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GALVANIZING

DESIGN GENERAL SPECIFICATION

GALVANIZING

5
4
3
2
1
0 27/05/01 ALY A.FATTAH JOHN DWYER ABDUL AZIZ AL AMERI ISSUED FOR IMPLEMENTATION
A 08/10/00 ALY A.FATTAH JOHN DWYER ABDUL AZIZ AL AMERI ISSUED FOR COMMENTS
Rev Date WRITTEN BY CHECKED BY APPROVED BY STATUS
DD/MM/YY

DOCUMENT REVISIONS
Sections changed in last revision are identified by a vertical line in the left margin

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CONTENTS

1. GENERAL ................................................................................................................................................................ 3
1.1 INTRODUCTION ...................................................................................................................................................... 3
1.2 PURPOSE .............................................................................................................................................................. 3
1.3 DEFINITIONS ......................................................................................................................................................... 3
2. CODES AND STANDARDS .................................................................................................................................... 4

3. REFERENCE DOCUMENTS ................................................................................................................................... 5

4. DOCUMENT PRECEDENCE................................................................................................................................... 5

5. SPECIFICATION DEVIATION/CONCESSION CONTROL..................................................................................... 5

6. QUALITY ASSURANCE/QUALITY CONTROL ...................................................................................................... 6

7. DOCUMENTATION.................................................................................................................................................. 6

8. SUBCONTRACTORS/SUBVENDORS ................................................................................................................... 6

9. HANDLING............................................................................................................................................................... 6
9.1 PACKAGING AND SHIPPING ..................................................................................................................................... 6
9.2 PRESERVATION AND STORAGE ...............................................................................................................................7
10. EXECUTION........................................................................................................................................................... 7
10.1 GENERAL REQUIREMENT ...................................................................................................................................... 7
11. SURFACE PREPARATION ................................................................................................................................... 7

12. GALVANIZING APPLICATION - HOT DIP ........................................................................................................... 7

13. REPAIR OF DAMAGED ZINC COATINGS........................................................................................................... 8

14. INSPECTION.......................................................................................................................................................... 9
TABLE 1.............................................................................................................................................................. 10
15. HANDLING........................................................................................................................................................... 10
TABLE 2.............................................................................................................................................................. 11

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1. GENERAL

1.1 Introduction
This specification gives minimum requirements for piping materials to be Hot-Dip galvanized.

1.2 Purpose
Generally these requirements are common for all galvanized items to be used in the construction.

1.3 Definitions

1.3.1 COMPANY - ABU DHABI GAS INDUSTRIES LTD. (GASCO)

1.3.2 CONCESSION REQUEST

A deviation requested by the CONTRACTOR, usually after receiving the contract package or
purchase order. Often, it refers to an authorization to use, repair, recondition, reclaim, or release
materials, components or equipment already in progress or completely manufactured but which
does not meet or comply with COMPANY requirements. A CONCESSION REQUEST is subject to
COMPANY approval.

1.3.3 CONTRACTOR
The party which carries out all or part of the Design , Engineering , Procurement, Construction and
Commissioning or Management of the Project.

1.3.4 MANUFACTURER
The service organization which actually manufactures the material/product in question.

1.3.5 PROJECT MANAGEMENT TEAM (PMT)

The COMPANY authorized party responsible for the overall day-to-day execution of the Project.
PMT is to serve as a Liaison between COMPANY and the CONTRACTOR(S) on the Project.

1.3.6 SHALL
Indicates a mandatory requirement.

1.3.7 SHOULD
Indicates a strong recommendation.

1.3.8 SUBCONTRACTOR
An organization providing specific services to the CONTRACTOR.

1.3.9 SUPPLIER
The organization which supplies the material/product to the CONTRACTOR/SUBCONTRACTOR.

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2. CODES AND STANDARDS

The following codes and standards, to the extent specified herein, form a part of this specification.
When an edition date is not indicated for a code or standard, the latest edition in force at the time
of contract award shall apply.
Alternate standards and codes meeting the requirements of the referenced standards and codes
may be used with the approval of the COMPANY.
AMERICAN SOCIETY FOR TESTING AND MATERIALS (ASTM)

A36 Specification for Structural Steel

A53 Specification for Pipe, Steel, Black And Hot-Dipped, Zinc Coated, Welded
And Seamless.
A90 Test Method For Weight (Mass) Of Coating On Iron And Steel Articles With
Zinc Or Zinc-Alloy Coatings
A121 Zinc-Coated (Galvanized) Steel Barbed Wire
A123 Specification For Zinc (Hot-Dip Galvanized) Coatings On Iron And Steel
Products
A143 Practice For Safeguarding Against Embrittlement Of Hot-Dip Galvanized
Structural Steel Products And Procedure For Detecting Embrittlement
A153 Specification For Zinc Coating (Hot-Dip) On Iron And Steel Hardware
A361 Specification for Steel Sheet, Zinc Coated (Galvanized) By The Hot-Dip
Process For Roofing And Siding.
A384 Practice For Safeguarding Against Warpage And Distortion During Hot-Dip
Galvanizing Of Steel Assemblies
A385 Practice For Providing High Quality Zinc Coating (Hot Dip)
A392 Specification For Zinc-Coated Steel Chain-Link Fence Fabric
A446 Specification For Sheet Steel, Zinc-Coated (Galvanized) By The Hot-Dip
Process, Structural (Physical) Quality
A525 Specification For General Requirements For Steel Sheet, Zinc-Coated
(Galvanized) By The Hot-Dip Process
A741 Zinc-Coated Steel Wire Rope And Fittings For Highway Guardrail.
B6 Specification For Zinc (Slab Zinc)
B695 Specification For Coatings Of Zinc Mechanically Deposited On Iron And
Steel
E376 Practice For Measuring Coating Thickness By Magnetic-Field Or Eddy-
Current (Electromagnetic) Test Methods
F1083 Specification for Pipe, Steel, Hot-Dipped Zinc Coated (Galvanized) Welded,
For Fence Structures.

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BRITISH STANDARD (BS)

729 Specification for Hot Dip Galvanized Coatings on Iron & Steel Articles
STEEL STRUCTURES PAINTING COUNCIL (SSPC)
SP 1 Solvent cleaning
SP 8 Pickling
SP10 Near-white Blast Cleaning
SP 11 Power tool cleaning to bare metal
Vis-1 Color Photographic Standard for Surface Preparation
OCCUPATIONAL SAFETY AND HEALTH ADMINISTRATION (OSHA)
Code of Federal Regulations, Title 29.

3. REFERENCE DOCUMENTS
The following reference documents, to the extent specified herein, form a part of this specification.
When an edition date is not indicated for a document, the latest edition in force at the time of
SUPPLIER’S contract award shall apply.
PROJECT SPECIFICATIONS
DGS-6600-010 Specification for Painting
DGS-6710-001 Preservation and Export Packing Specification

4. DOCUMENT PRECEDENCE
It shall be the SUPPLIER’S responsibility to be, or to become, knowledgeable of the requirements
of the referenced codes and standards.
The SUPPLIER shall notify the CONTRACTOR of any apparent conflict between this specification,
the related data sheets, the codes and standards, and any other specification noted herein.
Resolution and/or interpretation precedence shall be obtained from the CONTRACTOR in writing
before proceeding with the design/manufacture.
In case of conflict, the order of precedence shall be:
♦ National and/or Local Regulation
♦ Purchase Order or Contract
♦ Design Drawings
♦ Project Specifications and Standards
♦ Industry codes and standards

5 SPECIFICATION DEVIATION/CONCESSION CONTROL

Any technical deviation to the purchase order/contract and its attachment including, but not limited
to, the specifications shall be sought by the SUPPLIER only through the CONCESSION REQUEST
format. CONCESSION REQUESTS require the CONTRACTOR’S and the COMPANY’S review
and approval, prior to the proposed technical changes being implemented. Technical changes
implemented prior to COMPANY approval are subject to rejection.

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6 QUALITY ASSURANCE/QUALITY CONTROL
To ensure that all detailed design/engineering is being performed consistently and accurately, the
SUPPLIER shall have in effect at all times, a QA/QC program which clearly establishes the
authority and responsibility of those responsible for the quality system. Persons performing quality
functions shall have sufficient and well defined authority to enforce quality requirements that
initiate, identify, recommend and provide solutions to quality problems and verify the effectiveness
of the corrective action.
A copy of the SUPPLIER’S QA/QC program shall be submitted to the CONTRACTOR with its
quotation for CONTRACTOR’S review and concurrence prior to award. If SUPPLIER’S QA/QC
program and facility, where the work is to be performed, is ISO 9000 certified, then only a copy of
the SUPPLIER’S ISO 9000 certificate is required. In addition, if SUPPLIER’S facility is ISO
certified, CONTRACTOR’S QA audit requirements will be waived in favor of ISO 9000 registrar
audits, unless the CONTRACTOR’S trend analysis program indicates areas of concern.
The SUPPLIER shall identify in purchase documents to its SUBVENDORS all applicable QA/QC
requirements imposed by the CONTRACTOR, and shall ensure compliance thereto. On request,
SUPPLIER shall provide objective evidence of its QA/QC surveillance of its SUBVENDOR’S
activities.
The SUPPLIER shall submit certified reports of production tests as soon as the tests are
completed satisfactorily.
The COMPANY/CONTRACTOR reserves the right to inspect materials and workmanship at all
stages of manufacture and to witness any or all tests. The SUPPLIER, 30 days after award but
prior to the pre-inspection meeting, shall provide the CONTRACTOR with a copy of its
Manufacturing and Inspection Plan for review and inclusion of any mandatory
COMPANY/CONTRACTOR witness points.

7. DOCUMENTATION
The SUPPLIER shall submit an “Affidavit of Compliance” before beginning work. The affidavit shall
confirm that all material meets the requirements of this Specification.

8. SUBCONTRACTORS/SUBVENDORS
The SUPPLIER shall assume unit responsibility and overall guarantee for the galvanizing work.
It is the SUPPLIER’s responsibility to enforce all Purchase Order and Project Specification
requirements on its SUBCONTRACTORS.
The SUPPLIER shall submit all relevant SUBCONTRACTOR drawings and engineering data to the
CONTRACTOR.
The SUPPLIER shall obtain and transmit all SUBCONTRACTOR warranties to the
CONTRACTOR, in addition to the system warranty.
9. HANDLING

9.1 Packaging and shipping

Preparation for shipment shall be in accordance with the SUPPLIER’S standards and as noted
herein. SUPPLIER shall be solely responsible for the adequacy of the preparation for shipment
provisions with respect to materials and application, and to provide equipment at the destination in
ex-works condition when handled by commercial carriers.
Adequate protection shall be provided to prevent mechanical damage and atmospheric corrosion
in transit and at the jobsite.

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Preparation for shipment and packing will be subject to inspection and rejection by the
COMPANY’S/CONTRACTOR’S inspectors. All costs occasioned by such rejection shall be to the
account of the SUPPLIER.
After inspection and test, equipment shall be completely free of water and dry before start of
preparation for shipment.
Equipment shall be packed, securely anchored, and skid mounted when required. Bracing,
supports, and rigging connections shall be provided to prevent damage during transit, lifting, or
unloading. All temporary bracing/supports shall be marked, "REMOVE BEFORE EQUIPMENT
COMMISSIONING AND STARTUP."
Flanged openings shall be protected with wood or plastic coverplates to prevent damage during
shipment. Covers shall not be smaller than the flange outside diameter, using a minimum of 4 full
diameter bolts. Large diameter flanges will require enough full diameter bolts to seat the cover all
around. The cover and flange shall be taped for waterproof protection.
Open ends of tubes and pipe shall be protected with plastic caps.
Separate, loose, and spare parts shall be completely boxed. Pieces of equipment and spare parts
shall be identified by item number and service and marked with CONTRACTOR’S order number,
tag number, and weight, both inside and outside of each individual package or container. A bill of
material shall be enclosed in each package or container of parts.
Exposed finished and machined surfaces, including bolting, shall be given a coating of rust
inhibiting compound. Internal metal surfaces shall be sprayed or coated with a suitable rust
preventative prior to shipment. Openings shall be suitably tagged to indicate the rust preventative
applied.
Mechanical seal assemblies shall be fully protected from rusting and entry of moisture and dirt.

9.2 Preservation and storage

Equipment and materials shall be protected to withstand ocean transit and extended period of
storage at the jobsite for a minimum period of 18 months. Equipment shall be protected to
safeguard against all adverse environments, such as: humidity, moisture, rain, dust, dirt, sand,
mud, salt air, salt spray, and seawater.
All equipment and material shall be preserved and export packed in accordance with Project
Preservation and Export Specification.
10. EXECUTION

10.1 General requirement

All steel members, fabrications and assemblies to be galvanized shall be hot-dipped, unless
specifically noted otherwise, prior to shipment to the field in accordance with the requirements of
this specification. Mechanical galvanizing, if so noted, shall be in accordance with ASTM B695.
11 SURFACE PREPARATION

11.1 All steel surfaces shall be cleaned to remove oil, grease, mill scale, weld slag, and fabrication
markings prior to galvanizing. The method of surface preparation shall be as indicated in Table 1
including solvent cleaning, blast cleaning and acid pickling as minimum requirements in accordance
with SSPC-SP1, SSPC-SP10 and SSPC-SP8 respectively.

11.2 Pickled steel shall be stood on edge and not laid flat or stacked with surfaces in contact until
completely dry.
12 GALVANIZING APPLICATION - HOT DIP

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12.1 Hot dip galvanized steel members, fabrications and assemblies, as required by the Purchase Order
shall be galvanized in accordance with ASTM A123, A153 or applicable ASTM noted in Section 2.

12.2 Each component shall be completely submerged in the molten zinc. If multi-dipping is necessary for
complete coverage a procedure which gives the minimum amount of warping shall be used.

12.3 Each component shall be brushed or wiped after dipping to remove flux, icicles, dross, needle
points, sharp edges or any other irregularity in the zinc coating.

12.4 Any piece bent or distorted during galvanizing shall be restored to the specified shape prior to
delivery. The precautions specified in ASTM A384 shall be followed to minimize warpage and
distortion.

12.5 If any weld repairs are required after galvanizing, the area to be repaired shall be ground free of any
zinc prior to welding. Grind clean a minimum of two inches on either side of the weld.

12.6 Zinc for galvanizing shall conform to ASTM B6 and shall be at least equal to the grade designated
“Prime Western” (Z19001), with a maximum aluminum content of 0.01%. The composition of metal
in the galvanizing bath shall not be less that 98.0% zinc.

12.7 It shall be the SUPPLIER’s responsibility to safeguard against steel embrittlement in accordance
with ASTM A143.

12.8 It shall be the SUPPLIER’s responsibility to safeguard against warpage or distortion of steel
members in accordance with ASTM A384.

12.9 Defects in the substrate such as cracks, laminations, laps, and folds shall be removed prior to
galvanizing.

12.10 Items shall be galvanized after completion of all cutting, drilling, punching, riveting and welding
operations.

12.11 Items shall be galvanized before assembling by bolting. Components of bolted assemblies shall be
dipped separately with bolts removed.

12.12 Rough spots and burrs shall be removed by grinding prior to galvanizing.

12.13 Finish, uniformity and adherance of zinc coating shall conform to ASTM A123, ASTM A153 or other
applicable ASTM noted in Section 2.

12.14 Cold working of carbon steel items to be galvanized shall not be permitted unless the items are heat
treated in accordance with the recommendation of ASTM A143, paragraph 5, or tested for
embrittlement in accordance with ASTM A143, paragraph 8.

12.15 After immersion in the molten zinc, the items shall not be subjected to any process of scraping or
wiping which may reduce the uniformity or the specified weight of the zinc coating.

12.16 The zinc coating shall be free of voids, blisters, flux spots, inclusions, dross, acid or black spots.
The coating shall be adherent so it will not be removed by any reasonable process of handling or
erection. Lumps, globules, or heavy deposits of zinc, which could interfere with the intended use of
the galvanized item, shall not be permitted.

12.17 Weight of zinc coatings shall conform to the requirements of Table 2 of this specification and those
specified under “Weight of Coatings” in ASTM A123, A153 or other applicable ASTM noted in
Section 2.

13 REPAIR OF DAMAGED ZINC COATINGS

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13.1 Repair of damaged zinc coating using organic or inorganic coating shall be done only with
company’s written approval. This shall be restricted to as minimum as possible such as tie-in joints.
Wherever the material containing damaged galvanized coating can be removed, it shall be sent to
local contractor for hot dip galvanizing.

13.1.1 All oil, dirt, and foreign matter shall be removed by solvent or detergent cleaning, according to
SSPC-SP 1.

13.1.2 Areas of spot rust, burn residue, weld spatter, and other solid adherent foreign matter shall be blast
cleaned in accordance with SSPC-SP 10. In the event blast cleaning is not practical mechanical
cleaning in accordance with SSPC-SP 11 using non-woven abrasive discs (3M Company) may be
used with the CONTRACTOR’S approval. Welded joints of galvanized items shall be cleaned with a
non-woven abrasive cup wheel prior to feathering with a non-woven abrasive disc.

13.1.3 Cleaned and prepared surfaces shall be primed with the following materials in accordance with the
MANUFACTURER’s instructions, recommendations, and guidelines.

13.1.4 When the operating temperature is 93°C and below, organic zinc primer, having a minimum of 80
percent zinc by weight, shall be applied to a dry film thickness of 75 microns..

13.1.5 Metallizing with zinc is an acceptable alternative to the above coating repair procedures.

13.1.6 Galvanized surfaces shall be painted in accordance with Specification for Painting, DGS-6600-010.

14 INSPECTION

14.1 The adherence of the zinc coating to the surface of the base metal shall be determined by cutting or
prying with the point of a stout knife, applied with considerable pressure in a manner tending to remove
a portion of the coating. The adherence shall be considered inadequate if the coating flakes off in the
form of a layer or skin so as to expose the base metal in advance of the knife point. Testing carried
out at edges or corners (points of lowest coating adherence) shall not be used to determine adherence
of coating. Likewise, removal of small particles of the coating by paring or whittling shall not be used
to determine failure.

14.2 The distribution of the zinc coating shall be determined by visual inspection. Except for local excess
coating thickness which would interfere with the use of the product, or make it inconvenient or
dangerous to handle (edge tears or spikes), rejection for poor distribution shall be made only for plainly
visible excess coating not related to design factors such as holes, joints or special drainage problems.
If, in the opinion of the CONTRACTOR, visual examination is not conclusive, the distribution of zinc
shall be determined by using a magnetic thickness gauge after a sufficient number of readings, not
less than five and preferably ten, are taken at each end and in the middle of the piece being examined.

14.3 The average weight of the coating, given as grams per square meter, shall be determined by
multiplying the coating thickness (microns) by 6.9. The thickness is found by using a magnetic
thickness gauge. Where thickness measurement is not feasible, the coating weight shall be
determined as noted in the referenced ASTM standards for galvanizing.

14.4 The following, Table 1, Inspection Checklist for Galvanizing, is provided to assist with the complete
inspection of items that will be galvanized. The information contained lists the minimum requirements
to be completed before the item is to be galvanized, during the period it is being galvanized and after
the galvanizing has been completed.

14.5 Table 1 does not apply to standard piping components supplied from stock.

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TABLE 1
INSPECTION CHECKLIST FOR GALVANIZING

NO. ITEMS METHODS EXTENT (Frequency) CRITERIA

I. STEEL PRODUCTS
1. Appearance Visual All Surfaces No defects
2. Welds Visual All Welds Continuous/Smooth
3. Rough spots & Burrs Visual All sharp edges Round
4. Drainage Visual All Sections By Drawing
II. SURFACE
PREPARATION
1. Oil, Grease, & Dust Visual All Surfaces Non-Existent
2. Mill Scale
a. Blast cleaning Visual w/SSPC Vis 1 All Surfaces CONTRACTOR
approved procedure
b. Pickling Visual CONTRACTOR approved CONTRACTOR
frequency approved procedure
3. Pickling Bath
Condition
a. Temperature Thermometer CONTRACTOR approved CONTRACTOR
frequency approved procedure
b. Content Visual/Measurement CONTRACTOR approved CONTRACTOR
frequency approved procedure
III. GALVANIZING
1. Zinc Verify Certification All ASTM B6
2. Bath Condition
a. Temperature Thermometer CONTRACTOR approved CONTRACTOR
frequency approved procedure
b. Zinc Content Measurement CONTRACTOR approved Minimum of 98.0%
frequency
3. Dipping Time Measurement CONTRACTOR approved CONTRACTOR
(Clock or watch) frequency approved procedure
4. Appearance Visual All pieces CONTRACTOR
including uncoated (Sample comparison) approved procedure
areas, blisters, flux
deposits, acid &
black spots, dross
inclusion, lumps, and
other surface defects
5. Weight/Thickness of a. Magnetic thickness CONTRACTOR approved CONTRACTOR
Zinc Coating measurements, frequency approved procedure
b. Stripping method,
c. Weighing before
and after galvanizing
6. Adhesion a. Stout knife test Minimum of one test per No peeling of flaking
(ASTM A90 & A153) day for at least one item. allowed.
Minimum of one test per According to ASTM
b. Hammer test
day for at least one item. 153.
(ASTM A153)

15. HANDLING

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Protective slings shall be used for off-loading and erection of galvanized members. Extreme care shall
be taken to minimize damage to the zinc coating during loading, shipping & handling, and unloading of
all galvanized items.

TABLE 2
COATING REQUIREMENTS FOR GALVANIZING

GALV. Min. weight of zinc

Item to be galvanized
grams/m2
STD

Average of Any individual

specimens specimen
tested

Pipe Pipe A123 518.8 518.8

Class A: Castings-Malleable iron, steel A153 610.3 549.4

Hardware Class B: Rolled, pressed and forged articles A153

(except those articles included in Classes C and
D)
B1 - Thickness => 4.7 mm (3/16") & length > 610.3 549.4
381 mm (15")
B2 - Thickness < 4.7 mm (3/16") & length > 457.8 381.5
381 mm (15")
B3 - Any thickness & length <= 381 mm (15") 396.8 335.7

Class C: Fasteners over 9.5 mm (3/8") in A153 381.5 305.2

diameter and similar articles, washers
4.7 mm (3/16") & 6.3 mm (1/4") thick
Class D: Fasteners 9.5 mm (3/8") and A153 305.2 259.4
smaller in diameter, rivets, nails and similar
articles, washers under 4.7 mm (3/16") thick
Bolts High-strength bolts, A325 and Common bolts A153 381.5 305.2
A307

Note : 100 grams/m2 = 14.3 microns of coating thickness

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