LARSEN & TOUBRO LIMITED

MODULAR FABRICATION FACILITY

Hazira Works, P.O. Bhatha, Surat-394510, India Te.! "91 #$1 #%$0345 - #%$03$0 &a' ! "91 #$1 #%$0#0%, #%$0#10
Date: 12/04/2007
METHOD STATEMENT

Subject: - Hot Dip Galvanization As per ISO 1461 / MIS !4 "ev#6 $At %en&ors S'op(
Items: - "a) Materials s*+' as an,le- +'annels- pipes- plates et+#. /re-0a1ri+ate& pro&*+t/ite2s
s*+' as +a1le tra3s- stair+ase- panels- 'an&rails et+#
Procedure: - Steps t'at are to 1e 4ollo)e& 'ave 1een ill*strate& 1elo): -
1( "e+eive& 2aterials 4ro2 &i44erent +*sto2ers are 1ein, +'e+5e& 4or +o-relation as per t'e
+'allan an& t'e +learan+e +erti4i+ate/noti4i+ation 4ro2 t'e +*sto2ers 6#7 &epart2ent#
Points are to be checked: - i( Material i&enti4i+ation 2ar5 $i4 an3(. ii( /'3si+al
+on&ition. iii( 6*antit3. iv( 7*sto2ers inspe+tion release note. v( )'et'er vis*all3
a++epte&/&a2a,e&#
Responsibility: - Overall responsi1ilit3 s'all 1e )it' 6*alit3 7ontrol &epart2ent o4
89# Ho)ever t'e respe+tive 67 inspe+tor at ven&or:s s'op / 89 appointe& /IA
s'all 1e in&ivi&*all3 responsi1le 4or t'eir respe+tive s+ope o4 )or5#
Action points:- 6#7 inspe+tor approves t'e 2aterial 4or 4*rt'er pro+essin, onl3 a4ter
veri43in,/+o2pl3in, t'e a4oresai& +'e+5 points# A4ter s'op 6#7 +learan+e t'e 1la+5/ra)
2aterials are to 1e loa&e& on t'e 1*n5 4or t'e &e,reasin,/+leanin, p*rpose#
2( 0ro2 t'e 1*n5 t'e 1la+5 2aterials are to 1e i22erse& in to t'e &e,reasin, sol*tion#
;or2all3 t'e 2aterials are 5ept t'ere 4or 10-1< 2in*tes#
!( A4ter t'e step no#2 t'e 2aterials are to 1e rinse& )it' 'ot )ater# 'is is to 1e &one to
re2ove t'e resi&*al $i4 an3( part o4 t'e &e,reasin, sol*tion 4ro2 t'e s*r4a+e o4 t'e
i22erse& ite2s#
4( A4ter &e,reasin,- t'e 2aterials are to 1e i22erse& in H+l a+i& sol*tion o4 a&e=*ate
stren,t' $Stren,t' nor2all3 varies 1et)een 40 ,2/8tr to 1>0 ,2/8tr#( in or&er to +lean
t'e s*r4a+e#
<( 'e 2aterials are to 1e rinse& )it' 4res' +ol& )ater in or&er to re2ove t'e e?+ess a+i&
parti+les t'at 2a3 present on t'e s*r4a+e# 'e pH val*e o4 t'e +ol& )ater s'all lie in
1et)een 2 to <#
LARSEN & TOUBRO LIMITED
MODULAR FABRICATION FACILITY
Hazira Works, P.O. Bhatha, Surat-394510, India Te.! "91 #$1 #%$0345 - #%$03$0 &a' ! "91 #$1 #%$0#0%, #%$0#10
6( A4ter rinsin,- t'e 2aterials are to 1e loa&e& into +rates an& t'en t'e loa&e& +rates are to
1e i22erse& in to t'e zin+ a22oni*2 +'lori&e sol*tion as a part o4 /re 0l*?in,
operation# @e4ore &ippin, in to t'e sol*tion t'e spe+i4i+ ,ravit3 an& t'e pH val*e o4 t'e
sol*tion are to 1e +'e+5e& an& re+or&e&#
7( A4ter t'e step no#6 t'e 2aterials nee& to 1e &rie& an& as a part o4 t'e &r3in, operation t'e
loa&e& +rates $a4ter ta5in, o*t o4 t'e zin+ a22oni*2 +'lori&e sol*tion( are to 1e
*nloa&e& on 'ot plate 9 loa& in 4ra2es or 'oo5s as re=*ire&#
>( 'en t'e 2aterials are to 1e i22erse& in to t'e 2olten zin+ 1at' as a part o4 t'e
,alvanizin, operation# @e4ore i22ersion t'e 1at' te2perat*re is to 1e 2eas*re& an& i4
not spe+i4ie& 13 t'e relevant +o&e/ spe+i4i+ation t'e sa2e is nor2all3 2aintaine& in
1et)een 440A7 460A7- *nless ot'er)ise spe+i4ie&#
B( A4ter 'avin, i22erse& in to t'e 2olten zin+ 1at' 4or an a&e=*ate ti2e $t'e i22ersion
an& )it'&ra)al ti2es are to 1e note&( t'e ,alvanize& 2aterials / ite2s are to 1e
i22erse& in 4res' )ater tan5 4or re2ovin, t'e e?+ess zin+ resi&*als 4ro2 t'e 2aterial
s*r4a+e# 'e i22ersion ti2e in to t'e ,alvanize& 1at' is to 1e &eter2ine& )it' re,ar& to
t'e ,alvanization t'i+5ness nee&e&#
10( 'e ite2s alrea&3 1een ,alvanize& are to 1e i22erse& in to t'e &i+'ro2atin, sol*tion#
'is step is re=*ire& to prevent )'ile r*st 4or2ation as a part o4 t'e passivation
treat2ent#
11( I4 t'e post ,alvanization vis*al inspe+tion is O#C# t'en t'e t'i+5ness o4 t'e zin+ +oatin,
is to 1e veri4ie& 13 t'e t'i+5ness ,a*,e# 'e t'i+5ness ,a*,e 2eas*re2ent is to 1e ta5en
at ran&o2 an& at as 2an3 pla+es as possi1le over ea+' ite2 in or&er to +'e+5 t'e
*ni4or2it3 o4 zin+ +oatin, t'ro*,'o*t t'e )'ole s*r4a+e# As a part o4 t'e +ross
+on4or2ation t'e avera,e zin+ +oatin, t'i+5ness is trans4erre& to t'e 2ass o4 t'e zin+-
+oatin, an& veri4ie& as per t'e val*es ,iven in t'e relevant +o&es / stan&ar&s#
12( 'e a&'esive nat*re o4 t'e zin+ +oatin, over t'e ite2s are 1ein, +'e+5e& as a part o4 t'e
a&'esion test an& t'e sa2e is 1ein, &one B0 &e,ree $)it' re,ar& to t'e ,alvanize&
s*r4a+e( 'a22erin, 13 pivote& 'a22er / p*ttin, 5ni4e on t'e ,alvanize& s*r4a+e at
ran&o2 &istri1*te& t'ro*,'o*t t'e s*r4a+e $at 622 apart( an& see )'et'er t'ere is an3
+oatin, peel o44 or not#
1!( 'e ite2s are 1ein, i22erse& into t'e 7*so4#<H2O sol*tion 4or +'e+5in, t'e *ni4or2it3
o4 t'e zin+ +oatin, over t'e s*r4a+e# 'e te2perat*re o4 t'e sol*tion is 2aintaine& at 1>-
20 &e,ree 7elsi*s an& t'e spe+i4i+ ,ravit3 o4 t'e sa2e is 1ein, 2aintaine& at 1#1>6 as
2ini2*2# Sa2ples are 1ein, &ippe& into t'e sol*tion 4or 4 &ips o4 ea+' 1-2in*te
2ini2*2# A4ter 'avin, 1een i22erse&- t'e ite2s are rinse& )it' +ol& )ater to re2ove
LARSEN & TOUBRO LIMITED
MODULAR FABRICATION FACILITY
Hazira Works, P.O. Bhatha, Surat-394510, India Te.! "91 #$1 #%$0345 - #%$03$0 &a' ! "91 #$1 #%$0#0%, #%$0#10
t'e 4alse re& +opper &eposit 4ro2 t'e sa2ple s*r4a+e# ;o tra+e o4 re& +opper &eposit a4ter
t'e rinsin, / +leanin, o4 t'e s*r4a+e s'all 1e treate& as t'e a++eptan+e +riteria 4or t'e
sa2e#
14( A4ter ,alvanization- in +ase o4 pipes $parti+*larl3 4or t'e s2all 1ores( t'e inner s*r4a+e is
1ein, +leane& 13 2e+'ani+al 2eans to re2ove +lo,s- l*2ps et+# an& t'e t'i+5ness is
1ein, +'e+5e& at ran&o2 13 +*ttin, t'e sa2ple pipes in 1et)een#
1<( Dlti2atel3 t'e ite2s are to 1e 'an&e& over to t'e 4inis' 3ar& / &ispat+' 3ar&#
16( In t'e 4inis' 3ar& too- t'e ite2s are to 1e 5ept *n&er t'e s'e& an& s'all 1e pla+e& over t'e
plan5s / s*ita1le 1ases to avoi& t'e &ire+t +onta+t )it' t'e ,ro*n&#
17( It s'all 1e note& t'at i4 in an3 step t'e re=*ire& val*es / properties are not 2et t'en t'e
sa2e step is to 1e repeate& on+e a,ain to 'ave t'e &esire& propert3#
1>( /lease also re4er t'e atta+'e& 4lo) s'eet 4or ,alvanizin, operation 4or +larit3 in +aps*le
4or2#
1B( /lease note t'at i4 t'e &etails re,ar&in, t'e sai& steps are not 2entione& / spe+i4ie& in
ISO 1461 t'en t'e e=*ivalent @S / ASM / IS stan&ar& s'all 1e 4ollo)e&#
LARSEN & TOUBRO LIMITED
MODULAR FABRICATION FACILITY
Hazira Works, P.O. Bhatha, Surat-394510, India Te.! "91 #$1 #%$0345 - #%$03$0 &a' ! "91 #$1 #%$0#0%, #%$0#10
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