Galvanizing Tips

by Thomas J. Kinstler
ot-dip galvanizing is a “dip and

H drain” thermal-reaction process

that has significant requirements
for optimum results. Guidelines,
published standards, and consul-
tation/ assistance about design and fabrica-
tion for galvanizing are available from various
sources. The American Galvanizers Associa-
tion (AGA) has booklets, CDs, design aids,
and seminars about hot-dip galvanizing, avail-
able at no cost from the web site, www.galva-
nizeit.org. Local galvanizers usually are
available for consultation, and can be impor-
tant resources for practical knowledge as de-
signs and fabrications evolve. ASTM
Standards, particularly ASTM Standard A-385, tion having “thick” and “thin” sections Access
and A-143, are “tried-and-true” design and welded together will undergo induced ther- Access refers to the venting of vapors
fabrication aids. Most of the requirements for mal stresses (or stress reduction) as the article and the free flow of liquids through and
optimum galvanizing have other non-galva- transits the galvanizing thermal profile from from a fabrication, particularly those having
nizing-related benefits, such as ease of fabrica- ambient temperature, to ~850°F (~440°C), relatively closed sections, such as pipe and
tion, aesthetics, corrosion prevention, or and back to ambient. For plate girders, the HSS. This requirement is related to the aes-
fatigue resistance. lowest ratio of flange-to web thicknesses pos- thetics and integrity of the galvanized arti-
Some limitations on galvanizing relate to sible would be optimum, but in any case, not cle, and also to safety in the galvanizing
kettle size and weight-lifting capacity. Over the more than 4:1 if web “oilcanning” is a critical plant. The liquid immersion and flow, and
past five years, significant kettle length and design consideration. the thermal transient of galvanizing, can re-
width, number and location, and lifting capac- Uniformity also refers to the surface condi- sult in loads, pressures, and forces that are
ity have been added to the industry in North tion of the article to be galvanized. New steel controllable in the design and fabrication
America. A general guideline is that if a struc- and older pitted steel welded together, or process. Overlapped plates or surfaces
tural element can be transported by truck with- steels of differing grade or chemical composi- should be vented against pressure buildup
out special permits, and one dimension is less tion welded together will have a different sur- from residual aqueous solutions entrapped
than the width of the galvanizing kettle, it face appearance after galvanizing. This is due in crevice areas. All vent and drain provi-
probably can be galvanized, depending on di- to differences in surface profile or zinc reactiv- sions, including internal gussets and stiffen-
mensions and geometric complexity. “Double- ity. The “age” and smoothness of steel surfaces ers, should be tangential with the highest
dip,” or progressive galvanizing methods, can should be matched to the extent possible. and lowest points while in the galvanizing
extend the range of galvanizing capacity be- Weld metal can be different from the parent orientation.
yond the physical dimensions of a given galva- steel, and can result in aesthetic variation after Tubular assemblies of any type should
nizing kettle. If a structural member being galvanizing. Guidelines on galvanizing weld- allow for the full and rapid venting and expul-
designed is to have a depth or length more than metal compatibility are available from the sion of air, steam, and vapors, the free release
30% greater than a potential galvanizing kettle, AGA, and should be factored into selection for and complete flow of cleaning solutions and
detailed consultation with the galvanizing structural welding. zinc into and out of the fabrication, and inhibit
plant should be made before design is finalized. buoyancy. The completeness of that flow pat-
The factors which contribute to the lowest Cleanliness tern should be externally verifiable. AGA
cost and highest performance for galvanized Cleanliness refers to the degree of contam- guidelines and ASTM standards clearly iden-
steel, and which form the basis of the design ination or “foreign” residues present on the tify the venting and draining requirements for
aids and fabrication guidelines, can be found steel surface. The galvanizing process in- tubular sections. Adherence to these guide-
in five concepts: symmetry, uniformity, clean- cludes chemical surface preparation removing lines will result in safe galvanizing and ade-
liness, access, and reactivity. scale, rust, and many organic contaminants. quate coverage of all internal spaces, which
But since galvanizing is a metallurgical reac- cannot be achieved by non-immersion
Symmetry tion and requires intimate contact with processes.
Symmetry refers to the geometric cross-sec- molten zinc, the process can be inhibited by In addition, the access required can allow the
tion of components to be galvanized, and the surviving surface residues. While seemingly a rapid cooling of articles after galvanizing, aid-
balance of forces, such as residual stress from “negative” aspect of galvanizing, it is actually ing in retention of galvanized surface appear-
cold forming and welding. Symmetrical sec- “positive” in that contamination not removed ance, and in critical cases, the cohesive integrity
tions, such as “H” and “l” sections, respond to by the chemical-cleaning process cannot be of the coating. Another factor is the provision
the thermal transient of galvanizing more uni- “coated over” by zinc, and thus such incom- for suspending articles in the galvanizing
formly than non-symmetrical sections such as plete surface preparation results in an easily process, such as by bolt holes, or lifting lugs.
“C” and “T.” But beyond “mass” symmetry, identified defect in the galvanized coating. These should be oriented to allow and assist the
residual stresses from welding or forming, off- Such contamination generally is limited to draining and venting of the article while in the
set from the neutral axis and unbalanced, pipe lacquer, tars, and certain marking paints. galvanizing process spacial orientation.
could induce distortion potentials not found in Compatibility can be checked with the local To ensure the best results from the galva-
balanced or unstressed sections. galvanizing firm. nizing process, refer to the AGA guidelines
In addition, weld slag, anti-spatter com- and the ASTM standards. And don’t forget to
Uniformity pounds, and pipe lacquer “burned in” during consult with prospective galvanizers when
Uniformity, for purposes of this discus- welding can cause similar problems. Galva- working on a project. ★
sion, refers to uniformity of section thickness, nizing standards and conditions for other
as well as the composition and surface char- coating applications require such material to Thomas J. Kinstler is Principal of Galva-
acter of steel surfaces. For example, a fabrica- be removed. Science LLC, Springville, AL.

April 2004 • Modern Steel Construction