Technical

Quality control of hot dip galvanized coatings

The Association is sometimes invited to comment on what is perceived to be bad quality hot dip galvanizing. Although there are occasions where this does exist, most often, once the customer understands the process and the mechanism by which the coating occurs, and the surface, if necessary is cleaned up, the coating is acceptable and will satisfy the specification requirement of corrosion protection. However, when a bad quality coating has incorrectly been dispatched to a customer and the Association has been invited to comment, an unbiased report is normally written and sent to all parties involved and a non-conformance report, (NCR) is issued on the member by the Association. Because of these reports and the general feedback from the market over the last two years, and in the interests of all stakeholders of the industry, the Association sent out a letter highlighting the situation and invited all members to participate in a workshop to discuss the issues of bad galvanizing. Bad quality coatings might include, excessive amounts of ash at significant surfaces; drainage spikes or protuberances; excessive amounts of dross in the coating, particularly at significant surfaces; over cleaning, leading to bare spots; touch or jigging wire marks; uneven drainage or lumps or coating unevenness at mating or significant surfaces. A significant surface can be defined as, A surface, which impacts on the performance of that article. Other things such as the cleaning of clogged threads on male fittings; selection of repair materials and the
The old problem of excessive phosphorous in steel resulting in a surface finish called the tree bark effect. Not suitable for architectural quality. Raise a non-conformance before galvanizing the total job and prevent the customer or the end-user developing the idea that HDG does not provide a smooth uniform finish. If architectural quality is required the correct quality of steel must be specified.

identification of significant surfaces and whether the component is to be painted after hot dip galvanizing, etc. cannot be considered to be bad quality and must, in addition to reference to the specification SABS ISO 1461, be set out by the customer on the order or in the form of a sketch, for the galvanizers attention prior to the order being placed.

Fabrication inadequacies such as incorrect positioning of vent holes, leading to air traps and consequently possibly uncoated areas; stains caused by weeping of acid salts from porous welding; uncoated areas caused by marking with incorrect materials such as oil based paints; welding slag and weld spatter and most distortion related problems, can be eliminated by

Product double dipped and no post process [Link] job was [Link] customer said he would clean the product on site, but the net result was never the less a complaint from the architect. Should the customer not wish the product to be presented in terms of normal quality standard, a non-conformance report should be raised and the customer agree in writing that a variance from the standard quality, is acceptable.

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The Association is fully aware of the problem with reactive steels that can lead to quality problems. However, it is not sufficient to simply say that we as galvanizers cannot do anything about this problem. If we are to protect ourselves as well as grow the industry we must do something about it as well as any other quality issue. We cannot allow our customers to develop the perception that hot dip galvanizing is a difficult process with potential for quality and service complaints. Where a quality problem is first detected a non-conformance report should be raised in terms of the companys quality management system, the customer advised and corrective actions agreed. To simply continue processing and dispatching product into the market place knowing full well that it is substandard, is detrimental and counter productive. There is an old saying that is always used when dealing with this type of issue, we do not have time to do it right the first time, but we have time to redo it the second and maybe a third time. The examples shown on this and the previous page highlight some of the problems, but are by no means exceptions.
Black Spots Uncoated areas where no remedial work has been undertaken, due to the fact that the job was urgent. At the end of the day the perception and question, left in our customers mind, is this what hot dip galvanizing is all about?

This coating finish in the market place, no matter how or why it got there is unacceptable when we talk about architectural quality and the growth of the industry. Such product is detrimental to our industry and should never ever get to a site. (The coating in terms of corrosion protection for mining or industrial use, is acceptable but if used in an architectural application, is unacceptable.)

following certain guidelines and indulging in upfront discussions with the galvanizer. All articles that have not necessarily been correctly designed to prevent the incidence of distortion, that arrive at the galvanizers plant with an order to hot dip galvanize, the galvanizer must first contact the customer and highlight the possibility of distortion and only once the customer has been informed in writing and accepted this risk, should the articles be galvanized. This is of particular importance when items arrive from out of town and the customer is expecting the articles to be galvanized over night.

The objective behind the original letter to the members was not meant to criticise but to illustrate the urgent need to ensure that all the quality management systems are operative and not be allowed for whatever reason to be compromised. The letter urged members to respond. The following letter was received from Rob Southey of Voigt and Willecke, one of the Associations members in Durban: Thank you for the letter received in Dec 2003, regarding quality control. We however, would like to make some comments. Regarding quality, most galvanizers are acutely aware of any short comings in their

Ash inclusions and in some cases weld slag had not been removed. Questions of inadequate incoming or black steel inspections for the materials to be hot dip galvanized as well as the final exit inspection.

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quality systems and also the subsequent lapse in allowing sub-standard work back into the market place. However, we do not believe that the entire burden of poor quality should be laid at the door of the galvanizer or that it is his problem alone. We in KZN have in recent years noticed an alarming trend in the steel industry among steel suppliers and manufacturers, in that adequate time is no longer available to the galvanizer to do the pre and post galvanizing checks. Let alone enough time to process the work. We are not talking about garden gates, burglar bars or piece metal work but major contracts and it is not unknown for tonnages to arrive one day and demands for delivery on the next. Any inspection and subsequent cleaning systems that you have in operation are now redundant. Failure to comply with the above, elicits the standard retort, dont you want our work, or worse, that the client switches to a more user friendly galvanizer, who says he accepts and then overlooks the quality aspects. To alleviate most of the problems encountered in the industry, we believe that we need to reinvent the word time, obtain a commitment from major role players that they will allow sufficient time for galvanizing and take it from there. All galvanizers should stand firm on this one. With respect it is suggested that the topic of your letter also be circulated to Architects, Engineering Consultants, Quantity Surveyors, Steel Merchants and Manufacturers (steelwork contractors), to emphasize what happens when sub-standard steel and workmanship is dumped at the galvanizer, invariably late and who in turn is now left with the problem. Any mention of non-conformance is frowned upon, as most suppliers have the simplistic view that any steelwork, which does not come out of the galvanizing bath in pristine form is purely the galvanizers fault and any cost of rectification somehow falls upon his shoulders. Once again, any protestation from the galvanizer, the customer says, I will switch to another galvanizer. Again we need the work and therefore bow down to these excessive and unjustified demands. The problems encountered over the years in the galvanizing industry are still there, a snag list, which was probably relevant when galvanizing was first applied to steel is still relevant today and worth repeating. N Insufficient time i.e. Urgent. The main culprit. N Contaminants oils, grease, oil based paint, labels and welding slag. N Material unsuitable for galvanizing i.e. reactive levels of silicon and inordinately high levels of phosphorus. N Inadequate and inappropriately positioned vent and drainage holes. N Design unsuitable for hot dip galvanizing. N Sub-standard fabrication. N Lack of pre-manufacturing consultation. We believe we play an integral part in the steel industry and have somehow been sidelined by the major role players in the areas of consultation and would certainly like to be part of the consultative pre manufacturing stage. Editors Note: In order to adequately address pre and post inspection by the galvanizer, a lead time of about 7 days is recommended. This lead time may be negotiated with the specific galvanizer.

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