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CONTENTS

CONTENTS ................................................................................................................................................................ 2
1.0 SCOPE ................................................................................................................................................................. 3
2.0 REFERENCE ...................................................................................................................................................... 3
3.0 GENERAL REQUIREMENTS .......................................................................................................................... 3
4.0 PREPARATION FOR GALVANIZING ............................................................................................................ 5
5.0 PRE-TREATMENT ............................................................................................................................................. 5
6.0 HOT-DIP GALVANIZING .................................................................................................................................. 7
7.0 POST-TREATMENT QUENCHING ............................................................................................................. 7
8.0 DE-RACKING, INSPECTION AND TOUCH-UP ........................................................................................... 8
9.0 HOT DIP GALVANIZE OF FASTENERS ....................................................................................................... 8
10.0

EXPORT PACKING ..................................................................................................................................... 8

11.0

REPAIR OF DAMAGED AND UNCOATED AREAS AT FIELD .......................................................... 9

12.0

DESIGN FOR GALVANIZING.................................................................................................................. 10

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Scope
This specification covered the requirements for the execution of hot dip
galvanizing work for the steel structures inclusive of handrails, grating for
service platform and stairways & fasteners of Storage Tanks for S1501 Zeon
Project.

2.0

Reference

2.1

ASME Section VIII Division 1 (2010 Edition, 2011a Add.)

2.2

ASME Sect. IX ~ Welding and Brazing Qualifications

2.3

ASTM A 123/A 123M (Specification for Zinc (Hot Dip Galvanize) Coatings on
Iron and Steel Products

2.4

ASTM A 153/A 153M (Standard Specification for Zinc Coating (Hot-Dip) on Iron
and Steel Hardware

2.5

Approved For Construction Drawings

2.6

WPS & PQR

2.7

Welder Qualification Test Procedure

3.0

General Requirements

3.1

The purpose of this procedure is to create a uniform basis for the execution of
hot dip galvanizing work for steel structures and for the engineering and
fabrication of the steel structures to be galvanized.

3.2

The necessary adjustment shall be concurred between all parties from the
structural steel engineer, manufacturer and the hot dip galvanizing contractor at
an early stage in order to coordinate the design configuration, dimensions and
the pre-treatment methods.

3.3

In general, the galvanizing process is as per flow chart below:

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4.0

Preparation for Galvanizing

4.1

When planning the steel structures to be galvanized, it is essential to make

allowance for the size of the dip galvanizing bath with respect to the
dimensions of the pre-fabricated steel components.

4.2

Hollow bodies and hollow spaces eg like piping closed at both ends in handrails
shall be provided with intake and discharge openings in order to ensure
full-face galvanizing at all time.

4.3

Also necessary to have sufficient number of drainage openings in areas with

stiffening plates, linking plates and/or dead angles areas.

4.4

The openings should not collect water when installed at site.

4.5

Temporary attachments shall be welded or bolted to fabricate steel structures

components which are prone to distortion.

4.6

Prior to pre-treatment a post-fabricated inspection shall be performed to ensure

the above are all met. The steel items are inspected for:
a) Residual Welding Slag
b) Visual Damage
c) Surface Imperfections such as nicks and dents
d) Holes or Opening for chemical and zinc drainage or venting

4.7

Fabricated item to be galvanized shall be completed (including all cutting,

welding & clean up) prior to degreasing, acid pickling, prefluxing & galvanizing.

5.0

Pre-Treatment
Galvanized process is a metallurgical reaction, which can only occur between a
clean steel surface and molten zinc, so it is critical that the works galvanized
has to be prepared.

5.1

Degreasing
Articles are immersed in a hot alkaline cleaner (Sodium Hydroxide Caustic
Soda) solution at a temperature of approximated 80 0C to remove dirt, oil,
grease, soil and soluble paints.
Degreasing solution will not, however remove such things as epoxies, vinyl or
bituminous coatings. These coatings may have to be removed either by sand or

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grit blasting, in some extremes cases, uses of special solvents or by burning it

off.
5.2

Water Rinse
Following the degreasing process, articles are water rinsed in tow counter flow
tanks before immersion into the pickling acid. The usage of two water rinse
tanks in this operation is to ensure that there is no alkaline carry over to the
next process.

5.3

Acid Pickling
An acid bath is used to remove surface rust and mill scales to provide a
chemically clean metallic surface. Hydrochloric acid solutions are used for
pickling. Generally inhibitors are added to the acid to minimize attack of the
steel. Residing time in pickling acid vary considerable, depending on the work
being processed. Only a few minutes may be required for relatively clean steel,
but up to an hour or more for heavily scaled steel.

5.4

Water Rinse
After the pickling process, the materials are again rinsed to prevent any
carryover of acid into the preflux tanks and also to remove any adherent iron
salts.

5.5

Prefluxing
The final cleaning of steel surface is performed by prefluxing which involved
immersion of the materials for a short duration in an aqueous zinc ammonium
chloride solution (30 %). The primary purpose of the prefluxing is to dissolve
the thin oxide film formed on the steel surfaces after rinsing and also to prevent
further formation of oxides prior to entry into the molten zinc bath. Other
purpose of prefluxing is to re-activate the surfaces of the steel material to
ensure a chemical and metallurgical reaction between the steel and molten
zinc which will

therefore achieve a more consistent finish. Heating of the

preflux solution is highly desirable to promote faster drying of the steel

materials.

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Hot-Dip Galvanizing
The dried article is immersed into the molten zinc bath at approximated 450 ~
480 0C. Upon immersion the steel surface is wetted by the molten zinc to form a
metallurgical bonded thick zinc/zinc-iron alloy layers of the hot-dip galvanizing.
The period of immersion depends on the size, weight, material composition,
thickness, surface condition and the geometry of the article being done. As a
rule of thumb, the item is soaked until the boiling off is complete.
Note 1: The surface shall be dried prior to hot dip galvanizing and item shall be
galvanized in a single dip.
Note 2: Zinc for galvanizing shall be High grade zinc, which contains a
maximum of 0.03 percent lead and 0.01 percent cadmium.

As per ASTM A 123/A 123M, zinc thickness shall be:

7.0

Post-Treatment Quenching
The article is withdrawn from the zinc bath and the excess zinc is removed by
draining, assisted in some cases by vibrating for small items. The galvanized
item is then immersed into quench tank filled with sodium bi-chromate water.
Quenching prevent oxidation of the newly formed coating on the article. It also
helps with the removal of ash particles, which have adhered to the steel article
during withdrawal and facilities subsequent handling and finishing work.

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De-racking, Inspection and Touch-Up

The galvanized items are then transferred to the de-racking stations to be
untied, after being re-rack it will be transferred to the QC station for a final
inspection to ensure the galvanized items are free from defects such as zinc
ash residue, flux residues and sharp edged zinc tips besides uncoated
surfaces. Touch up shall be carried out to remove any defects as mentioned
above.

9.0

Hot Dip Galvanize of Fasteners

9.1

Fasteners such as bolts, nuts & washers to be used for the assembly of
galvanized parts shall be hot dip galvanized in accordance with ASTM A153/A
153M.

9.2

The zinc coating on threads shall not be subjected to a cutting, rolling or

finishing tool operation.

9.3

In order to meet overtapping allowances, tapping the threads of nuts or tapped

holes after galvanizing is not prohibited.

9.4

As per ASTM A 153/A 153M, thickness or weight of zinc coating shall be:

10.0

Export Packing
All finish surfaces to be protected from containment like rust and mechanical
scratches which can deteriorate the coating. Tying wires, banding strips shall
be galvanized or with equivalent coating in order to prevent rust contamination.

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11.0

Repair of Damaged and Uncoated Areas at Field

11.1

Damaged and uncoated areas are usually due to but not limited to following
reasons:
i.

Holes & lifting lugs to facilitate handling, filling, venting and draining during
galvanizing.

ii.

Design and fabrication features of the articles lead to difficulties during

galvanizing.

11.2

iii.

Dimensional/design change after galvanizing.

iv.

Drilling before / after completion of hot dip galvanizing.

v.

Site welding and grinding of edges.

vi.

Damage during transportation after galvanizing.

Carry out weld built up by mean of welding using approved WPS for repair to
touch up holes to facilitate filling, venting and draining during galvanizing.

11.3

Areas damaged by transport, site welding, site flame cutting, site handling or
erection shall be reinstated by zinc rich paint.

11.4

Degrease and remove all surface oil, grease or soil can be omitted on new welds
where no organic contamination of the exposed steel has occurred.

11.5

Remove flux residue, weld spatter and sharp edges if any by mechanical means:
grinding, chipping, etc.

11.6

Power tool/wire brushing clean to SSPC-ST3 to remove welding scale, slag and
corrosion product before apply the touch up coat.

11.7

Apply 2 coats of the zinc rich paint to the prepared area by spray or using brush.

11.8

If a close color match is essential, apply a light coat of aluminum paint over
repair area after drying.

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Design for Galvanizing

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