Hot Dip Galvanization with Substation Structures

Posted on September 23, 2022 by Galvanizers

The pace of development is rapidly increasing in modern times. With this increasing pace, we also need to ensure that the structures that we develop today are durable and sustainable. Fast energy transmission has been instrumental in this growth journey.

Substation Structures have played a vital role among all mediums created for transferring electricity. This blog will provide you with a brief overview of substations and how galvanized substations are the future.

What is a substation?

Substations are used for power generation in a power station. Their transformers assist in the smooth distribution of electricity and reverse the voltage from high to low. Electricity flows through different power plants and substations at different voltages. The voltage changes based on the demand of the consumers and pre-determined targets. Therefore, substations form the backbone in transferring electricity, so it is important to maintain them through hot dip galvanization.

Hot dip galvanization

Substation structures remain exposed to climate, heat, dust, and pollution. Therefore, it is essential that they are maintained appropriately. To make them durable and sustained for a longer period of time, it is necessary that they are galvanized.

Hot dip galvanizing makes these substation structures weatherproof and strong, which helps them resist against various external factors that cause harm to them. One of the most important factors in iron maintenance is the prevention of corrosion. Hot dip galvanization also ensures that these structures are corrosion-resistant.

Hot Dip Galvanization at Tanya Galvanizers

Hot dip galvanization is not an easy process. It requires tremendous professional expertise and experience to galvanize substation structures to make them appropriate for energy transmission.

We at Tanya Galvanizers possess more than six decades of experience in the galvanizing industry. Our expertise lies in creating hot dip galvanizing structures suitable to the requirements of a substation. We make the finest quality products to ensure the highest satisfaction of our clients.

We use various metals and alloys like angels, channels, plates, flats, rounds, zinc, primers, and paints to manufacture a galvanizer. At Tanya Galvanizers, we also abide by the highest testing standards through our scientifically developed and intensive inspection and testing processes.

Prologue

Don’t let the effects of weather and pollution affect your substation structures. Protect all your substation structures by getting in touch with us at Tanya Galvanizers.

Get in touch with our experts today, and they will provide you with end-to-end galvanizing solutions for all your substations structures.

Differences Between Hot-Dipped Galvanization & Pre-Galvanizing

Posted on August 22, 2022 by Galvanizers

Galvanizing is one of the widely used methods for protecting metals from corrosion. It involves applying a thin zinc coating to a thicker base metal like iron metal. The process helps to shield the metal from the surrounding environment. When a metal undergoes galvanization, it does not experience any corrosion. However, without the zinc coating, the metal remains exposed to the elements and potentially oxidizes and corrodes faster. There are several ways of galvanizing metals, including hot-dipped galvanization and pre-galvanizing.

Hot-Dipped Galvanization vs. Pre-Galvanizing: What Are They?

As the name suggests, in hot-dipped galvanization, experts dip the steel in hot, molten zinc. When the zinc coats the steel, a metallurgical reaction occurs between the iron component of the steel and the hot zinc. The reaction known as the diffusion process occurs when the coating collects perpendicular to every surface, creating a uniform thickness.

When the expert removes the steel from the zinc bath, it reacts with the oxygen in the air to form zinc oxide. It then reacts with carbon dioxide and forms the final protective coating of zinc carbonate. With multi-layered zinc coating and iron-zinc alloy, the steel becomes corrosion-resistant.

Pre-galvanizing, also called mill galvanizing, is another galvanizing process close to ho-dipped galvanizing. However, this process occurs at the very first stage of production. The process takes place at steel mills that have a specific shape. Pre-galvanizing involves a few steps of hot-dip galvanizing, like cleaning the surface, hot zinc bathing, and recoiling.

Key Differences Between Hot-Dipped Galvanizing and Pre-Galvanizing

Application Comparison

Hot-dipped galvanization is an economical choice that you can execute on simple and complex shapes. Experts use it on objects fabricated beforehand and yet not galvanized. The hot-dipped galvanization plays the last step.

On the other hand, a metal requires undergoing pre-galvanizing at the first production stage. It mainly occurs at the mill and later undergoes cutting into size and fabrication.

Coating Comparison

Since the galvanizing process involves the application of a protective coating for the steel and metals, it is essential to consider the coating finish of the two methods of manufacturing galvanized steel.

Coating Thickness

Although both methods result in uniform thickness, the hot-dipped galvanization produces a thicker layer of protection than the other method.

Coating Continually

Hot-dipped galvanizing requires dipping the entire steel and other metals into the molten vat of zinc. The galvanized steel comes with a continuous coating over the surface. On the other hand, pre-galvanizing requires performing before cutting the sheets into perfect sizes and pieces; therefore, the cut edges do not undergo any coating.

Coating Formability

Since the process of pre-galvanizing undergoes at the mills, any coating applied after cutting the metals does not damage the layer. On the other hand, coating formability applied on hot-dipped galvanized steel is not advisable, as it might damage the protective coating of the products.

Coating Appearance

The hot-dipped galvanization forms a bright finish for the galvanized steel, which might or might not be uniform. On the other hand, the pre-galvanizing process produces a uniform bright finish for the coating.

There are numerous differences between hot-dipped and pre-galvanizing processes. Understanding the differences helps in choosing suitable methods and products for different projects.

Understanding the difference between Hot dipped galvanized and Cold Galvanizing steel

Posted on July 12, 2021 by Galvanizers

Businesses dealing with metals like iron, aluminum, copper and more for the purpose of product development and service-related issues always faces the harsh reality of corrosion a challenge that disrupts the natural flow of these businesses. The process of corrosion highlights a naturally occurring phenomenon where refined metals are naturally converted into more stable composition when comes in contact with air, moisture, humidity and other natural elements to form oxide, sulphide and hydroxide state. These states even though create a more stable composition, but ends up decaying the metal from outside in or inside out. This usually results in weakening of the structure developed with the usage of metal, or result in decaying the metal to such an extent, that it becomes impossible to use the metal for any other function. It is because of the challenges laid down by the process of corrosion on metals, organization’s dealing in metal businesses often have to suffer huge financial losses resulting in loss of goodwill, loss related metal decay and more. It is because of this reason a solution was brought in by metal businesses throughout the globe with the advancement of technology. The solution was galvanization of the metal a solution discovered in 1742 by Melouin a French chemist, where he highlights the application of zinc on the metal surfaces to increase the longevity of the metal. Even though this application of zinc on metal dates back to 2500 B.C. but the discovery of 1742 laid the foundation of exploring the zinc application on metal to the extent where application methods used could result in a change of the timeline for metal longevity. Over the years of technological changes and chemical research two significant approaches of zinc application were discovered, hot and cold dip which functions as a pivotal discovery to today’s galvanization process in the industry.

The approaches to the process of galvanization on metals as signified earlier are of two types they are hot and cold dip galvanizing. Where both the approaches are ideal for protection against corrosion, but it is thoroughly based on your business requirement you should decide which galvanizing process you should take into account to create a protective layer for your metals used in the business.

Let’s take a look at what galvanization is and how hot and cold dip galvanizing differs from each other.

What is Galvanization?

For the common approach of understanding galvanizing process refers to the approach that highlights the application of a zinc coating to the surface of a metal. The usual metal taken into consideration for the process of galvanization are Iron (Fe) and Zinc (Zn). The process of galvanization is principally utilized as a defensive mechanism to prevent corrosion and, likewise, increment the workable existence of the secured metal segment. When appropriately applied to a steel surface, zinc coatings offer two main types of protection: galvanic protection and barrier protection, which in turn increases the longevity of the metal by protecting it against possible corrosion.

Understanding Barrier Protection

Barrier protection signifies the application of zinc on the surface of metal like steel, where the applied zinc hardens over time to create a sheet of layer on the steel. This sheet of layer acts as a protective agent for the steel by conversion of zinc into zinc oxide through the process of surface electrolyte. The hardened zinc oxide layer in turn protects the steel from corrosion against the electrolyte process that usually takes place when the metal comes in surface contact with air and moisture. This protection layout of barrier protection usually takes place because zinc oxide is impervious to moisture and air. This results in preventing the underlying steel to come in contact with air and moisture, which in turn prevents it from further corrosion and increasing its life to a great extent.

Understanding Galvanic Protection

Galvanic protection, also known as cathodic protection, protects the underlying steel substrate by corroding preferentially, thus sacrificing itself in the process. This sort of protection is particularly helpful for circumstances where the protected steel may get exposed because of scratches, cuts, marks or loss of coating due to rigorous usage. Since zinc is an exceptionally receptive and electronegative metal, it will assume the role of the anode, which will result it to be corroding first in an event where the steel underneath get exposed to surface contact. This process of approach by zinc will continue to offer galvanic protection until the coating is entirely consumed. This in turn protect the underlying steel for a longer period of time safeguarding it from exposure surface electrolyte process because of chemical balance that has created an equilibrium because of chemical approach that has been applied in covering the steel in the galvanic process, unlike that of barrier protection, where sheet layer removal can expose the steel to vulnerability.

This chemical approach to protection under galvanic process is divided into particular application methodology they are hot and cold dip galvanizing process. Let’s take a look at how each of these processes functions and how they provide protection to the underlying metal.

Hot Dip Galvanization

Hot-dip galvanizing process is one of the most used application of galvanizing process. This process highlights coating a steel or iron object by submerging it into a bath of molten zinc. The bath of molten zinc showcases temperatures around 840°F (449°C). Once removed from the bath, the zinc coating on the iron or steel’s exterior reacts with oxygen in the atmosphere to form (ZnO) Zinc oxide. This Zinc oxide further reacts with carbon dioxide in the atmosphere to form a more compact protective layer known as (ZnCO3) Zinc carbonate. This Zinc carbonate reflects a dull grayish film, which is relatively stable and adheres tightly to the surface of the steel or iron. This results in the hot-dip galvanizing process to create a chemical balance, which ensures that the zinc is chemically bonded to the underlying metal and becomes part of the steel or metal that is being protected through the hot dip galvanizing process.

How Hot Dip Galvanization is performed

Though the concept of hot-dip galvanizing may seem simple, the process consists of several crucial steps. The steel first goes through three cleaning stages to prepare its surface for galvanizing; these are degreasing, pickling and fluxing. Degreasing is used to remove dirt, oil and other organic residues; a mild acid bath, or pickling, etches the steel and removes mill scale and iron oxide; and fluxing further removes any oxides and coats the steel with a protective layer that prevents the formation of further oxides on the steel surface prior to galvanizing. Once the cleaning process is completed, and the structure has dried, it is ready to be immersed into the molten zinc bath. Molten zinc flows in and around the iron or steel object, thus thoroughly coating it to protect all surfaces. The coated material is then removed from the bath and air-dried before inspection.

Cold Dip Galvanization

Cold dip galvanizing is comparatively a much simpler process. The cold dip galvanizing process showcases application of a zinc-rich paint to the surface of a metal or steel element to protect it from corrosion. As such, the term “cold galvanizing” is considered to be a misnomer among some professionals in the coating industry. Zinc paints may be applied by brushes, rollers, spray guns, etc. Coatings may also be applied by the electro galvanizing:”Electro galvanizing is an electroplating technique used to place a layer of zinc metal on top of a steel surface. It involves immersing a steel component into a solution containing zinc salts followed by the application of electricity to induce an electrochemical reaction on top of the steel. The cold dip approach in comparison to hot dip galvanization process, the electro galvanizing approach provides a thinner coating and more aesthetic appearances.” method as well. The zinc-rich paints used in cold galvanizing are different from conventional coatings due to the presence of a binding compound. These binders allow the zinc to mechanically bond to the steel to offer an effective level of protection.

How Cold Dip Galvanizing is performed

Like hot-dip galvanizing, cold galvanizing can provide barrier protection and also some degree of cathodic protection. However, the zinc dust present in the paint or coating must be in high enough concentrations to promote electrical conductivity between the steel and the zinc. The surface preparation required for applying zinc-rich coatings is less demanding than hot-dip techniques. Before coatings operations begin, the surface of the steel must be clean and dry. Usually, a wire brush is first used to remove rust or any other corrosion products that may be present. Dirt, grease, chemicals and other organic compounds must also be removed accordingly. Once the surface is prepared, the zinc coating is applied to the surface in as many coats as required.

The introspection across both hot dip and cold dip galvanizing process clearly showcases how each of the approach is thoroughly different from other even though the processes aims at a common resolution of protecting metal from corrosion. The introspection throw light on how the hot dip is a chemical approach and more long lasting, while cold dip is a more physical surface contact approach, but less consistent in comparison to hot dip.

If you are into metal businesses related to services and product then galvanization process is a must for your organization. The choice of your galvanizing approach for your metal thoroughly depends on your organizational requirement, however if you want to know more about galvanization and which approach will compliment your business, please get in touch with us.

Why Choose Us

At Galvanizer our team work relentlessly to come up with innovation’s that can deliver you ultimate experience of galvanized products. Our multi-lateral testing and development process ensures delivering our client premiere quality of galvanizing process. With decades of industry experience we offer nothing but the best. We provide assistance in helping you select the best solution for your metal business. To know more on service and business-related inquiry get in touch with us.

Importance of Galvanizing Steel

Posted on April 2, 2021 by Galvanizers

The galvanization process:

The galvanization process is an assembling interaction where zinc covering is applied to steel or iron to offer insurance and forestall rusting. A few electrifying cycles are accessible, yet the most usually offered and utilized strategy is hot-plunge arousing.

Galvanized steel is among the most famous steel types due to its all-inclusive toughness, having the strength and formability of steel in addition to the consumption insurance of the zinc-iron covering. The zinc secures the base metal by going about as a boundary to destructive components. The conciliatory idea of the covering brings about a durable and top-notch steel item.

The galvanized steel carries out these following steps:

The steel is cleaned in a degreasing arrangement
After the cleaning, the steel dipped in salt by being brought down into a tank of weakened hot sulfuric acidic liquid.
The steel is then fluxed in a fluid arrangement
After the transition, the steel is excited through submersion in a tank of liquid zinc
A while later, the steel is assessed for consistency, and a total covering

Advantages of galvanized steel:

Low introductory expense: Contrasted with most treated prepares. Likewise, galvanized steel is promptly ready to utilize when conveyed. It doesn’t need extra planning of the surface, reviews, painting/coatings, and so forth, saving organizations more expenses on their end.

Longer life: With galvanization, a piece of industrial steel is required to last over 50 years in normal conditions and can last more than 20 years with profound water openness. There is no support necessary. The expanded toughness of the steel’s done item additionally builds the item’s unwavering quality.

Rust resistance: The iron components in steel are inconceivably inclined to rust; however, the expansion of zinc goes about as a defensive cradle between the steel and any moisture or oxygen. Galvanized steel is highly defensive, including sharp corners and breaks that couldn’t be secured with different coatings, making it impervious to harm.

Importance of Galvanized steel:

Full protection for damaged areas: Galvanized coatings erodes, especially to steel, giving cathodic or sacrificial security to little areas of steel uncovered through harm. In contrast to natural coatings, little harmed regions need no final detail.

Complete security: Every piece of a galvanized article is ensured to get protection, even breaks, sharp corners, and unavailable areas. No covering applied to construction or creation after fulfillment can give a similar assurance.

The simplicity of investigation: Galvanized coatings are evaluated promptly by the eye, and basic non-destructive thickness testing techniques can be utilized. The galvanizing cycle is to such an extent that if coatings seem sound and persistent, they are sound and continuous.

Conclusion:

Discovering the best administrations/services of Galvanizing Steel? stress less, we here give you the best Galvanizing cycle to advance your nature of steel, venture forward to us for the best administrations/services.

Importance of Crash barrier Hot Dip Galvanizing

Posted on February 23, 2021 by Galvanizers

What is Hot Dip Galvanizing?

The process of zinc coating on steel and Iron is known as Hot Dip Galvanizing. This process is widely followed to increase the life of the base metal and to ensure that the base metal does not rust with time. Be it a fabricated or an unfabricated piece of metal, the molten zinc is used to coat the base metal at about 840 degree Fahrenheit while performing a Hot Dip Galvanizing.

What is Crash Barrier?

Crash barrier is a strong fencing system used usually to barricade roads to avoid accidents or crashes. These fencings are made of solid metals acting as strong protection by the sides.

How does a galvanized crash barrier more efficient?

Galvanizing the crash barriers is the smartest option versus any other paint-on options. This process of galvanizing makes the crash barriers more durable and stronger as it gives a complete coverage. The zinc coat also makes the fences more absorbent to shock as these are abrasion resistant. Galvanizing the barriers also helps as the zinc coating grows parallel on the steel making the edges and corners the same thick.

Crash barrier hot-dip galvanizing acts as an extra protection when a sudden major accident takes place. This is more in demand when fencing on the highways to avoid fatal incidents.

Be a part of the environment

Zinc as being a renewable resource and available in abundance makes it more environment friendly option. Also, in the process of galvanizing the zinc does not lose its properties making it even more recyclable.

Crash Barrier is of different types including Roadside, Median, Bridge and work zone barriers.

Galvanizers make it easy for you to get the safest and the most affordable Crash barrier hot-dip galvanizing possible. They followed a step by step process to ensure galvanizing done right, keeping it safe being on the road. They ensure the best quality of hot-dip galvanizing making it possible for the crash barriers to sustain longer in extreme exposure to the environment.

Difference Between Hot Dip Galvanizing and Boronizing

Posted on December 23, 2020 by Galvanizers

Hot dip galvanizing and boronizing are two different processes that involves coating of a base metal or alloy to enhance its life to a significant extent. Both the process forms a protective surface layer on the chosen base metal or alloy but each of the processes are completely different from each other. To learn about the difference between these two processes, let us delve a bit deeper into each process.

Hot Dip Galvanizing

Hot dip galvanizing is a process in which the base metal usually steel is dipped into a bath of molten zinc at high temperatures of about 450 degrees Celsius or 840 degrees Fahrenheit. Before dipping, the base metal or steel is cleaned in a caustic solution for removal of dirt and then passed through an acidic solution for removing flakes of iron oxide. The base metal is further cleaned with the help of a chemical cleaning agent like ammonium chloride so that the bonding of the base metal with zinc can be better.

Boronizing

Boronizing, on the other hand, is process of surface hardening of steel. It is a thermo chemical process for hardening the surface of the base metal usually steel. In this process, boron is added to the base metal or alloy where the atoms of boron are diffused into the surface of the base metal.

Difference in Functionality

Now, we are clear with the differences between the two processes. Next, we would be learning about the functional differences or the beneficial difference between hot dip galvanizing and boronizing.

Hot dip galvanization of steel helps in the improvement of the corrosion resistance capacity of steel of aby other base metal used. But on the other hand, boronizing case hardens the base metal, thereby providing even higher or superior corrosion resistance.
Boronizing plays a vital role prevention of wear and tear of the base metal, thereby making sure that the base metal becomes highly durable in nature. Reduced wear and tear provide the base metal with great capacity to withstand any external elements without any kind of compromise in the functionality of the base metal so boronized.
Hot dip galvanization only helps in the improvement of the corrosion resistance capacity of the base metal. But boronizing not only case hardens the surface of the base metal but also plays a significant role in improving the temperature stability along with several other mechanical properties of the base metal.

Why Prashant Galvanizers?

If you are looking forward to premium quality hot dip galvanizing services or boronizing services, do not look any further and come to Prashant Galvanizers. With several years of experience and expertise in this field, Prashant Galvanizers have emerged as one of the top service providers in this field. So, for all sorts of galvanizing or boronizing requirements, all that the users need to do is to get in touch with the expert and dedicated team of Prashant Galvanizers for the best solutions.

Key Considerations for Hot Dip Galvanizing

Posted on November 5, 2020 by Galvanizers

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.

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