This document outlines the hot dip galvanizing process used by Al Jazira Metal Industries Co. LLC. The process involves 8 key steps: 1) Receiving materials and inspecting for quality, 2) Blasting and degreasing materials, 3) Preparing materials for galvanizing, 4) Pickling materials in acid, 5) Rinsing materials, 6) Fluxing materials, 7) Heating zinc to 450°C and dipping materials, 8) Maintaining quality control through inspections and laboratory testing. The goal is to coat materials in zinc to a thickness of 610 gm/Sq.meter according to applicable standards.
This document outlines the hot dip galvanizing process used by Al Jazira Metal Industries Co. LLC. The process involves 8 key steps: 1) Receiving materials and inspecting for quality, 2) Blasting and degreasing materials, 3) Preparing materials for galvanizing, 4) Pickling materials in acid, 5) Rinsing materials, 6) Fluxing materials, 7) Heating zinc to 450°C and dipping materials, 8) Maintaining quality control through inspections and laboratory testing. The goal is to coat materials in zinc to a thickness of 610 gm/Sq.meter according to applicable standards.
This document outlines the hot dip galvanizing process used by Al Jazira Metal Industries Co. LLC. The process involves 8 key steps: 1) Receiving materials and inspecting for quality, 2) Blasting and degreasing materials, 3) Preparing materials for galvanizing, 4) Pickling materials in acid, 5) Rinsing materials, 6) Fluxing materials, 7) Heating zinc to 450°C and dipping materials, 8) Maintaining quality control through inspections and laboratory testing. The goal is to coat materials in zinc to a thickness of 610 gm/Sq.meter according to applicable standards.
This document outlines the hot dip galvanizing process used by Al Jazira Metal Industries Co. LLC. The process involves 8 key steps: 1) Receiving materials and inspecting for quality, 2) Blasting and degreasing materials, 3) Preparing materials for galvanizing, 4) Pickling materials in acid, 5) Rinsing materials, 6) Fluxing materials, 7) Heating zinc to 450°C and dipping materials, 8) Maintaining quality control through inspections and laboratory testing. The goal is to coat materials in zinc to a thickness of 610 gm/Sq.meter according to applicable standards.
1. Customers requesting formal quality planning documentation such as Inspection and Test plans etc are provided with the standard Al Jazira Metal Industries Co. LLC. Quality plan for evaluation.
2. Comments, if any, are scrutinized by the G.M. for acceptability and the amended Quality Plan is submitted to the Customer as a revised version for approval. a. Reference: British Standard BS EN ISO 1461:2009 ASTM A 123/A 123M-02 ASTM A153/A 153M-01a
II. RECEIVING MATERIAL
3. Articles received for galvanizing are checked by the Supervisor/Assistant against the customer’s specification and delivery documentation for:
a. Correct quantity. b. Articles are checked for loading, condition and damage. c. Articles dimensions and shape are evaluated as suitable for the bath. d. Venting arrangements are checked for adequacy. e. Article’s vulnerability to distortion at galvanizing temperature is evaluated.
4. The delivery documentation is signed as a receipt for the articles received and inspected. Shortages are immediately notified to the customer.
5. Any unsatisfactory requirements identified are referred to the G.M. for resolution with the customer.
6. A Job Card is raised detailing the customer’s requirements and is reviewed by the G.M. to ensure that the Supervisor/Assistant has full information relating to:
a. Required coating thickness
b. Delivery schedule. c. Finish-normal or special smooth finish for painting & powder coating
7. Items are identified by the Al Jazira Metal Industries Job Card number while in care of Al Jazira Metal Industries.
AL JAZIRA METAL INDUSTRIES CO. Page 1 of 5
GALVANIZING Doc. No.: QF/MS-02/G Date : 16.09.2012 Rev: 00 PROCEDURE III. BLASTING & DEGREASING
8. The Supervisor determines the appropriate blasting method. Either Automatic, Manual or a combination depending upon the size, type, shape and condition of the article. For Automatic Shot Blasting, steel shot of size S330 or a mixture of S280 & S330 is used, whilst for Manual Blasting Garnet of size 30-60 is the media.
9. If the steel surface contains heavy oil or grease, it is immersed in the acidic degreasing tank. After acidic degreasing is carried out, water rinsing activity shall be carried out the effectiveness of the degreasing process is monitored in-house on a daily basis to maintain efficient process control. Samples from the bath are also monthly dispatched to an independent lab.
10. Articles are blasted to ensure that the surface is entirely free of rust and other visible contaminants. Blasted to a surface finish of SA 2 ½. Surface profile shall be between 40-80 microns.
11. Blasted articles are inspected by the Supervisor/Shift Foreman using the standard Surface Finish Chart.
12. The results of the post blasting/degreasing inspection are recorded in the Production Log.
13. Any incomplete blasted areas are assessed to determine whether the contaminant can be removed during the pickling process.
14. Articles failing inspection are rejected and returned for additional blasting and the rework is recorded on the Production Log.
IV. PREPARATION
15. The Supervisor/Foreman decides on the article suspension method, either tying or placing them in Standard Jigs taking into account the following requirements: a. Article shape, size & weight. b. Position of venting & drainage holes (if applicable). c. Availability of wiring points.
16. Vent holes if so required are drilled with consent from the customer.
17. The batched articles are spaced along the frame to ensure no permanent contact.
18. The Galvanizer’s attach the articles to the frame and check the wire twist for security.
19. The frames are attached to gantry lifts and the wired articles are checked for uniform distribution and suspension and correctness of venting and drainage.
20. The Supervisor/Foreman completes the columns on the Production Log for venting, jigging & drainage inspection.
V. PICKLING
21. Blasted/Degreased articles are immersed for approximately two minutes in the pickling solution
AL JAZIRA METAL INDUSTRIES CO. Page 2 of 5
GALVANIZING Doc. No.: QF/MS-02/G Date : 16.09.2012
PROCEDURE Rev: 00
Comprising of commercial grade HCL acid (32%) diluted to approximately 15% strength.
22. All non blasted articles shall be blasted after pickling. Non blasted/Non degreased articles are dipped for a minimum duration of 5 minutes, and are re-dipped until clean indicated by uniform coloring.
23. The Shift Foreman visually inspects articles for cleanliness after pickling as follows:
Material Inspection Criteria Result
Mild Steel Uniform bluish/grey color with no brown stain. PASS Cast Iron Uniformly clean appearance PASS
24. On rejection, articles are repeatedly pickled until the above conditions are achieved.
25. The results of the post pickling inspection are recorded in the Production Log.
26. Revitalizing of the HCL acid bath is carried out when required by adding a solution of HCL and water to the bath until the required concentration is achieved. The effectiveness of the pickling process is monitored in-house on a daily basis to maintain efficient process control.
27. Samples from the bath are analyzed monthly by an independent laboratory to evaluate the specific gravity and present strength of the acid the results are recorded in the calibration record.
VI. RINSING
28. Pickled articles are dipped into the rinsing baths and suspended over the second bath until water no longer pours off.
29. The effectiveness of the rinsing process is monitored in-house on a daily basis to maintain efficient process control. Samples are also monthly dispatched to an independent laboratory for determining pH value and results recorded in the calibration record.
VII. FLUXING
30. Rinsed articles are immersed in the flux bath ( Zinc Ammonium Chloride + Water ) or a minimum of two minutes, withdrawn and suspended above the bath until flux no longer runs off.( This process dissolves oxides on both the steel and Zinc surfaces to enable steel and zinc to make pure metallic contact with each other ).
31. The ZAC concentration is measured when deciding how much flux or water is needed to restore the flux to the required concentration in the bath.
32. The effectiveness of the fluxing process is monitored in-house on a daily basis to maintain efficient process control. Samples from the baths are also monthly dispatched to an independent lab and results recorded in the calibration record.
AL JAZIRA METAL INDUSTRIES CO. Page 3 of 5
GALVANIZING Doc. No.: QF/MS-02/G Date : 16.09.2012
PROCEDURE Rev: 00
VIII. ZINC BATH DIP
33. An average molten zinc temperature of 450 ○C is maintained. The purity of Zinc bath is 98.5%. (Pure Zinc 99.99%) The material shall be galvanized at 610 gm/Sq.meter, as per BS EN 1461 & applicable standards.
34. Articles are suspended above the zinc bath to assist flux drying and preheating.
35. The surface of the molten zinc is skimmed to remove oxides and flux residues immediately prior to immersing the articles.
36. Suspended articles are slowly dipped at an inclined position until fully immersed.
37. Depending on the type and thickness of the section, the article remains immersed until violent reactions have ceased.
38. The articles are swung and agitated to assist wetting.
39. The zinc surface is skimmed, the articles are slowly withdrawn inclined to allow free drainage of excess zinc and avoid lumps. Unsolidified excess zinc is removed by scrapers.
40. The purity of the zinc in the bath is monthly checked by an independent laboratory and results recorded in the calibration record.
41. The results of the visual inspection of galvanizing surface are recorded in the Production Log.
IX. COOLING
42. The article’s suitability for quenching is assessed by the Supervisor or Foreman.
43. Articles which may suffer distortion during quenching are cooled naturally by lowering onto the concrete floor (Welded sections, articles with low thickness & longer sections are prone to distortion when quenched in water).
44. Articles which will not suffer distortion are quenched in water by gradually immersing into the quenching bath in a manner which will enable the steam to escape safely.
45. Cooled and quenched articles are moved to the cleaning inspection operation.
46. The effectiveness of the quenching process is monitored in-house on a daily basis to maintain efficient process control. Samples from the quenching tank are monthly sent to an independent lab and results are recorded in the calibration record.
AL JAZIRA METAL INDUSTRIES CO. Page 4 of 5
GALVANIZING Doc. No.: QF/MS-02/G Date : 16.09.2012
PROCEDURE Rev: 00
X. CLEANING AND FINAL INSPECTION
47. Removal of excess lumps by grinding to ensure smooth finish and continuous final coat.
48. Wiring markings are cleaned and touched up with zinc rich paint.
49. The articles are inspected to ensure freedom from gross Imperfections.
50. Faults are reported to the Quality Inspector who investigates and determines whether to reject the article.
51. Articles, which are rejected and reworked, are inspected.
52. Coating thickness is measured with a calibrated Elcometer and recorded on the Article Inspection Record. This final inspection record is treated as the release note for dispatch.
53. Adhesion check-usually it is considered that adhesion is satisfactory if the coating can withstand normal use and handling. Normal handling does not include bending, curving and working. When required adhesion is carried out with the help of a pivoted hammer.
54. Coating certificates are provided if requested.
Visual Inspection : 100%
Coating Thickness Checking : 100% Coating Thickness Recording : In batches of 5 readings each.
