Key Considerations for Hot Dip Galvanizing

Key Considerations for Hot Dip Galvanizing

Hot dip galvanizing is a process where a piece of base metal is immersed into a bath of molten zinc for enhancing the durability and functionality of the base metal. After the completion of the hot dip galvanization process, the base metal is resistant to corrosion and hence appropriately suitable for the intended purpose of use. But the users need to make sure to choose a trusted, reputed, and reliable service provider so that the best practices are followed for the optimum quality galvanizing. One of the most important rules to be followed during the process is that the designer, fabricator, as well as the galvanizer should work together. An appropriate three-way communication plays a vital role in the elimination of most of the problems in the hot dip galvanization process.

To make the entire process smooth and hassle free, we have listed a few of the key considerations for the hot dip galvanizing process. 

Removal of Soil and Grease – Oil, grease, shop oil, and soluble paints are to be removed from the base metal with the help of a hot alkaline cleaner. On the other hand, soils like vinyl, epoxies, welding slag, and asphalt should be removed by grit blasting or other mechanical process of cleaning. 

Pickling – It is the process of chemically cleaning the surface of the base metal. An acid bath is used for the removal of rust and mill scale for providing a chemically clean surface of the base metal. It would be ideal to use hydrochloric acid since it is more environment friendly and does not affect the surface of the base metal. 

Prefluxing – The base metal which is usually steel needs to be immersed in a liquid flux for the removal of oxides and prevent oxidation before finally dipping it into the bath of molten zinc. It would be ideal to use zinc ammonium chloride solution for Prefluxing process.

Galvanizing – The prepared base metal then needs to be immersed into a bath of molten zinc at about 455 degree Celsius or 850 degree Fahrenheit to ensure appropriate metallurgical bonding of zinc to the base metal. 

Finishing – Once the metal is withdrawn from the molten zinc bath, it is essential to remove the excess zinc by draining, vibrating, or centrifuging. Next, it is important to cool the galvanized item in air or by quenching in water. The air quenching process takes a bit longer as compared to the water quenching method but it results in a much better surface finish, and hence an important consideration in architecturally exposed steel. 

Checking or Inspection – Checking or inspection of the final product is the ultimate step as well as consideration in the hot dip galvanizing process. In this step, the thickness and the surface conditions are checked for meeting the quality criteria. 

All these key considerations mentioned above would make sure that the base metal is appropriately galvanized. In this regard, it would be ideal to call in for the helps of a professional service provider for getting the best solutions. In this situation, Prashant Galvanizers would undoubtedly the ideal choice. With several years of experience in this field, Prashant Galvanizers makes sure to provide optimum quality galvanization so that none of the users get even a single chance to complain. So, for all your galvanization requirements, get in touch with the team of Prashant Galvanizers at the earliest. 

Hot dip galvanizing for corrosion control

Corrosion is an electromagnetic process. Corrosion destroys the metal, the colour changes and it becomes weak, easily breakable. Steel is at risk when it reacts with other elements such as oxygen, carbon dioxide, hydrogen, and bacteria, dirt. It forms rust over the metal and the duration of further degradation of the metal depends on the immediate climate in the surrounding. Hot-dip galvanizing controls and protects the iron from corrosion. 

Why hot-dip galvanizing?

It is essential to prevent the iron from rust. To protect, a layer or a barrier has to be created or added in between the iron and the atmosphere. Then only the iron will be secured from the harmful elements and it won’t corrode. One such process that can prevent the iron from rusting, corrosion, is hot-dip galvanizing. Hot-dip galvanizing acts as a barrier between the atmosphere and iron.

Hot-dip galvanizing process 

In hot-dip galvanizing, the coating of steel happens at a temperature of 449 degrees, absorbing properties of zinc which makes the steel stronger and durable. The effects of the surrounding climate and dust, bacteria are mitigated by hot-dip galvanizing. 

Galvanizer provides high-quality hot-dip galvanizing services. We are an experienced team of professionals that carefully conducted the process of galvanizing. The process of Galvanizing is complicated and it requires a proper pool of professionals to carry out the task. We are proud of the quality we provide. Galvanizer provides hot dip galvanizing services in Vadodara. 

Read more: Hot Dipped Galvanizing Services In Vadodara

Hot-dip galvanizing stages

As said earlier, the coating of steel happens at a certain temperature with properties of zinc. Before this process, it is essential to check the surface first. The surface has to be made adequate for the zinc to settle in and process.

After the hot-dip galvanizing process, proper finishing is to be given. Generally, we supply our products with the finish of Hot Dip Galvanized, Primer coated, Enameled paint coated OR Epoxy paint coated.

The inspection of the material is to be carried out. The things to be checked are thickness test, adhesion test, visual check, and uniformity of zinc coating test.

Corrosion is deadly for any metal. Rust is formed on the iron because of the immediate surrounding climate and the dust, bacteria. A barrier has to be created in order to protect from corrosion. The process of hot-dip galvanizing gives the much-needed layer on the surface that prevents iron from the climate and bacteria. Tanya Galvanizers offers top quality services because of the experienced professionals who follow the stages and process of hot dipping galvanizing in Vadodara.

For more information on hot dip galvanizing by Galvanizers, click the link:

https://galvanizers.co.in/hot-dip-galvanization.html

Difference between BATCH GALVANIZED VS PREGALVANIZED PRODUCTS

There is a general misunderstanding among common people that every zinc coating is called galvanization but this is not true as there might be many processes through which a zing coating can be applied. Hot Dip Galvanizing is a coating which is formed after immersing a steelwork in molten zinc. There are however two different processes of hot-dip galvanizing which are pregalvanizing and batch galvanizing. 

Batch galvanizing is a process that is used to coat fully fabricated items and includes chemical cleaning of work before immersing it in the galvanizing bath. The item gets completely coated including internal surfaces if hollow sections. The thick coating also provides the best level of available corrosion protection. 

Pregalvanization is a process where you take a specific product and galvanize them through an automated process. Steel tubes can be galvanized through an automated process. The immersion time is less and after removal, steam can be blown on the bore of the tube which gives it a good surface finish. In the case of reselling, the tubes can be cut to different sizes which creates uncoated edges. 

Strands of wire can be coated using an automated process. The immersion time is very short and the wiping procedure is used to remove excess zinc and give a smooth finish to the final product. It is better to use a mesh of wires so that thicker galvanized coating can be achieved. The steel sheet is uncoiled and passed through the reduced atmosphere before immersing in galvanizing bath for a brief period. 

Read more: Hot Dipped Galvanizing Services In Vadodara

After withdrawing the sheet from the galvanizing bath a mechanical wiper or air knife is used for removing excessive zinc so that the product has a smooth finish. The sheet after galvanizing is recoiled before the stockholder and then it is uncoiled and cut for sale which produces uncoated edges on the sheet. 

Both batch and pregalvanized coating have different characteristics and some of them are being enlisted below. 

  1. The coating continuity in batch galvanizing is continuous over whole item whereas in pregalvanizing the cut edges are left uncoated 
  2. In batch galvanization, coating formation after galvanization is not recommended as it can damage the product whereas in pregalvanization coating can be normally formed without any damage 
  3. Batch galvanization offers a high level of sacrificial protection whereas a pregalvanized product has less sacrificial protection because of the thin coating due to which rust formation can happen from cut edges of the sheet 
  4. The coating appearance after batch galvanizing can be bright but variable whereas pregalvanized products the overall finish is bright without any variation
  5. There is high resistance to abrasion in batch galvanizing due to thick and hard layer of iron and zinc alloy whereas in pregalvanization the alloy layer is very thin which can cause abrasion easily
  6. The coating thickness in batch galvanizing is very thick as compared to pregalvanized coating
  7. The consideration of design for galvanization is required in both batch and pregalvanized products 

At Tanya Galvanizers, we offer the best hot-dip galvanizing in Vadodara. We offer both batch and pregalvanization and you can choose the one which suits your requirements and falls in your budget.

Importance Of Inspection Of Hot Dip Galvanized Products-Tanya Galvanizers

Importance Of Inspection Of Hot Dip Galvanized Products

In today’s time protection is a must. The surroundings are getting challenging with each passing day. Although, the realization of the protective shield on things that are always exposed to the outer world is from our ancient past. Hence, way back in 17th-century scientist and researchers started their work towards protecting even metals from weathers. One such protection shield found was the process of Galvanizing. One of the best processes on galvanizing is hot-dip method. The hot-dip galvanization is a very popular and successful method.

The purpose of galvanizing was to create a protective shield through zinc coating on steel. The exposure of steel can be up to 200-degree temperature and will still be strong due to galvanizing. Metals have a tendency to get rusted with extensive exposure to weather and hence creating a protective shield is one such critical requirements. As mentioned before hot-dip galvanizing is the preferred method. In this method, coating happens at a temperature of around 449 degrees. At this level of temperature when steel goes through that heat, it also absorbs few properties of zinc, making it stronger.

The process is quite assuring as it sounds and further reassuring on effective inspection. Before the coating, the steel has to be well prepared which decides the future strength of the coating. It is like when you have to polish your shoes you need to first clean them and then polish. In the same way, cleaning of steel is primary for a longer future and ensuring the efforts are worth it. Although, the coating life always depends on the amount of exposure of the metal. One can ascertain these details based on the standards that are available.

While doing inspection there are few things to consider is the uniformity of the coating. When the coating is not done in required temperature many times it has cracks. Also when steel is not cleaned properly it will result in bumps through the metal, which leads to a breakthrough for breaking the shield. Let us list down checkpoints while doing inspection of hot-dip galvanizing.

  • The smoothness of the surface
  • Edges and cuts are well ventilated
  • Overlapping surfaces are well taken care of
  • The thickness of the coating be as defined or required
  • Continuity of the coating
  • Color and uniformity of the coating

The above are the basics of inspecting hot-dip galvanized products. The inspection list can be more extensive with the nature, design and type of the structure that is galvanized. Many time even the purpose of the product plays a significant role in deciding the type of galvanizing especially in products like jewelry and food graded stuff. You can always reach us to know more about the inspection details and the galvanizing process information.

Is Hot-Dipped Galvanized The Same As Galvanized?

Galvanization is the process where steel is coated with corrosion resistant zinc. The zinc coating prevents corrosion and in case the coating is scratched, the steel is still protected. Galvanization does not change mechanical properties of steel.

Hot-dipped galvanizing is oldest and most popular form of galvanization process. Metals can be galvanized in more than one method. In hot dipped galvanizing, clean steel is dipped in molten zinc and a unique coating formation takes place that forms strong bond with the steel.

The protective outer layer is more long lasting and tough than other coatings that bond mechanically or electrically. Hot dipped galvanized makes sure that zinc coating applied to protect steel surface provides extended durability outdoors.

Electroplated galvanized steel is softer as compared to hot dipped galvanized steel, electroplated galvanized steel is prone to scratches, daily wear and tear and rough handling.

Electroplated galvanized steel will last as long as hot dipped galvanized steel if it is being used for organizing socks in your closet. An electroplated galvanized bucket if left outside and face drops, scratches and dings will last than 70 years.

Both galvanizing method and the environment it is being used in test the performance of a galvanized metal. Electrogalvanized coating is made by applying zinc to steel strips and sheets by electrodeposition. The coating thickness is less than hot dip process but gives a smooth finish.

The steel used in car bodies is galvanized through electroplate galvanizing as decorative paint can be easily applied after galvanization. Zinc is electrodeposited to steel by immersing the steel in electrolyte a solution of cyanide or zinc sulfate. Pure zinc coats iron or steel surface through electrolytic action.

Hot Dip Galvanizing Services-Tanya Galvanizers

If an electroplated galvanized finish cuts the steel edges or gets damaged under the zinc layer it is prone to corrosion. Zinc product reacting with oxygen and water or white rust does not occur on smoothly finished galvanized buckets.

The advantages of hot dipped galvanized are thick coatings, corrosion resistant and sacrificial protection of zinc coating. The finished product can be used outdoors in all types of weather conditions. The method is popularly used in construction industry.

Thus, we see that hot dip galvanizing is much better than all types of galvanizing process existing today. We at Tanya Galvanizers provide services in various public sectors and our latest machinery and technology gives you quality products at reasonable price.