18.

GALVANIZED COATING DEFECTS

INTRODUCTION
Unlike many manufacturing processes, the hot dip galvanizing of
fabricated steelwork involves many variables that can impact on
the appearance and characteristics of the finished product.

Hot dip galvanizing is primarily an industrial protective coating

process designed to provide a tough and durable protective
coating for steel that will generally outlast the design life of the
structure to which it is applied.

The variables inherent in the process can each affect the Distortion of thin checker plate welded to
heavier supporting members can be reduced
appearance of the galvanized product. Many of these variables by fixing the checker plate after galvanizing
are classified as ‘coating defects’. Most are easthetic and do not
affect the performance of the galvanizing as an anti-corrosion
coating.

FACTORS AFFECTING HOT DIP GALVANIZED COATINGS

The factors affecting hot dip the appearance and characteristics of hot dip galvanized coatings include:

• The size and shape of the item

• The steel chemistry
• The steel surface condition
• The design of the item with respect to
• The metallurgy of the galvanizing process.

The hot dip galvanizing process involves immersing steel items in molten zinc at 450oC after pre-
treatment to remove organic materials, rust and mill scale. This hot dipping process, where the
steel is immersed in the molten zinc for several minutes, gives the galvanized coating its unique
characteristics.

SIZE & SHAPE OF THE ITEM

Zinc freezes at 420oC, so there is very little superheat in the molten zinc as the item is withdrawn from
the bath of molten zinc. Thicker sections will retain their heat longer and promote better drainage of the
molten zinc from their surfaces than thinner sections.

The angle with which the work can be withdrawn from the bath will influence the drainage
characteristics. One-dimensional items that are short enough to dip vertically will produce smoother
and more uniform coatings than 2- or 3-dimensional items where some surfaces will be at shallow
withdrawal angles from the molten zinc.

THE STEEL CHEMISTRY

The rate at which molten zinc reacts with steel to form the galvanized coating is dependent on the
steel chemistry. Pure iron has a very low reaction rate and for this reason, galvanizing kettles are
manufactured from steel of this type.

Structural grades of steel always contains alloying elements, the most common of which are carbon,
manganese and silicon. Sulfur and phosphorous are residual elements arising from the raw material
used to make the steel, although some special steels have these elements added deliberately.

Of these elements, silicon and phosphorous have the most significant effect on the galvanized
coating’s characteristics, with silicon being the most common steel alloying additive affecting coating
appearance.
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 18. GALVANIZED COATING DEFECTS

High silicon levels 9obive 0.20%) may result in the galvanized

coating have a duller or matt gray appearance, or a blotchy
variable appearance.

High phosphorous levels (not normally found in structural steels)

can give rise to dark gray or browning coatings that are prone to
delamination from the steel’s surface.

STEEL SURFACE CONDITION Drainage spikes will always occur where

The surface condition of the steel will be reflected in the edges are parallel to the molten zinc surface.
galvanized coating in two ways. Rougher surfaces have a These are removed by grinding of filing during
higher surface area per unit of surface and thus generate thicker the inspection process.
galvanized coatings. Hot rolled sections typically produce hot
dip galvanized coatings 30-50% thicker than smooth, cold rolled
surfaces.

Galvanized coatings on steel with gross surface defects such as

pitting will conform to the defects and follow the surface profile
of the steel.

While the coating will provide the same degree of protection

from corrosion, the appearance may not be acceptable to the
end-user and thus steel surface quality is an issue where the
highest standards of surface appearance are required. Blinding of small holes (6mm or under) will
occur because of the surface tension of the
DESIGN OF THE ITEM FOR GALVANIZING molten zinc. This can be minimised by detailed
attention to the item as it emerges from the
The design of a fabrication is critical in determining the surface
molten zinc.
quality of the finished product. Unless the pre-treatment
chemicals can penetrate to all surfaces of the item, the
inaccessible surfaces will not be galvanized.

Conversely, if the molten zinc cannot completely drain from the work, zinc puddles will freeze in
pockets and cause problems.

The techniques of designing for galvanizing are well understood by galvanizers and consultation in the
design stage of fabrication will always result in a better quality outcome.

The main issues to be addressed in designing for galvanizing to minimise defects are as follows:

1. The item needs to be suspended during galvanizing. The provision of lifting lugs to eliminate touch
marks from wire or chains is an example of design improving quality.

2. The item needs to be have adequate venting and draining provisions to ensure the smooth flow of
zinc into and out of the item.

3. The dimensions of the item need to comfortably fit within the bath dimensions to allow adequate
withdrawal angles. Double dipping of the item will frequently produce a better quality than single
dipping an item that can be barely submerged in the bath.

THE METALLURGY OF THE GALVANIZING PROCESS

Many of the surface imperfections that are characteristic of hot dip galvanized coatings are a function
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 18. GALVANIZED COATING DEFECTS

of the metallurgy associated with the process.

Prior to galvanizing, the steel is chemically pre-treated and at

the final stage, is immersed in a zinc ammonium chloride (ZAC)
preflux solution. This process puts a thin film of ZAC crystals on
the steel surface.

When the steel is immersed in the molten zinc bath, a number of

reactions take place. These are:
Blinding of small holes (6mm or under) will
1. The preflux is activated by the molten zinc and performs a occur because of the surface tension of the
final cleaning action on the steel surface. Oxidation molten zinc. This can be minimised by de-
products are produced by this reaction that contain a tailed attention to the item as it emerges from
combination of zinc chloride and zinc oxide. These the molten zinc.
oxidation products are lighter than zinc and float to the
surface. This is called zinc ash.

2. When the steel reaches galvanizing bath temperature, the zinc reacts with the steel to form a series
of zinc-iron alloys. Some of these zinc-iron alloy crystals float off the surface of the steel and enter
the zinc bath.

3. The zinc bath becomes saturated with iron in solution, either from work entering the bath or from
the steel galvanizing kettle. This saturation level is typically about 250 parts of iron per million at
galvanizing temperature.

4. Over time, these zinc-iron crystals coalesce and sink to the bottom of the zinc bath. This forms
a mushy layer called ‘dross’. The dross is periodically removed by scooping it from the bath with
special equipment. Zinc dross is crystalline and has a much higher melting point than zinc (650oC
versus 420oC).

5. The molten zinc surface is constantly oxidising, and this oxide film is always present on the zinc
surface to a greater or lesser degree.

In the process of galvanizing a steel fabrication, the presence of ash and dross may have the following
effects on the appearance of the hot dip galvanized coating:

• If the item comes in contact with the dross layer in the bottom of the bath, the dross can get
caught in or on the work and form a rough, lumpy deposit.

• If areas of the item are inaccessible for skimming, ash may stick to the surface of the galvanizing as
it is withdrawn from the bath.

• If the rate of withdrawal varies or stops during the extraction of the galvanized item from the bath,
tide marks (oxide lines) may appear on the surface of the galvanizing causing variations in the shiny
appearance of the coating.

• With smooth-surfaced work such as tanks or large diameter pipes, dross crystals floating in the
bath may be caught up on the galvanized coating. These ‘dross pimples’ give the coating a gritty
appearance.

STEEL DEFECTS AND THEIR EFFECTS ON GALVANIZED COATINGS

Hot dip galvanized coatings, as described above, are not ‘coatings’ in the conventional sense, but
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 18. GALVANIZED COATING DEFECTS

alloys that form on the steel to make the galvanized steel item a
composite material.

As such, galvanized coatings, unlike paint coatings are not very

effective at covering up defects in the steel, and are more likely
to highlight steel surface quality problems.

Steel, like most manufactured products, can be prone to a

variety of common defects, most of which are associated with
the casting, rolling and manufacturing processes.
Threaded items will usually require post-
galvanizing treatment to clean the threads
The surface area of the steel per unit of area has a significant of zinc. This can be done by reheating the
effect on how the zinc reacts with the steel to form the threads to galvanizing temperature (450oC),
galvanized coating. Rough surfaces will react more vigorously then removing the excess zinc by wire brush-
ing.
than smooth surfaces to form thicker galvanized coatings.

Hot rolled surfaces with mill scale may have 30 to 50% more surface area per unit than smooth, cold
rolled surfaces. Abrasive blasting will artificially increase surface roughness and is a way to deliberately
increase coating thickness for heavy duty applications.

Galvanized coatings are totally unlike paint films in the way in which they conform to sharp edges or
corners. The surface tension effects with paint films tend to thin the paint film out over corners and
edges.

Hot dip galvanized coatings,, on the other hand, tend to be thicker on edges and corners because the
crystals in the alloy layer can flare out and have more room to grow around the corner radius.

For this reason, hot dip galvanized coatings may exaggerate the appearance of defects where rolling
defects cause sharp ridges on the steel surface.

Small particles or slivers of steel can be rolled into the steel’s surface, and these may be almost
invisible to the naked eye. However, when the steel is pickled and the surrounding oxide is removed
from these shells and scales, as they are called, the galvanized coating can take on a pimply
appearance as the zinc reacts more quickly with these small, loosely attached steel slivers.

The manufacturing operations performed on some steel sections can also show up in the form of visual
defects, the most common of these being striations. These are narrow (typically about 1-2 mm wide)
longitudinal raised lines in the coating usually running the full length of the section.

The most common cause of striations is stress lines on the surface of the steel caused by cold working
of the section. Heavy gauge rod will sometimes show a spiral striation pattern arising from the rod or
wire being passed through a roller/straightener prior to final manufacture.

Welded sections will frequently have much thicker coatings in the weld areas. While this is rarely a
problem on structural steel sections, it can cause aesthetic problems on high quality fabrications such
as wrought iron and security doors, where the welds have been ground flush and the item is to be
painted after galvanizing.

This phenomenon is caused by the differing chemistry of the weld metal compared to the parent metal.
Most weld metals contain high levels of silicon, and the higher silicon in the weld metal will result in
thicker (sometimes 3-4X as thick) galvanized coatings.

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 18. GALVANIZED COATING DEFECTS

A reverse of this phenomenon can occur where heavier steel

sections (over 12mm) are flame-cut. The edges of flanges of
welded beams are a common example

The flame cut edges of these heavy plate sections will

frequently show a wide variation in coating thickness from zone
to zone in the flame-cut area.

This is caused by irregular oxidation of some of the constituents

in the steel on the surface, giving the flame cut surface a
variable metallurgy compared to the parent metal. The zinc The fracture of Bisalloy wear plate is a result
coating in these flame cut areas may appear as a series of of Hydrogen embrittlement arising from the
sharply defined plateaus, with low thickness coatings where pickling process. High strength (over 800 MPa)
significant oxidation has taken place, and normal coating steel is susceptible to this type of embrittle-
ment.
thickness, typically well over the minimum standard required, in
less affected areas.

EMBRITTLEMENT
Embrittlement of steel as a result of the hot dip galvanizing process is rarely encountered with
structural grades of steel. However, the use of higher-strength steel grades or inappropriate fabrication
techniques can lead to embrittlement problems with galvanized steel.

There are three types of embrittlement encountered in the hot dip galvanizing process. These are:

1. Hydrogen embrittlement
2. Strain-age embrittlement
3. Liquid metal embrittlement

Hydrogen embrittlement is most commonly encountered and affects susceptible steel whole yield
strength is above 800 MPa.

Hydrogen atoms from the acid pickling process penetrate the grain boundaries of these high strength
steels and can cause brittle fractures under certain conditions.
Many high strength steels can be galvanized and standard pre-
or post-galvanizing treatments are available to eliminate the risk
of hydrogen embrittlement.

Consultation with the galvanizer is essential where fabrications

involving the use of high-strength steel are involved.

Strain-age embrittlement is caused by excessive cold working of

the steel prior to galvanizing. The heat of the galvanizing process
accelerates the embrittlement , so susceptible steels present a These lateral striations are a result of surface
long-term embrittlement risk, even if they were not galvanized. stresses in the steel section cause by the roll-
ing process reacting at a higher rate with the
Localised heating of severely cold worked steels through weldingmolten zinc than the surrounding steel.
may also precipitate stain-ageing failure.

Bending steel through too tight a radius, re-bending already cold worked steel, or hole punching
through thick sections are all manufacturing processes that can give rise to strain-age embrittlement
problems.

Many manufacturing standards for products such as re-bar address this issue within the standard,
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 18. GALVANIZED COATING DEFECTS

and fabricators and manufacturers who abide by established

practices and use appropriate steel grades rarely experience
problems.

Liquid metal embrittlement is specific to certain types of steels

that are infrequently encountered in the galvanizing process. The
most susceptible are many grades of stainless steel that from
time to time, are attached to mild steel assemblies as fittings or
components. The `white rust’ on these galvanized flat bar
sections has been caused by their being wet
The molten zinc penetrates the grain boundaries of these in the bundle. Galvanized coatings require
steels and fracture under load may result. If the use of stainless good ventilation when newly applied to allow
the passive oxide films to develop.
steel components is required, mechanical attachments after
galvanizing is strongly recommended.

DISTORTION
Distortion in galvanizing is one of the most common causes for
concern, In practice, a small proportion of fabricated items are
prone to distortion during the galvanizing process.

Some items will always represent a high risk of distortion, and

the galvanizer is well aware of the types of steel sections that are
prone to distortion.
Dross pimples on this pipe spool arise from
There are three significant causes of distortion with steel dross crystals being stirred up from the bot-
sections. These are: tom of the galvanizing bath by long or deep
items. Appearance is unsightly but durability
1. The thickness and shape of the section being galvanized. is unaffected.
2. The design of the fabrication with respect to location of
welds, symmetry and fabrication stresses present prior to
galvanizing.
3.The way the work is handled during the galvanizing process.

It is the heat of the galvanizing process and the manner it is transferred and withdrawn from the steel
during processing that determines the dimensional stability of an
item being galvanized.

The work has to be heated from around ambient temperature to

450oC almost instantaneously as it enters the molten zinc.

Not all of the item is heated at the same time as it has to be

lowered into the bath at a rate that is safe for the operators and
consistent with the ability of the molten zinc to flow over and
into the item.

At the galvanizing temperature, steel loses 50% of its yield

strength, and regains it as it cools down. Much research has
been done on the effect of the galvanizing process on steel Hydrogen embrittlement failure of Hercalloy
strength, and this has revealed that there is no measurable loss, chain is caused by exposing this 1200 MPa
and in most cases, there is a slight increase, in yield strength steel to pickling acid. These types of steels
should not be galvanized.
after galvanizing.

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 18. GALVANIZED COATING DEFECTS

Thin plate sections are most prone to distortion, and this is

caused by the rapid differential heating and cooling of the
sections, and its relative weakness as a thin section.

Thin steel that has been processed into hollow sections or cold-
formed structural shapes is much more stable and is routinely
galvanized without problems. Corrugating thin sheet will also
largely eliminate the tendency to distort.

Fabrications that are asymmetrical, or have significant welding

on one side of the section are in a highly stressed state due to This miss in the galvanized coating is caused
the heat effects of the welding processes. Hot dip galvanizing by surface contamination by residual oxides
will stress relieve these sections and distortions may result, not removed in the pickling process.
typically cambering or sweeping of beam sections.

Fabrications containing elements of significantly different section thickness are another potential
problem area, and high stresses can be generated during the heating and cooling cycle that may cause
distortion due to differential heating and colloing..

Platforms with checker plate welded to structural framing are a common problem area that can be
avoided by galvanizing the thin and thick sections as separate elements.

The galvanizer has the responsibility to handle the work in a way that will reduce the risk of distortion.
Locating lifting points located at the optimum points to support the fabrication so that its own
unsupported weight does not contribute to it bending or sagging during galvanizing is a galvanizers’
responsibility.

The way the item is immersed in the molten zinc and the post galvanizing quenching process may also
have an influence on the dimensional stability of the finished product. Competent galvanizers should
be aware of these issues and be prepared to advise the client on design details that can minimise
distortion problems.

Where distortion is unavoidable, particularly with products such as waste bins and trailers, clients
are now prepared to accept the appearance of the thin metal
plate sections because of the dramatic increase in service life
provided by the coating.

The acceptance of unavoidable distortion during hot dip

galvanizing will thus always be a trade-off between appearance
and performance. Only the client can decide.

PICKLING CORROSION
Hydrochloric acid is used for pickling steel prior to galvanizing.
Some galvanizers add inhibitor to the acid but most operate at
Zinc run caused by zinc freezing while draining
acid concentration levels of around 10%. from flat RHS surface. Durability is enhanced
but thick runs may interfere with connecting
At this level, the acid will efficiently attack and dissolve rust and surfaces
mill scale but will not react with the base steel at a very high
rate.

The exception is with high sulfur steel. The main application for
these types of steel is for small part manufacture of machined
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 18. GALVANIZED COATING DEFECTS

components.

The sulfur is added to the steel to weaken its grain structure so

that during high speed machining operations, the chips break off
in short sections and facilitate the machining operations.

These steels are used for non-critical components such as

threaded fittings and repetition machined steel non-stressed
components.

From time to time, threaded fitting such as sockets, spigots, Flux staining has occurred on unsealed vent
nipples and bushes are welded into fabricated assemblies. holes in overlaps on this fabrication. The stains
are caused by iron salts, that have penetrated
the overlap during pre-treatment, re-hydrating
Attack by the acid on these threaded components can quickly with atmospheric moisture.
dissolve the threads and render the item unserviceable.

The corrosion of the threaded area may also be caused by zinc

attack in the galvanizing bath, but it is largely a function of acid
attack during the pickling process.

BLOWOUTS AND BLEEDING

Molten zinc at galvanizing temperature is only about 30 degrees
above its freezing point. The viscosity of the molten metal limits
its ability to penetrate small cavities and crevices, and gaps less
than 1 mm in width may not allow penetration by the molten
zinc.

Many fabricated items have overlapping surfaces, and during The gray coating on these pipes is a result
of high silicon content of the steel, making it
the pre-treatment process, pretreatment chemicals will more reactive and converting all the coating to
penetrate these overlaps and may not drain out because of zinc-iron alloy. These gray coatings are typi-
surface tension holding the liquor in place. cally thicker than shiny galvanized coatings on
similar sections.
When the item enters the galvanizing bath, any moisture
trapped in these crevices will rapidly boil and eject steam and
pretreatment resides onto the adjacent surface of the work.

This contamination interferes with the zinc’s ability to react with

the steel and uncoated areas adjacent to these `blowouts’ will
result.

Another defect arising from unsealed overlapping surfaces is

the `bleeding’ which occurs out of the overlap after galvanizing.
This miss in the galvanized coating is caused
by surface contamination by an incorrect type
This is commonly referred to as `acid staining’. Hydrochloric of marking paint that is resistant to removal by
acid vaporises at below 200 degrees C so there is never any pre-treatment chemicals.
acid residues left in or on the item after galvanizing.

The staining that occurs is caused by flux residues that have

been desiccated by the heat of the galvanizing process, re-hydrating from contact with atmospheric
moisture.

The brown liquor bleeding from overlaps is not particularly aggressive to zinc but causes unsightly
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 18. GALVANIZED COATING DEFECTS

staining of the work and highlight the lack of a galvanized

coating, and a potential for corrosion, in the uncoated overlap
area.

FLAKING
Flaking of galvanized coatings can occur on reactive steels
which produce thick alloy layers in the galvanizing process.

On thick reactive steel, coating thicknesses in the order of 300-

500 microns may be produced. These alloy layers are very hard
and inflexible and differential expansion or contraction of the The textured surface on this steel angle results
steel can cause areas of the alloy layers to shear off the steel from the rough as-rolled surface of the base
surface. steel, usually cause by excessive mill-scale on
the steel section in the hot rolling process.

Localised flaking can occur with these types of coatings if

there are subject to impact or point pressure from lifting slings
or handling equipment. Flaking can be minimised by quick
cooling of the work after it exits the galvanizing bath but may be
aggravated by slow air-cooling.

Modification of standard galvanizing practice in handling

reactive steel sections prone to flaking will generally minimise
the risk of delamination of heavy coatings after galvanizing,
but careful design is required to ensure that the items can be
immersed and withdrawn from the molten zinc as quickly as Fishbone striations on large diameter pipes
possible. arise from surface stresses in the steel causing
different zinc-steel reaction rates on the pipe
surface.
WHITE RUST
Zinc is a reactive metal, relying on the development of inert
complex carbonate oxide films for its excellent atmospheric
corrosion resistance.

When freshly galvanized steel is exposed to pure water (rain,

dew, condensation), the zinc will react with the water to form
zinc hydroxide, a characteristically bulky white deposit.

If the zinc surface remains wet and cannot get access to good
air circulation (the main source of carbon dioxide to form the
stable oxide films), the water will continue to react with the zinc Thin, flat sheet will always buckle in the galva-
nizing process. Corrugating or ribbing of these
and can severely damage the coating at worst and result in
type of sections will significantly reduce the
unsightly staining at best. likelihood of distortion during galvanizing.

Most galvanizers post-treat items with a chromate solution

integral with the quenching process. This provides a short-term
passivating film on the zinc surface that will prevent white rusting in the event of wet weather.

The main white rusting problems arise where galvanized work is stacked or packed in tightly nested
bundles, where water can be trapped and air circulation is poor.

Additional post-treatments that provide more durable protection from white rust over time can be
arranged in consultation with the galvanizer , usually at an additional small cost.

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 18. GALVANIZED COATING DEFECTS

Exposure to sea water will also rapidly promote white rust, and for
this reason, it is recommended that galvanized products such as
boat trailers be washed down with fresh water after each salt water
immersion.

Leaving salt water to dry on the surface will accelerate the

consumption of the galvanized coating as the chlorides will strip
the stable carbonate film from the surface.

PINHOLING
On some fabrications, particularly welded beams and heavier
sections that have been assembled using submerged arc welding
techniques, the weld areas may show evidence of a series of small Where jigs are used to support large items
in the galvanizing processes, touch marks
pinholes along the weld bead. These pinholes are generally less will occur where the galvanized coating
than 1mm in diameter. adheres to the jig at the point of cobntact.

The small size of the pinholes, combined with the thickness of

the galvanized coating on the weld metal (typically 200 microns
or more) means that they have no measurable effect on coating
performance.

The cause of this phenomenon has been attributed to small

particles of sub-arc welding slag powder being fused into the
weld surface. These refractory particles are not affected by the
pre-treatment processes and remain on the surface throughout
the galvanizing process and form small barriers to the galvanized
coating’s formation. Weld splatter left on the steel will be gal-
vanized along with the work, resulting in a
rough and pimply appearance.
PUDDLING, DROSS & SPLATTER
Puddling caused by poor drainage, dross caught in an item, and
splatter from the zinc bath ending up in or on the surface of the
galvanized item are processing issues. Some of these, such
as removal of splatter, are dealt with the inspection/QA stage.
Design issues are the main cause of puddling and can only be
eliminated by good design.

CONCLUSION
With the exception of blowouts and bleeding, and where the
galvanized coating is missing, most galvanizing defects have no
effect on the coatings’ durability. In fact, many `defects’, because
they result in thickening of the coating or deposition of much
more zinc or zinc-rich residues, coating life may be increased
significantly.
This small RHS section has severe galvanized
For example, a dull or mottled galvanized coating may be 2X or coating delamination arising from very high
phosphorous levels in the steel, creating a
3X as thick as a standard shiny coating that complies with the
thick, fragile coating almost 1000 microns in
relevant standard. The thicker gray coatings will thus have a thickness.
coating life 2X or 3X as long as the standard coating.

Where aesthetic issues are involved, hot dip galvanized coatings can only deliver a level of quality
within the limitations of the process.

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 18. GALVANIZED COATING DEFECTS

However, an understanding of the issues of design, steel composition and the hot dip galvanizing
process will go a long way to ensure that hot dip galvanized coatings on structural fabrications can be
produced to a standard that will satisfy architectural applications.

84
01 SPECIFIERS MANUAL
02 INDUSTRIAL GALVANIZERS COMPANY PROFILE
03 ADHESION OF PROTECTIVE COATINGS
04 BOLTING GALVANIZED STEEL
05 BURIED GALVANIZED STEEL
06 CONCRETE DURABILITY & GALVANIZED REBAR
07 CORROSION MAPPING
08 COST FACTORS FOR HOT DIP GALVANIZED COATINGS
09 CUSTOM COATING PACKAGES
10 CUT EDGE PROTECTION
11 DESIGNING FOR GALVANIZING
12 ILLUSTRATED GUIDE TO DESIGN FOR GALVANIZING
13 DEW POINT TABLES
14 DIFFICULT STEELS FOR GALVANIZING
15 DOCUMENTATION - CORRECT PAPERWORK ENSUES EFFICIENT PROCESSING
16 ENVIRONMENTAL ISSUES FOR INDUSTRIAL COATINGS
17 ZINC, HUMAN HEALTH AND THE ENVIRONMENT
18 DEFECTS IN GALVANIZED COATINGS
19 GALVANIC SERIES
20 GLOSSARY OF GALVANIZING TERMS
21 GUARANTEES FOR HOT DIP GALVANIZED COATINGS
22 LIFE CYCLE COSTS OF INDUSTRIAL PROTECTIVE COATING SYSTEMS
23 PAINTING OVER GALVANIZED COATINGS
24 POWDER COATING OVER GALVANIZED COATINGS
25 QUALITY AND SERVICE FACTORS AFFECTING GALVANIZED COATINGS
26 RESTORATION OF PREVIOUSLY GALVANIZED ITEMS
27 REPAIR OF GALVANIZED COATINGS
28 STEEL STRENGTH AND HOT DIP GALVANIZING
29 STANDARDS - AS/NZS 4680:2006
30 STANDARDS - AUSTRALIAN AND INTERNATIONAL STANDARDS
31 STEEL SURFACE PREPERATION
32 SURFACE PREPERATION FOR PAINTING HOT DIP GALVANIZED COATINGS
33 THICKNESS MEASUREMENT OF PROTECTIVE COATINGS
34 WELDING GALVANIZED STEEL
35 AN INTRODUCTION TO THE HOT DIP GALVANIZING PROCESS
36 ZINC COATING PROCESSES - OTHER METHODS
37 GALVANIZED COATINGS AND BUSHFIRE
38 LIQUID METAL ASSISTED CRACKING OF
GALVANIZED STRUCTURAL STEEL SECTIONS
39 GALVANIZING 500N GRADE REINFORCING BAR
40 PREDICTING THE LIFE OF GALVANIZED COATINGS
41 CHEMICALS IN CONTACT WITH GALVANIZED COATINGS.
42 ATMOSPHERIC CORROSIVITY ASSESSMENT
43 GLOBAL WARMING - CLIMATE CHANGE AND GALVANIZING
44 STEEL - ITS CORROSION CHARACTERISTICS
45 GALVANIZED STEEL AND TIMBER
46 WHITE RUST PREVENTION AND TREATMENT

2
01 - SPECIFIERS MANUAL – THIRD EDITION

Industrial Galvanizers Australian Galvanizing Division (IGAG) operates nine galvanizing plants around
Australia, ranging in size from large structural galvanizing facilities to specialised small plants designed
to process small parts.

The Australian Galvanizing Division has galvanized in excess of 2 million tonnes of steel products
in Australia since its first plant was commissioned in 1965 and is recognized for its ability to handle
complex and difficult projects, as well as routine contracts.

This experience has been collated in the Specifiers Design Manual, to assist those involved in the
design of steel products and projects to better understanding the galvanizing process and allow the
most durable and cost-effective solutions to be delivered to these products and projects. All sections of
this Third Edition have been completely updated and additional sections have been included to provide
additional technical information related to the use of hot dip galvanized steel.

In addition to its Australian Galvanizing operations, Industrial Galvanizers Corporation has a network of
manufacturing operations in Australia, as well as galvanizing and manufacturing businesses throughout
Asia and in the USA.

The company’s staff in all these locations will be pleased to assist with advice on design and
performance of hot dip galvanized coatings and products. Contact details for each of these locations
are located elsewhere in this manual.

This edition of the Industrial Galvanizers Specifiers Manual has been produced in both html and .pdf
formats for ease of access and distribution and all documents in the Manual are in .pdf format and can
be printed if paper documents are required.

The Specifiers Manual is also accessible in its entirety on the company’s web site at
www.ingal.com.au.

Additional copies of the Specifiers Manual are available on CD on request.

PUBLISHER:
Industrial Galvanizers Australian Galvanizing Division,
PO Box 503, MOOROOKA
QLD 4105
Ph: 07 38597418

EDITOR:
John Robinson,
Mount Townsend Solutions Pty Ltd
PO Box 355, JESMOND NSW 2299
Ph: 0411 886 884
Email: [email protected]

LAYOUT AND DESIGN:

Adrian Edmunds,
Nodding Dog Design
Ph: 0402 260 734
Email: [email protected]
Web: www.noddingdogdesign.com