Galvanizing Defects Rectifications

Galvanizing Defect & Repair Methods
Legend: A- Accept R-Reject N- Negotiate C- Clean REP- Repair
Responsibility: G- Galvanized D- Designer B- Builder / Fabricator S- Steel Type / Surface
Prepared By:
M.Sreedhar Patnaik
In charge-Process & QA
Visakha Steel Allieds
S.No. Description Cause Effect / Remedy / A/R/N/C/
Responsibility REP
1 APPEARANCE OF Although the recommended quantity Maintain concentration of
SODIUM of sodium dichromate is about 0.15 Sodium dichromate at about A
DICHROMATE. to 0.3 %, occasionally when topping 0.15 to 0.30 %.
A small amount of up, more is added. This often results G
sodium dichromate in a dark yellow to brown colour on
is generally added the galvanized surface. The darker
to the quench water colour will provide enhanced initial
bath for corrosion protection.
passivation.
2 ASH DEPOSITS. Zinc oxide deposits cool take place The coating is normally intact A/N
Ash deposits are when the component is dipped or underneath the ash deposits.
grey, non-metallic when it is removed from the bath. Ash must be removed and the
deposits consisting coating thickness verified for
of zinc oxide that conformance to the
have been specification requirements. REP
deposited on the hot Remove ash from all liquid If
dip galvanized conveyance pipes necessary
coating.
S.No. Description Cause A/R/N/C/

REP
3 BARE SPOTS. There are several causes of bare spots. A/R

Although excluded These include:
from ISo 1461, bare Over drying. If the time between fluxing and hot dip galvanizing is
spots of about 5mm prolonged or the drying temperature is toe high, the barrier protection
(2.2 x 2.2mm), due provided by the flux may be lost. This is indicated by a rusty
to small localized appearance on the ungalvanized article, which can result in coating
flows, ore discontinuities after hot dip galvanizing. G
adequately
protected by the Excess Aluminium. A condition some times referred to as black spots
sacrificial may occur if the aluminium content of a bath becomes too high. No
properties of zinc trouble should be experienced if flux concentration is correct and the
Prepared By:
and will have very aluminium content of the bath is maintained below approximately
M.Sreedhar Patnaik
little effect on the 0.007%. G
In charge-Process & QA REP
service life of the
Visakha Steel Allieds If necessary
coaling. Where Further causes are:
necessary, such Blowouts: flux deposits: stains and inclusions; mechanical damage;
spots may be touch marks; uncoated surfaces caused by surface contaminants, scale
S.No. Description Cause Effect / Remedy / A/R/N/

Responsibility C / REP
4 BLACK STEEL Components should be checked Insufficient inspection prior to A/R

INSPECTION. for distortion caused during rolling hot dip galvanizing can be the
Inspection prior to or fabrication. Check for causes of dispute. G
hot dip galvanizing is appropriate vent, fill and drainage
extremely important. holes; removal of weld slag and
spatter; venting of overlapping
surfaces; temporary identification
markings; clearance for moving
ports and potential distortion due
to the process.
Incurred nozzle pressure; nozzle

5. BLASTING angle; sweeping distance; size of A hot dip galvanized coating
DAMAGE. abrasive and recycling of grit. wi8 be partially or fully R
Sweep blasting, done destroyed by excessive blasting.
correctly, Refer to the HDGASA Cede of
substantially practice.
increases paint D/B
adhesion and final
coating appearance
hut done incorrectly
can result in coating
damage.
Prepared By:
M.Sreedhar Patnaik

6 BLOWOUTS. Pre-treatment chemicals Pre-heat item prior to A

Staining and coating penetrating sealed overlap areas immersion in zinc bath to dry
defects around through the required vent holes out overlap area as much as
unsealed weld areas and escaping during immersion in possible.
and vent holes, the molten zinc. This effect tends
similar to stains to damage the flux coating, D/G
ceased by weeping. causing localized uncoated areas. C/ REP
If
Necessary
Molten zinc has a high surface

7 CLOGGED HOLES. tension and will not easily drain Make holes as large as possible.
Zinc film clogging or from holes under 8mm in Removal of molten zinc over
partly bridging holes. diameter. the bath and utilization of A
vibrators will reduce the
likelihood of clogging.
D/G C
If
Required
Prepared By:
M.Sreedhar Patnaik

8. CLOGGED Insufficient centrifuging or poor The correct centrifuging R

THREADS. drainage of threaded attachments equipment or post galvanizing
Threaded on withdrawal from the thread cleaning by heating, wire
components or galvanizing bath. brushing or oversize tapping of
attachments have nuts, will generally remove
threads dogged with clogging. If necessary specify C / REP
zinc. delivery of bolts and nuts in
nutted up farm.
G
9. DESIGN Double dipping can sometimes be Touch up and repair can be A

STRUCTURES IN used to hot dip galvanize avoided, the cost of hot dip
MODULAR fabrications that are too long or galvanizing reduced and the
LENGTHS AND wide far single immersion. If the overall quality improved, if the
OPTIMUM WIDTHS fabrication exceeds the bath size, design of the component is
TO SUIT members in the fabrication may restricted to the length, width C / REP
AVAILABLE BATH require touching up. and depth of the galvanizing
SIZES. bath.
D/B
10. DISCOLOURING Material stored in contact with Once the cause has been A
AFTER HOT DIP rusty steel, or iron filings can removed the stain will
GALVANIZING cause surface rust staining. gradually disappear.
CAUSED BY B C
GRINDING OR If
OTHER RESIDUES. Possible
Prepared By:
M.Sreedhar Patnaik

11. DISTORTION. The hot dip galvanizing process Use symmetrical designs; Use A/N
Distortion is the occurs all molten zinc temperature sections of similar thickness;
unwanted warping of 450deg C. This is at the lower Stiffen un supported thin will
that occasionally end of the stress relieving sections; Use performed
becomes evident after temperature for treating steel. members with the correct
hot dip galvanizing. Thus, any inherent rolling or minimum bend radii; Use
welding stresses in the fabrication, balanced or staggered welding REP
are likely to be released. This may techniques; Make use of If
result in a dimensional change, i.e. temporary braces on thin possible
distortion. walled sections such as troughs,
cylinders and angle frames.
Avoid quenching after
galvanizing. Components can
be straightened after hot dip
galvanizing.
D/G
A/N
12. DRAINAGE The edge most likely to have these Drainage spikes are easily
SPIKES. spikes is the last to leave the bath removed at the bath while still
Spikes and teardrops on withdrawal. This applies molten but with complex
of zinc often appear particularly to complex fabrications, the solidified C / REP
along the edge of a fabrications. spikes will be removed by IF
component after hot fettling by the galvanizer prior Possible
dip galvanizing. to inspection. G
Prepared By:
M.Sreedhar Patnaik
S.No. Description Cause Effect / Remedy / A/R/N/C/
Responsibility REP
13. DROSS. Gross Dross deposit from the Dross consists of the same R/N
Dross particles are bottom of the zinc bath, trapped in iron/zinc alloy as the coating, it Mechanically
iron/zinc alloy the corner of a fabrication. The will provide the same corrosion remove if
crystals produced dross incorporated in the coating protection as a normal hot dip possible,
when hot dip prevents drainage of the zinc in the galvanized coating. G repair or re-
galvanizing steel. intermediate area and a build up galvanize
These precipitation to occurs.
the bottom of the bath C/REP
and are removed by IF
the galvanizer. necessary
14. DULL GREY OR This appearance indicates the Although not as aesthetically
MOTTLED presence of extensive iron/zinc pleasing as a coating with free
COATING alloy phase growth mused by zinc on the surface, a dull grey A
APPEARANCE. steels with high reactive levels of coating provides similar or
Dull grey or mottled silicon and phosphorous in steels. hotter corrosion protection.
coatings can appear D/S
as a dark grey
circular patter, a
localized dull patch
or, may extend over
the entire surface of
the component
15. FLAKING OR High phosphorous content (greater Use a steel that has a
DELAMINATION than 0.03% causes entire coating phosphorous content of lower R/N
OF COATING. to delaminate from the steel. than 0.03%
No adhesion of zinc D/S
to steel surface.
Thick, rough coating.
Prepared By:
M.Sreedhar Patnaik
Visakha FLUX
16. Steel Allieds
DEPOSITS, Flux deposits or stains may occur Flux deposits or stains should
STAINS AND as a result of excessive “dusting” be removed and the underl~4ng
INCLUSION. with ammonium chloride on coating measured to determine A

17. DISCOLOURATION Inadequate repair of a damaged Make use of the correct repair
OF THE PAINT surface on the hot dip galvanized materials and application R
COATING OVER coating prier to the application of a procedures when touching up
HOT DIP paint coating. cut or welded hot dip
GALVANIGING galvanized components,
AFTER EXPOSURE REP
TO THE B
ENVIRONMENT.
18. COATING No matter how the zinc coating is Specify hot dip galvanized R
THICKNESS applied, the coating life is fasteners to ISO 1461, where
PROVIDED ON proportional to its thickness in a required. Alternatively overcoat
FASTENERS USE given environment. Often fastener with an approved zinc
TO ASSEMBLE electroplated fasteners with rich point or epoxy.
HOT DIP insufficient coating thickness are
GALVANIZED incorrectly used in external D/B
STRUCTURES environments. C / REP
If
acceptable
Prepared By:
M.Sreedhar Patnaik

19. MECHANICAL The use of chains, wire ropes, Warming labels, highlighting a A
DAMAGE. dragging or dropping of the thick coating and possible
Mechanical handling component onto a hard surface, damage if manhandled, should
or transport damage can cause mechanical damage. be attached by the galvanizer,
may occur, This is particularly relevant with before the component is REP
particularly with thick brittle coatings. transported. The use of nylon If
extremely thick lifting slings is recommended. necessary
coatings, which tend G/B
to be brittle in nature.
20. OXIDE LINES. Due to the shape and / or drainage No effect on corrosion A
Light aluminium conditions of some components, resistance. The overall
oxide film lines on the hoist crane has stopped and appearance becomes uniform in
hot dip galvanized started upon withdrawal of the time. G
surface. items from the molten zinc.
Prepared By:
M.Sreedhar Patnaik

21. PIMPLES OR Dross pimples result from agitation of The galvanizer should avoid A
BLISTERS. the dross layer at the bottom of the disturbing the dross layer at the
Pimples or blisters bath or from dragging material bottom of the bath by
formed during hot dip through the dross layer. They appear controlling immersion depths
galvanizing are as small, hard lumps on an otherwise and dressing regularly. Since C
usually associated normal galvanized surface. Blisters dross pimples represent minor If
with surface may be formed by hydrogen, which is disturbances in coating necessary
imperfections such as absorbed daring pickling and diffused uniformity, they do not affect
dross inclusions. at galvanizing temperatures. corrosion resistance.
G
22. REACTIVE AND This difference in coating thickness, is

NON-REACTIVE brought about by a combination of a
STEELS WELDED more reactive silicon killed steel,
TOGETHER. and/or high phosphorous resulting in a
Variations in coating thicker coating and a less reactive
thickness can arise aluminium killed steel, resulting in a
when reactive and coating thickness sometimes below
non-reactive steels that required in the specifications.
are welded together. should the galvanizer be asked to re-
Efforts to increase galvanize in accordance with the
coating thickness on specification, the resultant coating
the less reactive steel thickness on the reactive steel will be
may result in an excessively thick, resulting in a brittle
undesirably thick and coating more susceptible to damage
brittle coating on the
most reactive steel.
Prepared By:
M.Sreedhar Patnaik

23. REMOVAL OF Excessive cleaning of the coating, The affected areas usually only R
ZINC COATING BY particularly the edges, by mechanical appear after the component is
EXCESSIVE methods, can result in uncoated areas. installed. Care should be
CLEANING. exercised by the galvanizer to
Unless otherwise avoid over cleaning. REP
agreed, the galvanizer G/B At the
will limit cleaning of galvanizer
the final coating by or
mechanical means to alternatively
that required in the at site
specification.
A
24. ROLLING Steel may occasionally include Surface flaws in the base
DEFECTS IN laminations, laps, folds and material may be removed by
STEEL. nonmetallic impurities, which result in local grinding after hot dip
These defects maybe silvers rolled into the metal surface. galvanizing followed by repair
broadly classified as Defects of this type are sometimes of the affected surface. Minor
surface detected before or after pickling, but surface defects will not REP
discontinuities in the may only become apparent after hot adversely influence coating life. If
steel that have been dip galvanizing. S necessary
elongated during
rolling.
Prepared By:
M.Sreedhar Patnaik
S.No. Desciption Cause Effect / Remedy / A/R/N/

25. ROUGH Rough surfaces, typical of coatings on The rougher surface will A
COATINGS, corroded steel surfaces, can be hot dip produce a thicker coating and
CAUSED BY STEEL galvanized satisfactorily. The coating result in a longer service life.
SURFACE will, however, reflect the texture of the S
CONDITIONS. substrate. Other causes of rough
surfaces include uneven cold working,
over pickling, a high galvanizing
temperature and / or extended
immersion in the molten zinc.
26. ROUGH HEAVY Rough, heavy coatings refer to hot dip A/R
COATINGS, galvanized components showing
CAUSED BY A markedly rough surfaces. This can
ROUGH SURFACE include coatings that have a generally
AND / OR THE rough surface and, in some cases,
CHEMICAL groove type surface configurations,
COMPOSITION OF “tree bark effect” caused by variations
THE STEEL “TREE in surface steel analysis.
BARK EFFECT”
Prepared By:
M.Sreedhar Patnaik

27. ROUGH HEAVY Efficient centrifuging, will generally Provided the steel/casting R
COATINGS remove excess zinc and provide a surface is reasonably smooth,
CAUSED BY smooth and attractive exterior. correctly centrifuged articles
INSUFFICIENT will provide an acceptable
CENTRIFUGING finish, C / REP
G If
acceptable
28. STAINS CAUSED The Salts from acid or flex that have The stain can be easily A
BY WEEPING penetrated porous welding or between removed by means of bristle
contact surfaces during pickling can brushing. Should the
weep after hot dip galvanizing and component be destined for a
water quenching, producing a stained corrosive area, the crevice
C / REP
area. should be sealed with a sealant
If
after cleaning.
necessary
D/B
29. TIGHTLY Heavy walls and thick flanges used in R
ADHERENT the manufacture of piping can act as a The galvanizer should ensure
LUMPS OF ZINC heat sink when immersed in molten all zinc hen been removed from
ON THE INSIDE OF zinc. This effect considerably the aside of the pipe by longer
HEAVY WALLED lengthens the immersion time. immersion times. C / REP
STEEL PIPING. Occasionally the galvanizer will G If
remove the pipes before all the zinc acceptable
has melted from the inside of the pipe.
Prepared By:
M.Sreedhar Patnaik

30 TOUCH MARKS. Articles entering the galvanizing baths Minimize contact between A
The zinc in the should not be in tight contact with components and jig
galvanizing bath each other. Jigging wire should also be connections. (Loosen jigging
should have free loosely attached to eliminate wire wire). Small components can be
access to all marks. Where a component has been centrifuged. REP
component surfaces resting on jigging or dipping If necessary
or small unmated or equipment, an uncoated area and G and
damaged areas can touch mark could appear. acceptable
result.
31 TYPICAL Surface appearances may very Small additions of aluminium A

SPANGLED HOT according to the chemical composition to the molten zinc, brightness
DIP GALVANIZED of the steel. Cooling rate has a direct the coating.
COATING. A typical effect on the surface brightness and
hot dip galvanized spangle size. Easter cooling usually S/G
surface is shown in results in a brighter coating with a
the example. The smaller spangle size.
surface is silver grey
in color and not
necessary but often
has a spangled effect
(Zinc Crystals) in a
range of sizes.
Prepared By:
M.Sreedhar Patnaik

32. UNEVEN The condition can occur over the Although not particularly A
DRAINAGE. Uneven entire surface grin isolated areas. attractive, this condition dons
drainage results in an Uneven drainage also includes drips not adversely affect coating
uneven or lumpy area and the ends of pots, runs near halos. performance. Protuberances
on which zinc build The cause is withdrawal speed too and lumps, which interfere with C
up has occurred. high or low galvanizing temperature. mating surfaces are If
unacceptable. necessary
G
A/N/R
33. UNCOATED Residues, such as oil based paint, Ensure all paint or grease is
SURFACES grease, oil or labels on the steel removed prior to hot dip
CAUSED BY STEEL surface or incorrectly positioned vent galvanizing. Make usual
SURFACE holes, can result in localized un- suitable marking pens for
CONTAMINANTS galvanized areas in an otherwise temporary identification.
OR ENTRAPPED continuous galvanized coating. Correctly position adequately
AIR. Defects after galvanizing can very in sized vent hubs.
color from grey black to brown while B REP
no galvanized coating has been If
formed. necessary
Prepared By:
M.Sreedhar Patnaik

34. UNGALVANIZED Sand on cast iron or scale on the steel These un-galvanized areas may R/N
SURFACES surface is generally caused by the occur in a linear pattern on
CAUSED BY process used to form or roll the angles, channels or other rolled
SCALE OR SAND. product. A localized un-galvanized products. They can also appear
area in an otherwise continuous on cast iron products. REP
coating can occur if scale or sand from S/G If
the moulding or rolling is not removed acceptable
by acid pickling or abrasive blasting.
35. UNGALVANIZED A localized un-galvanized area near a Weld slag deposits should be R/N
AREA IN THE weld can be caused by weld slug removed by the fabricator by
VICINITY OF A deposit, weld porosity or weld means of abrasive blast
WELD. undercut. Oxide deposits and residues cleaning. The deposit can also
from welding area resistant to normal be removed by proper chipping
pickling adds and mint be removed or wire brushing. Shielded arc
before the work is pickled and hot dip welding as opposed to slick
galvanized. welding is preferred for REP
components which are to ho If
hot dip galvanized. necessary
B
Prepared By:
M.Sreedhar Patnaik

36. USE Conventional drilling and bolting after Coating repair can be done by A
CONVENTIONAL hot dip galvanizing is preferred. zinc metal spraying, zinc rich
FIXING METHODS Should welding or noon conventional painter epoxy, providing the
SUCH AS BOLTS method of fixing be used, resulting in product conforms to the
AND NUTS, OR damage to the coating, an approved requirements of the REP
REPAIR DAMAGED repair method is necessary. specification.
COATINGS
CAUSED BY D/B
WELDING OR NON
CONVENTIONAL
FIXING METHODS.
WELD SPATTER.
37. Weld spatter is Weld spatter is caused by weld pool Loosely adherent weld spatter A/N
oxidized, normally explosions when improper welding should be removed prior to hot
spherical expelled parameters are used, or if the material dip galvanizing. Although not
weld metal, that is is dirty or contaminated. acceptable in terms of the
fused or not onto the specification the presence of
surrounding material tightly adherent weld spatter
during welding. after hot dip galvanizing will
not affect the corrosion resistant
properties of the coating.
B
Prepared By:
M.Sreedhar Patnaik

38.. WET STORAGE Wet storage stain (Zinc hydroxide) is Wet storage stain ceases when A
STAIN OR WHITE formed on freshly galvanized surfaces the cause is eliminated. If the
RUST. which are in closed contact in coating thickness at the affected
Wet storage stain or presence of moisture. Freshly area is equal to, or greater than
white rust as it is galvanized coatings react with the the minimum required in the C
commonly called, is a environment until such time as a specification, it is not a cause If
white voluminous stable zinc carbonate film is formed for rejection, other than for necessary
deposit that is on the cooling surface. aesthetic reasons. The latter is
occasionally found on subject to discussion with the
the surface of a end user. Customer during
freshly galvanized transport and storage.
coating. G/B
A
39. ZINC METAL In order for zinc metal spraying to Prepare surface for repair by
SPRAYED REPAIR adhere on application, the damaged adequate blasting. Loosely
APPLIED TO surface must be adequately blasted. As applied zinc metal sprayed
INADEQUATELY it is difficult not to over spray, excess coating at the perimeter of the
BLASTED zinc metal. Spray loosely adheres to repair should removed by wire
SURFACES OR the surrounding coating. brushing if net removed, there
NOT WIRE is no compromise in the C
BRUSHED AFTER corrosion resistance,
APPLICATION. G/B
Prepared By:
M.Sreedhar Patnaik

40. ZING SPLATTER. When hot dip galvanizing an The loosely adherent zinc A
Splashes and flakes unusually deep fabrication by double splashes are easily removed.
of loosely adherent dipping , moisture an the surface of An experienced galvanizer
/zinc, caused by the steel contacts with the molten zinc can ensure the coating
moisture on the steel causing splashes of zinc to loosely overlap on double end dipped C
surface when hot dip adhere hot dip galvanized surface. surface. Is not visible.
galvanizing G
Prepared By:
M.Sreedhar Patnaik

Galvanizing Defects Rectifications

Caricato da

Informazioni sul documento

Titolo originale

Copyright

Formati disponibili

Condividi questo documento

Condividi o incorpora il documento

Opzioni di condivisione

Hai trovato utile questo documento?

Questo contenuto è inappropriato?

Copyright:

Formati disponibili

Galvanizing Defects Rectifications

Caricato da

Copyright:

Formati disponibili

Galvanizing Defect & Repair Methods

Galvanizing Defect & Repair Methods

Legend: A- Accept R-Reject N- Negotiate C- Clean REP- Repair

Responsibility: G- Galvanized D- Designer B- Builder / Fabricator S- Steel Type / Surface

S.No. Description Cause A/R/N/C/

3 BARE SPOTS. There are several causes of bare spots. A/R

S.No. Description Cause Effect / Remedy / A/R/N/

4 BLACK STEEL Components should be checked Insufficient inspection prior to A/R

Incurred nozzle pressure; nozzle

S.No. Description Cause Effect / Remedy / A/R/N/

6 BLOWOUTS. Pre-treatment chemicals Pre-heat item prior to A

Molten zinc has a high surface

S.No. Description Cause Effect / Remedy / A/R/N/

8. CLOGGED Insufficient centrifuging or poor The correct centrifuging R

9. DESIGN Double dipping can sometimes be Touch up and repair can be A

S.No. Description Cause Effect / Remedy / A/R/N/

S.No. Description Cause Effect / Remedy / A/R/N/

S.No. Description Cause Effect / Remedy / A/R/N/

S.No. Description Cause Effect / Remedy / A/R/N/

22. REACTIVE AND This difference in coating thickness, is

S.No. Description Cause Effect / Remedy / A/R/N/

S.No. Desciption Cause Effect / Remedy / A/R/N/

S.No. Desciption Cause Effect / Remedy / A/R/N/

S.No. Desciption Cause Effect / Remedy / A/R/N/

31 TYPICAL Surface appearances may very Small additions of aluminium A

S.No. Desciption Cause Effect / Remedy / A/R/N/

S.No. Desciption Cause Effect / Remedy / A/R/N/

S.No. Desciption Cause Effect / Remedy / A/R/N/

S.No. Desciption Cause Effect / Remedy / A/R/N/

S.No. Desciption Cause Effect / Remedy / A/R/N/

Potrebbero piacerti anche