Specifying and Detailing for Hot-Dip Galvanizing AN OVERVIEW FOR ENGINEERS, ARCHITECTS, AND DETAILERS igh quality galvanized coatings are obtained when steel assemblies are designed to promote un- restricted flow of cleaning solutions and molten zinc during the hot-dip galvanizing process. A basic understanding of how steel is handled in the galvanizing plant and what the steel undergoes in the application of the galvanized coating will aid steel detailers in preparing drawings that will produce the best possible galva- nized finish Keep the following details in mind when developing and reviewing structural details and shop draw- ings: Are the vent and drain holes of sut- ficient size and quantity? © Are the vent and drain holes locat- ‘20 properly? (One or more for drain and one of more for venting.) & Are comers of gussets, stifeners, land bracing cropped to allow tree flow of zinc? HII the fabrication is comprised of steel of two oF more thicknesses, Js it designed to promote minimal ‘change in camberistraightness? © Are welds at overlapping surfaces seal welded? 1 Does the fabricator know ta remove all weld flux and to use a weld mate- tial of suitable chemistry to produce {good zinc coating? Have | accounted for marking! tracking of the paris through the galvanizing process and on to the jb site? & Have | planned for tapping of nuts or threaded holes after galvaniz- ing? By Philip G. Rahrig and John Krzywick’ ‘The viscosity of liquid zine at the galvanizing temperature plays a large role in which assemblies can be galva- nized easily. The viscosity of molten inc prevents it from entering gaps or ‘crevices less than 3/32”. Inside comers fn steel fabrications also present qual- ity issues if not properly designed for galvanizing. In general, the number of corners should be minimized. When applicable, corners should be cropped or enough space (3/32") must be pro- vided for the molten zine to easily flow in and out of tight spaces. When this issue is overlooked, zine will tend to “pool” in these areas causing excessive- ly thick coatings that may easily flake ‘when subjected to rough handling. In addition, cleaning solutions are much less viscous than molten zinc and can tenter tight spaces that the zinc cannot. Dried residue from cleaning solutions may remain trapped in the crevices af- ter galvanizing and may bleed onto the surface if they come into contact with re, This will cause unsightly rust staining on the surface of the steel. Arguably the most important com- ponents of galvanized steel design are Idontiication marks or tags for each piece ‘eed to be sturdy enough fo survive the gal vanizing process. ‘94 » June 2005 + Modem Steel Construction vent and drain holes. Tubular or hollow fabrications must allow for cleaning so- lutions and zine to freely flow on both the interior and exterior surfaces. To accomplish this, vent and drain holes should be placed near the ends of steel articles to allow zinc to penetrate the interior, as well as drain from the inte- rior upon withdrawal from the galva- nizing kettle. Recommended Detail for Hot-Dip Galva- nized Structures producedbythe American Galvanizers Association (AGA), is a use- fulreferenceand an bedownloaded from www.galvanizeitorg/refidetails. It in- chides working drawings containing the ‘most commonly galvanized structures and includes the necessary details re- quired for quality galvanizing. Another useful reference is. Designing with Hot Dip Galwanized Steel, an AGA-produced CDROM, After choosing hotip galvanizing as the comsion prevention system for your project, ASTM A123/A123M-02, Standard Speciation for Zinc (Hot-tip Galoanized) Coatings on Tron and Ste! Pructs should be the comerstone of your project speci fication. ASTM A123 applies to structural Cropped corners alow molten zinc to flow in ‘and out of tight spaces, avoiding "pooling" in these areas causing excessively thick coat- ings that may flake during rough handlingDesigners’ and Detailers’ Galvanizing Checklist Will the steel surface exhibit extreme develop- ments of mill scale, welding slag, or water-in- soluble contaminants? ‘These may not be removed by the cleaning chemicals in the galvanizing plant. Abrasive blasting or other types of mechani- Cal cleaning may need to be employed to remove excessive developments of water-insoluble surface contaminants, Has the steel been cold-formed? | Avoid designs with notches, which increase stress. Flame- citing or sawing) preferred, particulary for heavy sections, but ‘ther methods are acceptable. Dill, rather than punch, holes in material thicker than 3/4” (19 mm). I holes must be punched, they should be punched undersize and then reamed an addi- tional 1/8" (3 mm) overall or died to size. Material between 1/4 ‘34 (6.5-19 mm) thickis not seriously affected by cold-punching ifthe punching is done under good shop practice, Meterals up to 1/4" (6.5mm) thick that have been cold-punched do net need stress-rlieving operations before galvanizing, [Are there sharp bends in the steel fabrication? Best practice is to keep bend diameters as large as pos- sible when parts are bent cold before galvanizing, A minimum bbend radius of three times the section thickness will remote pimum galvanized coating properties (refer to ASTM A143, Standard Practice for Safeguarding Against Embritiement of Hol-Dip Galvanized Structural Stoo! Products and Procedure for Detecting Embritlement, for additional information). If ex Ccossive cola bending or forming is necessary, the steel must bbe heat tated at 1100 F (590°C) for one hour for every inch Of section thickness to relieve stresses, ‘Are there thin sections of steel or varying thick- nesses of steel that are going to be joined to- gether by welding prior to galvanizing? Thin sections of siee! (less than 1/8"), asymmetrical fabrica- tions containing varying thickness steel, and articles that must be progressively dipped (aka "double-dip") have 2 higher sus- Ccoplibilty of warping (refer to ASTM A384, Standard Praciice for Safeguarding Against Warpage and Distortion During Hot- Dip Galvanizing of Stee! Assembfes, for additional informa- tion). To eliminate concems over warping, bracing— perma: ‘ent or temporary— can be used to provide stability curing the thermal expansion and contraction eycle. Occasionally, when bracing is not used and warping andior distortion occur, the part will return to its original shape during cool-down, Does the steel assembly contain moving parts? During the galvanizing process, steel is immersed in molten zine. Upon removal from the kettle, the once-molten zinc metal will solidy. As a result, the possibilty exists for mow- ing parts such as drop-handles, shackles, shafts, and hinges to freeze together. ‘Are there threaded holes or clearance holes in the design? Typical galvanized coatings range from 9-8 mils (75-200 mi- ‘rons) thick. When designing and detaling tapped holes, the increased thickness is important. Best practice suggests that the hole be tapped after galvanizing, removing the coating on the interior mating surface. Ita galvanized components used to ‘mate with the hole (recommended to avoid galvanic corrosion), the galvanized coating on the mating surface wil cathodically protect the bare steel of the interior threads. This also reduces the thickness loss of the hole and ensures a clean connection ‘On threaded assomiblias with diameters greater than 1.5" (3.8 ‘om), itis oten more practical, if dasign strength allows, to have the male thread cut 0.031" (0.8 mm) undersize belore galvaniz- ing s0 a standard tao can be used on the nut (refer 1o ASTM ‘ASES, Standard Specification for Carbon and Alloy Steel Nuts, for overtapping allowances). [Are there sections of the steel where wire or chain ‘can be connected so that cranes can be used to lift the material? ‘To ensure proper handling, liting points should be incorporat- {6d into the fabrication’s design. Lifting points provided only for hot-dip galvanizing purposes may be removod alter galvaniz- ing. For smaller parts (less than 18" in length, e.g. fasteners) baskets are used to handle the material and lifting points are not required. In some instances, the galvanizer may have specially designed racks to accommodate the galvanizing of certain products, Wise | provided the necessary vent and drain holes to produce a quality galvanized coating and ensure operator safety at the galvanizing plant? itis important to property vent hollow, overlapped, and contact- ing surfaces to prevent trapped moisture or gas from flashing to steam in the heated galvanizing ketle, which may result in localized uncoated surfaces. Additionally, pressure Increases resulting ftom trapped moisture flashing to steam can violently rupture the fabrication, endangering galvanizing plant person- nel, ASTM A385 coniains guidelines for properly venting nu merous types of assemblies. Have | used the proper weld metal? Silicon levels greater than 0.25% inthe weldrod willcouse thicker caetings to form in the weld areas. Itis important to se- lect welding rods that do not have excessive amounts of slicon. Is the steel going to receive an additional coating €n top of the galvanizing? inform the galvanizer that the steel is going to be coated after galvanizing so they de not quench the material. Alter the article removed trom the kettle, itis often quenched to increase the rate of cooling andlor to coat the steel with a passivation layer to protect the galvanizing in transit and storage. This pas- sivation layer may interfere wth addtional coating operations (coler to ASTM 06386, Standard Practice for Preparation of Zne (Hol-Dip Galvanized) Coated iron and Steel Produc! and Hardware Surfaces for Painting). [78,2 sebeation going to it inthe galvanizing kettle? Toughout North Americ, a vary of izes of hot-p gahaniz- Ing tates avatablo,aloving a wide szevange ol suctxel febrcaton tobe geNarized (fro wom. galvanize orghel! GgaWvanlzes fora complte ising of Acero Noth Arner an gevaners end thet Kelle zee). Dosgning and brat ing in modules sutable forthe evalable gevariang facies slows almost any component tobe galvanized. For overaized febreatons, bet rectce suggest hat they be detgned in Imodvles or subunit and assembled aor gahaning, some inatarces,fabicton that ere larger than he galvanizing keto nay be progress cippod odoin complete coals cover age onal surfaces June 2005 * Modem Stee! Construction » 35: