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Design & Fabrication

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Design & Fabrication
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Materials Suitable for
Hot-Dip Galvanizing
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Hot-Dip Galvanized Fasteners
Hot-dip galvanized
fasteners are
recommended for joining
HDG structurals
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The Galvanizing Reaction
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Typical Zinc-Iron
Alloy Layers
Irregular Zinc-Iron
Alloy Layers
Coating Microstructures
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Steel Reactivity
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Coating Growth
Other factors that effect the growth of the
coating
Other chemical components of steel besides
silicon:
Phosphorus
Manganese
Steel Surface Roughness
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Appearance of HDG
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Combining Different Materials
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Dissimilar Thicknesses
Different thickness
Zinc bath
temperature at
different times

Similar thickness
Maintain original
shape
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Weld Rod Chemistry
Just as the base steel
chemistry influences
coating growth, so
does the chemistry of
the weld rod.
Si < 0.04% or
0.15 < Si < 0.22
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Welding Procedures
& Flux Removal
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Seal-welding
The viscosity of
molten zinc prevents
it from entering gaps
of 3/32 and smaller.
Solutions used to
clean the steel can
penetrate small gaps

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Welding after Galvanizing
American Welding Society
Remove coating 2-4 away from weld area
Repair area using ASTM A 780
Welding Galvanized Steel
Slower welding speeds, higher energy input
Damage galvanized coating in the Heat-
Affected Zone (HAZ), repair is necessary
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Cold-Working
Severe cold-working
of steel increases the
likelihood for strain-
age embrittlement.
ASTM A 384
Keep bend radii as
large as possible, but
at least 3 times the
section thickness

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Galvanizing Oversized Pieces
Progressive Dipping
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Material Handling
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Venting & Drainage
Cropped Corners
(Preferred)
Holes Close to Corners
(Alternatively)
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Cropped Corners
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Venting & Drainage
Drain
Vent
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Venting & Drainage: Base Plates
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Venting & Drainage
Vent Drain
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Venting & Drainage: Tanks
Vent diagonally opposite fill hole
Cropped internal baffle (top & bottom)
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Venting & Drainage: Tanks
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Examples of Good Tank Design
Good
Design
Poor
Design
Flush interiors
provide good
drainage
Trapped
Zinc
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Minimizing Distortion
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Temporary Bracing
Large diameter, thin-walled pipe may require
temporary bracing to prevent possible distortion.
Temporary Bracing
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Castings
Castings usually
require some form of
mechanical cleaning
to remove
encapsulated sand
particles from
crevices.
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Marking
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Masking
Compound used to prevent the galvanized
coating from forming in certain areas of the steel
(a.k.a. stop-offs)
Threads
Areas to be welded
Studs
Not 100% effective and adds significant labor in
application and removal after galvanizing