The Process of Hot Dip Galvanizing – Tanya Galvanizers

The Process of Hot Dip Galvanizing – Tanya Galvanizers

With technology showing its positive colors almost everywhere, there are fields where its magical benefits are not so popular, but for those who are involved in it, are truly thanking the technology for bestowing such great innovations to them without which things have been difficult. One such innovation and invention is the hot dip galvanization process – a process to safeguard people from adverse effects of electricity and providing them a security shield as well as unhindered flow of electricity.

Going into deep, hot dip galvanizers are a form of protective barrier where the zinc coatings act as a sacrificial anode. Presence of zinc coat makes a great protective barrier to the metal and it works by many chemicals interacting. The process here goes like when zinc comes in contact with oxygen, it becomes zinc oxide which then reacts with water molecules in the air and later transforms into zinc hydroxide. And later, while reacting with carbon dioxide, it produces a thin, air tight, strong and very insoluble dull grey layer of zinc carbonate – thus protecting the metal form further corrosion and giving a full proof safety, protection and security from unforeseen accidents.

You may carry the perception that galvanization is required only if the metal or steel is not properly taken care of. But in reality the problem with paints and other coats occurs at the time when the coated objects are scratched or damaged with some or the other reasons. Once a scratch is formed, it exposes the steel to moisture and hence results in corrosion. And as soon as the rust appears in one spot of surface, immediately it spreads to other parts as well causing the paint to peel away in no time. So, carrying out hot dip galvanizing process creates a metallurgical bond between zinc and steel which leaves no chance of rusting by providing you uniform coats that will leave you tension free about corrosion issues.

This galvanizing system is carried out by many but out of all the best and trusted galvanizing company is Tanya Galvanizers. Being a popular hot dip galvanizing consultant, it renders a secured solution for rust prevention. With flux heating system and other such big and small processes, Tanya Galvanizers renders a secured and safe solution that will ensure you with a corrosion free object for long.

If you are into one such industry and looking for perfect and trusted galvanized solution for long, here is Tanya Galvanizers – a hot dip galvanizing consultant that will be a perfect resort to all your requirements.  Get the secured solutions and corrosion free objects now just with Tanya Galvanizers.

The Many Benefits To Hot Dip Galvanizers

The Benefits

There are many benefits to using metals that have been treated in hot dip galvanizers. Cars that have been made using the treated metals are going to look better and last longer than cars with untreated metal. There are many kinds of outdoor furniture pieces that are made out of metal. People who purchase metal furniture that was not zinc protected are going to have to replace their furniture a lot sooner than people who purchase their metal furniture that was protected. Besides looking better, the treated metal furniture will also last longer without falling apart and possibly breaking when people are on it.

Galvanizing-Process

Galvanizing-Process

Protecting Your Items In Three Different Ways

The process of hot dipped galvanizing will protect the material in several different ways. Material that was hot dipped galvanized will weather at a much slower rate which gives the item a longer and more predictable lifespan. The coating also sacrifices itself to small areas that are exposed through cutting, damage and drilling. It also protects larger areas from damage and it also prevents the creep of sideways rust.

No matter how you look at it hot dip galvanization is key to keeping your items looking great!

For more information visit: http://www.galvanizers.co.in/hot-dip-galvanization.html

Advantages of Hot Dip Galvanizing

150 year old practice of protecting steel from corrosion using molten zinc at a high temperature is called hot dip galvanizing. This method is often referred to as just “galvanizing” as it is a developed form of galvanizing. Zinc is the root element used in this method of galvanizing. Hot dip galvanizing cannot be done without using zinc. Zinc is used in galvanizing, is a healthy metal which is completely recyclable.

Hot-dip galvanizing is the process whereby fabricated steel, fasteners, structural steel, castings, or small parts, including small parts are immersed in a kettle of molten zinc, resulting in a metallurgically bonded alloy coating that protects the steel from corrosion. Generally flat or coil form of steel from the 10 gauge to 28 gauge range, is also protected from corrosion in a slightly different process by hot-dip galvanizing.

Electro-statically applied zinc, Steel coated with zinc-rich paint, and mechanically applied zinc are commonly known as hot dip galvanizing is used incorrectly in the society. All of these methods of applying zinc to steel for corrosion protection are very different from this method, and may be not appropriate for environmental exposures and many situations.

Hot dip galvanizing generally has lower cost in comparison to other commonly used protective coatings for steel. The application cost of labor coatings as painting has risen far more than the cost of factory applied on hot dip galvanizing.

The initial cost of hot dip galvanizing in some cases is higher than alternative coatings. Galvanizing is invariably more cost effective due to lower maintenance costs during a longer service life. Maintenance is even more costly when structures are located in remote areas. Maintenance process has a negative impact on productivity.

The life of hot dip galvanized steel or iron is more than 50 years in most rural environments, and from 10 to 30 years in most corrosive urban and coastal environments. It is 20% more than alternative coatings.

Immersion in acid ensures uniform cleaning of the steel surface, in contrast organic coatings must be applied on scratchy cleaned surfaces and verified by third party inspection. Additionally, the application of unrefined coatings is limited in terms of prevailing environmental temperature and relative humidity which adds to the cost of applying a paint system.

Prashant Galvanizer has an experienced team of skilled worker for manufacturing Hot Dip Galvanizing plants. The Galvanizer who is famous in Gujarat as the Galvanizer Consultant, provide consulting services to the engineering, galvanizing, and manufacturing industries regarding all phases of hot dip galvanizing.

Galvanizer Suppliers and Consultants in India

Galvanization is the process wherein, steel is dipped in the in the molten zinc alloy for few minutes to give it an extra coating that protects it from rusting. The basic elements to the galvanizing process involve Surface Preparation, Galvanizing and Finishing. Prashant Galvanizers have a vast knowledge of nearly so many years in providing galvanizing service, producing, manufacturing and dealing. Engagedin manufacturing and supplying of galvanizing plants, hot dip galvanizing plants, weakening resistant hot dip galvanizing plants, catholic protection galvanizing plants and barrier protection galvanizing plants, Prashant Galvanizing Suppliers are one of India’s foremost advisor, dealer and constructor of Hot Dip Galvanizing Plants (address: G-18, Gajanand Complex, Nr Makarpura Bus Depot, Vadodara – 390010).

Engaged in selling and manufacturing of galvanizing plants like wire galvanizing plants, electro galvanizing plant, constant type wire galvanizing plants, multi strand non-stop wire galvanizing plants.The physical as well as laboratory tests are performed in order to check Thickness, homogeny of coating and Appearance. Goods are galvanized according to the worldly acceptedideology given by American Society of Testing and Materials i.e. ASTM and other links like Canadian Standards (CSA).Essential aspects like surface preparation , galvanizing and concluding plays a key role in the galvanization process which makes choosing of a good Galvanizer Consultant important.

They are one of the hardest working Galvanizer consultants in India who believe in doing their work perfectly and in the specified time limit. The suppliers provides exact amount of information about the important plans, construction papers to the clients. Galvanized bolts are just like any other bolt but they are unbreakable with an electrochemical process called galvanization.This process makes a bolt stronger, able to withstand the harshest weather conditions, especially for bolts used in marine applications to keep away from corrosion. Electroplated nails are good examples of these. Hot dip galvanizing for bolts on the other hand are best suited for outdoor applications. Electroplating though is general among nails and bolts as they are much cheaper to do and manufacture, and does offer some level of resistance to rust if not worn outdoors. The problem with paints and other coats occurs when the coated object gets spoiled or damaged. A scratch exposes the base steel to wetness and this result in rusting. Once rust appears in one spot of a surface, it spreads all over the surface. This rust spreads under the paint or any other coat, causing the paint to skin away in due time.

Tanya Galvanizers – Hot Dip Galvanizing

What is Hot Dip Galvanizing?

Hot Dip Galvanizing is a factory controlled metallurgical combination of zinc and steel that provides corrosion resistance in a wide variety of environments. Hot Dip Galvanizing protects steel from corrosion in two ways. It provides cathodic protection and barrier protection.  It is one of the oldest methods of zinc coating which includes the immersion of a fastener in molten zinc by which Tanya Galvanizers provides corrosion protect finish. This zinc coating provides sacrificial protection to the steel. The process of hot-dip galvanizing results in a metallurgical bond between zinc and steel with a series of distinct iron-zinc alloys. The resulting coated steel can be used in much the same way as uncoated. Galvanized steel can be welded. As zinc is more reactive than iron, the zinc galvanized coating corrodes first, protecting the steel substrate.

At Tanya Galvanizers we take care of the Hot Dip Galvanizing method. Here at the Tanya Galvanizers the Hot Dip Galvanizing process starts by carefully cleaning the surface of the steel to prepare it for galvanizing. After cleaning, the parts are dipped in a flux tank containing (typically) an aqueous solution of zinc ammonium chloride or they are fluxed by passing through a layer of molten zinc ammonium chloride floating on the top of the molten zinc. In the galvanizing tank, the parts are completely immersed in a molten bath consisting of a minimum of 98% zinc. After slowly withdrawing the parts from the molten zinc, the fasteners are spun in a centrifuge while the zinc is still liquid to remove excess zinc. The parts are then either air or water cooled to solidify the zinc and to permit handling.

For over 150 years Hot Dip Galvanizing has had a proven track record of protection in a myriad of applications. Hot-dip galvanized steel strip (also sometimes loosely referred to as galvanized iron) is extensively used for applications requiring the strength of steel combined with the resistance to corrosion of zinc. Applications include: roofing and walling, safety barriers, handrails, consumer appliances and automotive body parts. One common use is in metal pails.  Galvanized steel is also used in most heating and cooling duct systems in buildings. The most important method of inspection for galvanized articles is visual. At Tanya Galvanizers variety of simple physical and laboratory tests may be performed for:

  • Thickness
  • Adherence of the coating
  • Uniformity of the coating
  • Appearance

Hot Dip Galvanizing: The best galvanizing method

Hot dip galvanizing or HDG method is one of the most advanced methods of galvanizing used by the galvanizer companies. Besides, it is also a widely used procedure to protect the steel made or iron made metal surfaces from the corrosion. In this method used by the galvanizers, a four layered zinc coating is created electrochemically on a metal surface. Therefore, the iron or steel base is moved across the molten bath of zinc at the temperature of 460˚C. It allows the zinc to create a bond with the iron or steel base at any molecular level.

Additionally, as per the hot dip galvanizing consultant companies; the galvanized coating covers the total surface quite easily, including all the scratched, joints and the holes. Due to its effectiveness and the corrosion resistant properties; nowadays, the hot dip galvanizing process is used widely used in the numerous applications starting from the handrails, automotive body parts, and consumer appliances to walling and roofing. Besides, this HDG method is also used to shield the exterior panels as well as the automotive parts. Usually, this kind of galvanized strips made by various galvanizer companies are used in the cooling and heating duct systems in the buildings as well as in the metal pails.

As per the galvanizer consultant companies, it is completely recyclable with the less energy needed to process this galvanizing method for using to protect the corrosion. So, it can be used as the ultimate material by the galvanizers in order to protect the structures of the parks, airports and the waterways of the various countries and states. Here, in this article, we have put together several advantages of this HDG procedure over the other methods of galvanizing. Read along to know more:

  • According to the hot dip galvanizing consultant companies, this method of galvanizing offers the advantage of having low initial costs over the other techniques of corrosion protection. Besides, this process also includes lesser labor intensive while comparing to the other procedures.
  • The coatings of this process enjoy the expectancy of a much higher life of around 40 years and more even in the severe urban and coastal environments. Additionally, this kind of performance and life expectancy of this process are also easily predictable.
  • In some rare cases, the process of hot dip galvanizing includes a higher initial charge, but then also it is much more cost effective than the other methods of galvanizing as it is more durable along with the little maintenance requirements. As this method provides superior resistance to the mechanical and water damage as well as the abrasion damage during erection, service and transportation.
  • Another important advantage of this method is that it is quite straightforward, closely controllable and simple. Besides, all the coating thicknesses are predictable, easily specifiable and regular. All these features enable this method to be precise during design and usage.

Prashant Galvanizers is one of the reputable galvanizer consultant companies in India who also specializes in the hot dip galvanizing methods.

Surface Preparation for Hot Dip Galvanizing

The method of hot dip galvanizing may differ slightly from one galvanizer to another. But all the galvanizers have to go through the three basic steps of hot dip galvanizing are surface preparation, galvanizing and inspection.

Surface preparation is the most important step in the application of any coating. In most instances incorrect surface preparation is generally the cause of a coating failure before its expected service lifetime. The surface preparation step in the hot dip galvanizing process has its own quality control in that zinc simply are not reacting metallurgically with a steel surface which is not perfectly clean. Any failures in surface preparation will immediately be apparent when the steel is withdrawn from the molten zinc because the unclean areas will remain uncoated. The galvanizer has to take action to correct immediately. This can result in problems in coordinating activity that lead to costly and time-consuming delays, errors, and disputes concerning responsibility and financial liability.

Surface preparation for hot dip galvanizing typically consists of three steps: caustic cleaning, acid pickling and fluxing.

  • Caustic Cleaning – Dirt, paint markings, grease and oil from the metal surface are removed by a hot alkali solution. Epoxies, vinyl, blacktop or welding slag must be removed by sand-blasting, grit-blasting and other mechanical means before galvanizing.
  • Pickling – Scale and rust normally are removed from the steel surface by pickling in a dilute solution of hot sulfuric acid or ambient temperature hydrophobic acid. Surface preparation also can be accomplished using abrasive cleaning as an alternative to or in conjunction with chemical cleaning. Abrasive cleaning is a process whereby sand, metallic shot or grit is propelled against the steel material by air blasts or rapidly rotating wheels.
  • Fluxing – Fluxing is the final surface preparation step in the galvanizing process. Fluxing removes oxides and prevents further oxides from forming on the surface of the metal prior to galvanizing. The method for applying the flux depends upon whether the galvanizer uses the wet or dry hot dip galvanizing process.

Prashant Galvanizer has an experienced team of skilled worker for manufacturing Hot Dip Galvanizing plants. The Galvanizer who is famous in Gujarat as the Galvanizer consultant, provides consulting services to the engineering, galvanizing, and manufacturing industries regarding all phases of hot dip galvanizing.

An Introduction to the Hot Dip Galvanizing Process

Galvanizing was known to the world from the beginning of 17th century. It is essential for iron and steel in protecting their life and utility. Science and technology has developed the process of Hot Dip Galvanizing in the 18th century in USA. The first hot dip galvanized iron sheets were imported to Australia in the 1850s. The molten zinc was found to react with steel to form a metallurgical bonded protective coating that had more durability to any other coatings for atmospheric exposure.

Hot-dip-galvanizing

Hot-dip-galvanizing

The characteristics of the coatings applied by these continuous galvanizing technologies are quite different to those of coatings applied by the traditional batch in galvanizing process.While all early hot dip galvanized items were manufactured by dipping them in batches in a molten zinc bath. Different technologies have been developed to more efficiently apply zinc-based coatings to continuously manufactured products such as wire, sheet and tube.

The main difference in the nature of these galvanized coatings is the time that the steel is immersed in the molten zinc alloy. This time is very short (a few seconds) in continuous galvanizing processes, and much longer (4 to 8 minutes) in the hot dip galvanizing process. The resulting zinc-based coatings produced by these processes are quite different and lesser than hot dip galvanizing in their characteristics and performance.

The hot dip galvanized coating is the result of a metallurgical reaction between the steel and the molten zinc, and this reaction will not occur if the steel’s surface is contaminated with paint, grease, oil or rust.Steel fabrications or sections are delivered to the galvanizing plant. These items may contain steels of differing chemistry and surface condition and may be coated with pre-construction primers or other applied protective coatings, including continuously applied zinc coatings.

For this reason, the pre-treatment of the steel sections or fabrications to remove grease, oil, paint and rust is critical to the successful application of the galvanized coating. Acid pickling is done after degreasing and paint removal. Remaining process go through pre-fluxing, galvanizing and quenching. Inspection and dressing is the final process of hot dip galvanizing.

Check Points for Ideal Galvanizer Supplier

The term ‘galvanizing’ broadly refers to an electro-deposition procedure where a thin layer of another metal is supplemented to an item made of steel. The reason of galvanizing is to defend the base steel by preventing rusting. However, one of the most efficient galvanizing methods does not utilize any electrochemical deposition. It is known as hot dip galvanizing or merely HDG.Galvanizing is one of the most common means of rust prevention and is widely used these days. Since hot-dip galvanizing creates a metallurgical bond between zinc and steel there is no chance of rusting. Hot-dip galvanizing gives you a more uniform coat and you will never have to worry about wear or deterioration. Galvanizing companies usually deal in applications that include automotive body parts, consumer appliances, roofing and walling, metal pails.

There are several points that you may consider while choosing your galvanizer suppliers or galvanizer consultants as a partner.Quality is the most important vital factor for choosing the right galvanizer service provider. Hot dip galvanizing is a specialized process and requires good circumstances and road and rail network. A company that meets these provisions and that too adhering to the highest quality standards must be chosen. Galvanizer suppliers must own the essential knowledge in meeting customers’outlook. Experienced galvanizer suppliers like Prashant galvanizer would be able to perfectly assess your requirements and offer their services in helpful way.

Galvanizer suppliers or galvanizer consultants have dedicated themselves to do their bit to save this planet in order to make surrounding pollution free. For this they use environmentally-suitable, no-lead zinc bath besides adhering to the international standards for environment management. Your choice of a hot dip galvanizing company may also depend on the value extra services that are provided along with the main service. This usually includes additional surface preparation, installations, and assembly operations. Capacity is significant to assess the material handling capacity of the Galvanizer consultant before finalizing any one of them because industrial applications could vary in scale, choose a group with one of the largest material handling capacities both in terms of overall lengths and overall weight. Experienced Staff in a company should have the necessary know-how as an industrial galvanizer.Choosing the correct galvanizing service provider is critical to the success of your industrial application as well as environmental conservation. It is advisable to investigate well before zeroing in on an exacting galvanizing company. Employee security and Health Program is significant to choose a company as that shows the dedication and care of the company to keep its employees safe.