Reference: FASGC-SOP-01

SOP FOR GALVANIZING PROCESS Rev: 01

Dated: 27/9/2022

1. Scope:
This document deals with the galvanizing procedure of the hot-dip galvanizing of iron and steel. It includes the
detailed process description and inspection in FASGC hot dip galvanizing plant.
2- Definitions
o ASTM: American Society for Testing Materials
o QA/QC: Quality Assurance / Quality Control
o HCl: Hydrochloric Acid
3- References
Following are the reference standards and specifications applicable to our process procedure.
 ASTM A-123: Specification for Zinc (Hot-Dip Galvanized) coatings on iron and steel products.
 12-SAMSS-007: Saudi Aramco Materials System Specification
 Engineering Specification G16S-0205-03 : The Dow Chemical Company Painting Global
 Engineering Specification G16S-0205-01: Repair of Hot-Dipped Galvanized Surfaces (two coats)
 ASTM A-143: Safeguarding against Embrittlement of hot-dip galvanized structural steel products and
procedure for detecting Embrittlement.
 ASTM A-153: Standard specification for Hot Dip Galvanized zinc coating on Iron and steel hardware.
 ASTM A-384: Standard practice for safeguarding against warpage & distortion during hot dip galvanizing of
steel assemblies.
 ASTM A-385: Standard practice for providing high-quality hot dipped galvanized coatings.
 ASTM A-780: Standard Practice for repair of damaged and uncoated areas of hot dip galvanized coatings.
 ASTM A-90: Standard Test Method for weight (Mass) of coating on Iron and Steel articles with zinc or zinc
alloy coatings.
 ASTM A239: Standard Practice for locating the thinnest spot in a zinc galvanized coating on iron or steel
articles.
 ASTM E-376: Standard Practice for safeguarding for measuring coating thickness by magnetic field or Eddy
(Electromagnetic) Test methods.
 American Galvanizers Association(AGA) (Hot Dip Galvanization Steel items inspection Course for QC
Inspectors)
4. Responsibilities
4.1. Production Department:
Supervision of the whole galvanizing process. Primarily responsible for production, planning and scheduling. Production
supervisor shall ensure that all workers involved in the production are fully aware of the galvanizing techniques.
Production foreman will prepare Daily Production Plan (FASGC-QMS-F-14, Rev-0) while Production Supervisor will prepare
and record Daily Production Report (FASGC-QMS-F-17 Rev-0).
4.2. Quality Control Department:
QA/QC department will;
 Ensure all process solutions are within the process control parameters and the process control measures are
implemented.
 Carry out examination and tests as per documented procedures and standards, required for receiving, in-process
and final inspection prior to release and dispatch.
 Verify the product has passed the previous inspection checkpoint before proceeding with the work.
 In case of any Non-Conformance, QA/QC and Operations manager will be responsible to take appropriate action to
close the issue.

5. GALVANIZING PROCESS STEPS:

5.1 Incoming Material
When customer’s material is received, shipping department will check it for the weight and physical quantity. It will
also be checked whether the material complies with the customer delivery note or not.

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 Reference: FASGC-SOP-01
SOP FOR GALVANIZING PROCESS Rev: 01
Dated: 27/9/2022

Following must be checked in addition by Black Material QC inspector;

5.1.1 Material has no paint markings, lacquer, welding slag, excessive grease or oil and other contaminants. Also,
check if abrasive blasting is required. Such comments must be written on receiving documents. IF customer
has any special coating requirements, that must also be mentioned.
5.1.2 Proper vents, drainage and hanging holes per standards A- 385 for free flow of chemicals & zinc, handling,
and safety aspects are provided.
5.1.3 Customer Job identification tags/ hard punch is on the material surface is available.
5.1.4 Material damage/ distorted during Transportation.
5.1.5. Result of the above inspection must be recorded in Black Material inspection Form. (FASGC-QMS-
F08, Rev-0). In case of any problem in the material, concerned Sales officer will be informed to contact the
customer to resolve the issue. Summary of Daily Black Material inspection will be sent to all the concerned using
document Daily Black Material Inspection Status (FASGC-QMS-F-11, Rev-0).
5.1.6 Proper unloading arrangements of material at designated area will be done.
5.1.7 In case of any discrepancies, QC Inspector will issue a nonconforming Report for corrective actions.
5.2 Production Schedule & Job Travel Card:
5.2.1- A white material receiving sticker should be tied into the black material upon verification of correctness
of receiving document. The production foreman will prepare the Daily Production Plan (FASGC-QMS-F-14,
Rev-0).
5.2.3. The production department should check holes for tying purpose or venting/draining during the actual
galvanizing process. Standard practice for making holes for venting and draining purpose should be as per
applicable standard ASTM A-384. It should also be ensured that wires and chains are placed between
surfaces in order that acid penetration would be very effective. Upon completion of the material
preparation process, the preparation leadman shall fill-up the Job Travel Card (FASGC-QMS-F-09, Rev-0) and
bring the material inside the production building for further processing.
5.2.4 Inspector (Process) will fill up the Job Travel Card (FASGC-QMS-F-09, Rev-0).This card is applicable to each
jig prepared and dipped in a day.
5.2.5 Lead man of each area (Preparation, Dipping, and Finishing) will conform and control the quantity of
material in every jig and note it down on Quantity Monitoring Card (FASGC-QMS-F-16-Rev, 0).

5.3 Inspection of Process Baths and Galvanizing Kettle

5.3.1 Assigned in-process inspector must check process chemical baths parameters, daily updated by Lab Chemist
on sign boards fixed in front of each process Baths before the production shift starts and verify to the
production supervisor that the process parameters are up to the required standard limits. In case there
are any discrepancies, in-process inspector will inform his Supervisor / Lab chemist about the observed
discrepancies prior to proceeding with surface preparation. The parameters are also recorded on
Chemicals Parameter Record (FASGC-QMS-F-10, Rev-0). The detailed analysis of bath tanks will be done by
the chemist at least three times a week.
5.4 Material Racking & Loading Arrangements.
5.4.1 MS wires, chains and hooks will be used to hang/hook the material to be galvanized.
5.4.2 In-process QC inspector will ensure the following before moving the material for surface
preparation/chemical treatment.
5.4.2.1. Wire, Chains, Hooks are strong enough to hold the loaded material on Jigs.
5.4.2.2. Loaded material are not touching each other and there is No Overlap.
5.4.2.3. Ventilation holes are in correct position & are prepared especially for the products are
fabricated with pipes & tubes like handrails etc.
5.4.2.4. Sample for Mechanical Test such as tensile test, Embrittlement & Peerce test (Coating uniformity) if
required, shall be processed with the primary material.
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 Reference: FASGC-SOP-01
SOP FOR GALVANIZING PROCESS Rev: 01
Dated: 27/9/2022

5.5. Degreasing
Purpose: Removal of grease/oils from material surface delivered to be galvanized.
Chemical Bath Name: Degreasing
Dipping Duration Time: 10-20 mins (Depends on the soil, dirt, oil and grease)
Chemical Used: Acid Degreaser (pH < 3)
Inspection Stage: Observe and check whether the material is free from soil, oil and grease
Inspector’s Role: 1. monitoring the degreasing process is correct
2. Check whether process control parameter is within limits.
Process Control Parameters:
1. pH Value = 3.0 minimum
2. Bath Level = 150 cm below
5.5.1 Removing of contaminations like oil, grease etc. over the surface to be galvanized. Cleaning carried out by
dipping the work in degreasing bath and should be raised and lowered to allow degreasing solution to enter
inaccessible areas.
5.5.2 Then immediately after the degreasing, the work should be rinsed in water.
5.5.3 Material will be checked by the crane operator whether it is free from grease/oils and withdraw from the
bath and transfer to the next process.
5.5.4 Assigned QC inspector will check whether the material is already free from soil, oil and grease. Take note of
the time in and time out and affix his signature in the Job Travel Card (FASGC-QMS-F-09, Rev-0).
5.5.5 In case the level of the bath or the pH is lower/higher than the allowed limits. The level and pH of the
degreasing tank must be monitored following the lab procedure.
5.5.6 In case material surface is found unsatisfactory; the rack operator is instructed to repeat degreasing
process until the material surface is completely cleaned.

5.6. Pickling
Purpose: to remove Mill Scale, Rust and other material surface oxide.
Chemical Bath Name: Pickling
Dipping Duration Time: 20-30 mins (Depends on the degree of rust)
Chemical Used: Hydrochloric Acid (18%), Acid Inhibitor to avoid fumes/over-pickling.
Inspection Stage: Observe and check whether the material is free from rust and mill scale.
Inspector’s Role: 1. Check that the material is free from rust and mill scale.
2. Monitor the control parameters.
Process Control Parameters:
1-Specific Gravity = 1.30 below
2-Bath Level = 150 cm below
5.6.1. In pickling a diluted solution of hydrochloric acid with range 14-18%, with a suitable acid inhibitor is
used at ambient temperature with Iron contents less than 100 gm/liters is used.
5 . 6 . 2 . The material is dipped for about 10 to 20 minutes or depends on the degree of rust and strength of the
acid. A freshly blasted material would require only few minutes’ retention in the pickling tank.
5.6.3 The QC inspector will check whether the material is free from mill scale, material surface oxides and rust.
5.6.4 Time in and Time out will be noted with in the Job Travel Card (FASGC-QMS-F-09, Rev-0) by QC inspector &
release the material for next operation if the material is found satisfactory.
5.6.5. If the material surface is found unsatisfactory, Rack operator is instructed by In-process QC Inspector to
repeat the Pickling process until the material surface is completely cleaned.

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 Reference: FASGC-SOP-01
SOP FOR GALVANIZING PROCESS Rev: 01
Dated: 27/9/2022

5.7 Rinsing
Process Control Parameters:
1-Bath Level = 150 cm below

5.7.1- A Sweet water bath with pH range 4-6 is used to wash material prior to dipping in Fluxing bath to prevent
iron & HCl mixing in flux solution.
5.7.2- QC Inspector will check whether the rinsing process was adequately done. On satisfactory observation
and filling up the Job Travelling Card, material will be transferred to the next stage.
5.8 Flux Solution
Purpose: Oxides Removal and Oxidation Prevention before material dipping in Molten Zinc.
Chemical Bath Name: Fluxing Solution
Dipping Duration Time: 4-5 mins (Sometimes can be prolonged)
Chemical Used: Zinc Ammonium Chloride (ZnCl2.2NH4Cl)
Chemical Trade Name: TIB FLUX D1100
Inspection Stage: 1. Check that the material is 100% clean and ready to be galvanized.
2. Check whether the manner of hanging in jigs and frame is correct.
Inspector’s Role: Monitoring the fluxing process and control process.
Process Control Parameters:
1-Specific Gravity - 1.16-1.26
2-pH Value = 3.5 – 5.0
3-Iron Content – Lower than 5g/l
4-Bath Level = 150 cm below
5- Temp = 50 Degree C

5.8.1-A solution bath of Zinc chloride & Ammonium chloride with density ranging from 20 to 25 Baume at
40° to 60 °C temperature with Fe contents less than 5.0 gm/liter and pH 3.5-5pH. Flux is used to remove
oxides, and further prevent any oxide formation prior to articles dipping in a molten Zinc bath.
5.8.2-QC Inspector (In process) will ensure that the material is completely immersed in Flux bath & properly
fluxed.
5.8.3- After the QC inspector has checked whether the fluxing process was adequately done, a go signal to
proceed to galvanizing is given by the QC inspector. The small paint markings on the steel are cleared by
light buffing/using paint remover and the area cleared is applied with flux manually before dipping. The QC
inspector shall fill up the Job Travel Card (FASGC-QMS-F-09, Rev-0).
5.8.4-If the material is found unsatisfactory, the Rack operator is instructed to repeat the process till
material is found properly fluxed.
5.9 Galvanizing
Chemical Bath Name: Galvanizing
Dipping Duration Time: 3-12 mins depending upon the type and thickness of the material.
Chemical Used: 99.995% Zn. (In Ingots)
Inspection Stage: 1. Check whether the manner of hanging in jigs and frame is correct.
Inspector’s Role: 1. Check whether the skimming of zinc ash is done properly.
2. See if the withdrawal speed of material is correct and no two surfaces touch
each other.
3. See if there is no zinc ash and dross adhering to the material upon withdrawal.
Process Control Parameters:
1-Temperature – 445 – 455 ˚C
2-Bath Level – 20 cm below
3-Zinc Dross Level – 10cm max
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 Reference: FASGC-SOP-01
SOP FOR GALVANIZING PROCESS Rev: 01
Dated: 27/9/2022

4-Aluminum content – 0.007% max

5.9.1. A galvanizing bath has a minimum 98 % pure molten zinc. (ASTM A123-17)
5.9.2. The galvanizing bath is typically operated at temperature ranging from 445°C - 455°C for structural
material. Production team should control the bath temperature within the range. The actual bath
temperature should be measured by using a calibrated digital thermometer with a thermocouple probe.
Zinc temperature readings from the control panel are recorded in Daily Zinc Bath temperature (FASGC-
QMS-F-33 Rev-0) each hour.
5.9.3. The production department must maintain the zinc bath level and it should not be lower than 20 cm from
the top of the bath.
5.9.4. QC Inspector (In process) must ensure the following prior to dipping the material in galvanizing bath:
5.9.4.1. Before dipping the material inside, ash should be completely removed from the surface of
the zinc.
5.9.4.2. Ash from galvanizing bath surface prior to withdrawing the material must be completely
removed.
5.9.4.3. Excessive zinc from surface of articles shall be removed by draining and vibrating.
5.9.4.4. Total dipping time taken by the item inside the molten zinc is recorded in the form Daily
Material Dipping Report (FASGC-QMS-F-03, Rev-0). It is tried to minimize the dipping time as it can
result in more coating thickness.
5.10 Quenching
Chemical Bath Name: Quenching
Dipping Duration Time: 2-5 mins
Chemical Used: Only Water
Inspection Stage: 1. Check whether the material should be quenched or not.
Inspector’s Role: 1. Monitor the correctness of quenching process control parameters.

5.10.1. Quench tank containing sweet water ranging 6.0-6.5 pH is used.

5.10.2. Assigned QC inspector (in process) will ensure that the articles are properly quenched.
5.10.3 Sign and hand over the job traveling card to visual inspector and for visual & final inspection.

6 Visual and Testing Inspection

All HDG QC inspectors have successfully completed AGA HDG Inspection course at Azman.
6.1 QC inspector will ensure that sampling of each lot shall be performed for conformance with the requirements
of ASTM A123.
6.1.1 Visual and final inspection are carried out by QC Inspector (Visual & Final) to ensure that galvanized
material is complying with the standard specifications. Appearance of the galvanized items shall be
continuous and reasonably smooth and uniform in thickness as the weight, size, shape of the item, and
necessary handling of the item during the dipping and draining operations at the galvanizing kettle will
permit. (ASTM A123 Clause 6.2)
6.1.2 Upon shipment from the galvanizing facility, galvanized articles shall be free from uncoated areas, blisters,
flux deposits, and dross inclusions. Lumps, projections, globules, or heavy deposits of zinc which will
interfere with the intended use of the material will not be permitted. (ASTM A123 Clause 6.4)
6.1.3 Surface roughness of the articles to be painted or powder coated and the smoothing of the galvanized
coating before painting or powder coating shall be mutually determined by the galvanizer and the customer.
(ASTM A123, Clause 6.4)
6.2 Assigned QC Inspector (Visual & Final) will conduct the visual inspection and ensure the following:
6.2.1. Material is free from white deposit, dross & ash Inclusion, black & bare spots, pimples, blister, flux
inclusions, lumpiness and runs etc.
6.2.2. Measures coating thickness with calibrated magnetic coating measurement device as defined in ASTM

Page 5 of 7
 Reference: FASGC-SOP-01
SOP FOR GALVANIZING PROCESS Rev: 01
Dated: 27/9/2022

A123 Clause 8.2.1. (Elcometer 456)

6.2.3. Conduct Adhesion Test as per ASTM A123 Clause 8.3.
6.2.4. Collect test sample (if available) hanged by process inspector for Mechanical and other tests and
arrange to send to one of the approved facility for inspection and testing.
6.2.5. Sign Job Travelling Card and release the material for cosmetic and packing work.
6.2.6. In case of observed repairable defects instruct finishing supervisor to apply the repair procedure
to remove the defects.
6.2.7. Re-inspect the articles after visual defects are fixed and sign the job traveling card if material found
satisfactory with following actions. QC inspector sticker is pasted with the passed status on the
bundle.
6.2.8. Finishing leadman will move the material to the assigned released material area in the yard.
6.2.9. QC inspector, if required will arrange for client’s inspection by sending Request for Inspection (FASGC-
QMS-F-05, Rev-0).
6.2.10 Release the material for dispatch once QC released.
6.2.11. In case of rejections, QC inspector will issue a Non-Conformance Report and paste the QC reject/Hold
sticker (Red Color). Finishing lead man will move the material to the designated Non-Conformance/Hold
area. QC inspector can affix Taps of defined color as red-white for HOLD, yellow/green-White for released
in case of large quantity of bundles.
6.2.12. QC inspector will report the inspection details in FASGC-QMS-F-07, Rev 0 (Daily Final inspection
Report)
6.2.13. For each lot being delivered, QC department will issue compliance certificate. (FASGC-QMS-F-02 Rev-0)
7. Stripping & Regalvanizing
Apart from the material which is rejected due to any defect, if a customer has pre-galvanized items
to be re-galvanize, the same process steps would be followed except for the initial stripping of zinc
coating. For stripping, material is kept in the pickling acid tank for longer duration since it takes time
to remove the existing coating entirely. The QC process inspector inspect periodically to check the
condition and progress of the process. Once, the coating has been completely removed, the items
are shifted for processing, following the standard procedure. To reprocess the galvanized items, the
cost has to be agreed upon before starting the job because of the extra consumption of acids and
time.
___________________________________________________________________________
NOTES:
a- Any threaded area has potential of getting clogged with zinc after galvanizing.
b- In case drain/vent holes are missing, galvanizer will proceed to make holes in the material after discussing and getting
approval from the customer.
c- Zinc Bath Size = 1.6m width, 2.3m depth and 13m length. Larger material can be handled by double dipping.
Related Documents:
FASGC-QMS-F-02, Rev-01 - Galvanizing Certificate
FASGC-QMS-F-03, Rev-01 - Daily Material Dipping Report
FASGC-QMS-F-05, Rev-01 – In Process QC Inspection Report
FASGC-QMS-F-34, Rev-01 – Request for Inspection Form
FASGC-QMS-F-07, Rev-01 – Daily Final inspection Report
FASGC-QMS-F-08, Rev-01 - Incoming Black Material Inspection Report
FASGC-QMS-F-09, Rev-01 – Job Travel Card
FASGC-QMS-F-10, Rev-01 – Chemicals Parameters Record
FASGC-QMS-F-16, Rev-01 – Quantity Monitoring Card
FASGC-QMS-F-33, Rev-01 – Daily Zinc Bath Temperature
FASGC-QMS-F-35, Rev-01 - Inspection & Test Plan

Page 6 of 7
 Reference: FASGC-SOP-01
SOP FOR GALVANIZING PROCESS Rev: 01
Dated: 27/9/2022

A flow sheet and a process diagram (App # 01 and App #02) are attached on next page.

APP # 01

APP#02
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