Professional Documents
Culture Documents
Submitted by:
EDUAGIN, RODIMAR T.
Submitted to:
Engr. Dennis E. Ganas
Instructor
July 2017
HISTORY
The earliest known example of galvanized iron was encountered by Europeans on 17th-century
Indian armor in the Royal Armouries Museum collection. It was named in English via French
from the name of Italian scientist Luigi Galvani. Originally in the 19th century, the term
"galvanizing" was used to describe the administration of electric shocks; this was also
called Faradism. This usage is the origin of the metaphorical use of the verb "galvanize", such
as to "galvanize into action" meaning stimulating a complacent person or group to take action.
In modern usage, the term "galvanizing" has largely come to be associated with zinc coatings,
to the exclusion of other metals. Galvanic paint, a precursor to hot-dip galvanizing, was
patented by Stanislas Sorel, of Paris, in December 1837.
In 1742, French chemist Paul Jacques Malouin described a method of coating iron by dipping
it in molten zinc in a presentation to the French Royal Academy.
In 1772 Luigi Galvani (Italy), galvanizing's namesake, discovered the electrochemical process
that takes place between metals during an experiment with frog legs.
In 1801 Alessandro Volta furthered the research on galvanizing when he discovered the electro-
potential between two metals, creating a corrosion cell.
In 1836, French chemist Stanislas Sorel obtained a patent for a method of coating iron
with zinc, after first cleaning it with 9% sulfuric acid (H2SO4) and fluxing it with ammonium
chloride (NH4Cl).
Galvanizing Process
Hot-dip galvanizing is the process of immersing iron or steel in a bath of molten zinc to
produce a corrosion resistant, multi-layered coating of zinc-iron alloy and zinc metal. While
the steel is immersed in the zinc, a metallurgical reaction occurs between the iron in the steel
and the molten zinc. This reaction is a diffusion process, so the coating forms perpendicular
to all surfaces creating a uniform thickness throughout the part.
Figure 1: Model of the Hot-Dip Galvanizing Process
The hot-dip galvanizing process (Figure 1) has been used since 1742, providing long-lasting,
maintenance-free corrosion protection at a reasonable cost for decades. Although hot-dip
galvanizing has been utilized to protect steel for generations, the galvanizing process
continues to evolve with new technologies and creative chemistries. The three main steps in
the hot-dip galvanizing process are surface preparation, galvanizing, and post-treatment, each
of which will be discussed in detail. The process is inherently simple, which is a distinct
advantage over other corrosion protection methods.
Figure 2 shows a series of steel structures with visible evidence of corrosion. Rust and
corrosion are expensive for owners and taxpayers. Deteriorating buildings, roads, bridges,
etc. are costly to repair, and without sufficient corrosion protection, maintenance is done
often, or in the worst cases, the structure must be rebuilt. With the push toward sustainable
development, specifying structures with longevity that require little maintenance over time
provide both environmental and economic benefits.
Surface Preparation
The purpose of surface preparation in the hot-dip galvanizing
process is to obtain the cleanest possible steel surface by
removing all of the oxides and other contaminating residues.
Thorough surface preparation is paramount as zinc will not react
with unclean steel. In order to move the steel parts through the
cleaning steps and galvanizing bath, the articles are hung using
chains, wires, or specially designed dipping racks (Figure 3).
Cleaning steel to prepare for the hot-dip galvanized coating
consists of three steps:
Figure 3: Hanging of Steel Products
Degreasing/Caustic Cleaning
First the steel is immersed in an acid degreasing bath or caustic solution to remove organic
contaminants such as dirt, oil, and grease from the surface of the steel. After degreasing the
steel is rinsed with water.
Pickling
After degreasing, pickling, and fluxing, the surface of the steel is a near white metal clean,
completely free of any oxides or other contaminants that might inhibit the reaction of the iron
and molten zinc in the galvanizing kettle.
Galvanizing
Once the steel has been completely cleaned, it is ready for
immersion in the zinc bath. The galvanizing kettle contains
zinc specified to ASTM B6, a document that specifies any
one of three grades of zinc that are each at least 98% pure.
Sometimes other metals may be added to the kettle to
promote certain desirable properties in the galvanized
coating.
Figure 5: Hot-Dip Galvanizing Kettle
The galvanizing kettle (Figure 5), is heated to a temperature ranging from 820-860 F (438-460
C), at which point the zinc is in a liquid state. The steel products are lowered into the
galvanizing kettle at an angle, and stay in the bath until the steel heats to the bath
temperature. Once the diffusion reaction of iron and zinc is complete, the steel product is
withdrawn from the zinc kettle. The entire dip usually lasts less than ten minutes, depending
upon the thickness of the steel.
The coating, as seen in Figure 6, is typical for low silicon steels with silicon impurities less
than 0.04% and where the thickness of the coating is limited by the interdiffusion of iron and
zinc
Post-Treatment
There are many other types of corrosion protection systems, such as coating steel with oil,
grease, tar, asphalt, polymer coatings or paints, or corrosion resistant materials such as
stainless and weathering steel, sacrificial anodes, plating systems and impressed current
systems. These are some of the most commonly used corrosion protection materials and
systems and are sometimes used in conjunction with hot-dip galvanized steel. Most of these
materials rely on barrier protection, while some of them rely on cathodic properties to resist
steel corrosion. The most effective system that provides both barrier and cathodic protection
is hot-dip galvanizing.
In addition to the systems and materials listed above, there are a wide variety of other zinc
coatings used for corrosion protection. Many people use galvanizing to describe all of these
coatings, but each has its own unique characteristics and performance. These coatings have
several applications based on their properties and respective thicknesses. The corrosion
protection offered by a zinc coating is directly linear to the coating thickness. The most
commonly used coatings are hot-dip galvanized, metallized, zinc-rich paint, continuous
galvanized sheet, and electroplated. The relative thickness for each of these zinc coatings can
be seen in the photomicrograph (Figure 8). Below is a brief explanation of each type of zinc
coating
Metallizing
Continuous Galvanizing
Specification
A hot-dip galvanized coating is relatively easier and cheaper to specify than an organic paint
coating of equivalent corrosion protection performance. The British, European and
International standard for hot-dip galvanizing is BS EN ISO 1461 which specifies a minimum
coating thickness to be applied to steel in relation to the steels section thickness e.g. a steel
fabrication with a section size thicker than 6 mm shall have a minimum galvanized coating
thickness of 85 m.
Further performance and design information for galvanizing can be found in BS EN ISO
14713-1 and BS EN ISO 14713-2. The durability performance of a galvanized coating depends
solely on the corrosion rate of the environment in which it is placed. Corrosion rates for
different environments can be found in BS EN ISO 14713-1 where typical corrosion rates are
given with a description of the environment in which the steel would be used.
Galvanizing Standards
Drying Oven
The drying oven is available in two types, electric heating type and gas heating type. A hot air
circulation system is also designed. The frame of the furnace is welded by stainless steel, while
the internal walls are welded by grade 316L stainless steel which can prevent the corrosion
from the ammonium salt. Alumina silicate cellucotton is chosen as the high temperature
resistant lining material for the purpose of heat conservation.
Cooling
In hot-dip galvanizing line, the air cooling and water cooling are combined together to cool the
steel rapidly. Thus, we can effectively control the thickness of the zinc-iron alloy layer, and
enhance the smoothness of galvanized steel.
APPLICATION
The selection of a steel coating system is an integral part of all engineering design. The main
consideration for the engineer in the selection of the most suitable corrosion protection system
would be the performance of a steel coating and the economics of the application of the steel
coating system. There is no other corrosion protection system that could match the performance
and economics of hot dip galvanizing.
In the building of a power station for power generation, steel is a major construction material.
Galvanized steel is used in platforms, equipment buildings, stairs and handrails. In the area of
fuel supply to the main power generating plants galvanized steel conveyor systems are common
in a coal fired power station. Cooling water, water reticulation and fire protections systems
consume huge amounts of galvanized steel in the form of piping and it fittings. As for power
transmission every piece of steel in a transmission tower is completely galvanized from the
main steel frame, every piece of bolt and nut used to fasten the angles together to the cable
support systems are completely galvanized. They are now many transmission towers that are
also painted with special paint system for identification purposes.
TELECOMMUNICATION TOWERS
Telecommunication steel towers are difficult structures to maintain considering its location
which normally are difficult to access since it is situated on hills slopes and on top of mountains.
For easy installation these Steel Towers are fabricated from Steel Tubes in different sections
and steel Angles of various sizes and lengths, Hot Dip Galvanized and fastened with
Centrifuged Hot Dip Galvanized Bolts, Nuts and Washers. These 3 Leg Telecommunication
Towers are 100% Hot Dip Galvanized and Duplex coated for long term corrosion protection
and aerial Identification.
Government of many countries now invest and spent huge part of their budgets in improving
the infrastructure such as road highways and expressways, railways, Light Rail Transport
system (LRT) and Mass rapid Transportation system (MRT) , Port terminals and airport
facilities. These projects consume huge amounts of exposed steel and as such hot dip
galvanizing is the preferred corrosion protection system.
As for other developments such as schools, hospitals, community halls and other public places
galvanized steel are mainly in galvanized products such as galvanized water tanks for fire
protections systems, street lights, safety barriers and road and drain covers.
Hot dip galvanized reinforcement steel was only used in critical construction areas such as
coastal or marine concrete structures. In the last decade the use of hot dip galvanized
reinforcement steel increased with the rapid expansion of the road, highways and expressways.
Steel rods and strips for reinforced earth (RE) walls and soil nails are always hot dip galvanized.
Guardrails, crash cushions, decorative street lights, high masts, pedestrian overhead bridges,
noise barriers, parapet handrails are some of the other products that are corrosion protected
with hot dip galvanizing
The Twin Tower in Kuala Lumpur and the Kuala Lumpur Tower are prestigious projects in
Malaysia. For durability most steel are Hot Dip Galvanized and Duplex coated. Commonly
found in the open areas are Forged Welded Gratings hot dip Galvanized, Garden Lighting Poles
Hot Dip Galvanized and Children Play Stations all Hot Dip Galvanized and Duplex Coated.