in closed contact in presence of reasons. The latter is subject to discussion with the end
moisture. user. Customer during transport and storage.
 Discoloration due to Overgrinding

CAUSES REMEDY
Finishing of Hot dip Galvanized Gratings has been done with In case of appearance then zinc spray can be used to cover
emery disc paper Grinder for removal of zinc skimming’s and them on temporary basis. As over larger time period the
pimples color of surface will become uniform due to weathering