DESIGNING FOR
HOT-DIP GALVANIZING
February 12, 2020
Williamsburg, VA
LEARNING OBJECTIVES
▹Upon seminar completion, you will be able to:
▹Understand the need for communication throughout the design
process
▹Identify best design practices for products to be galvanized based on
ASTM specification guidelines
▹Avoid fabrication and design issues that subtract from long-term
corrosion protection
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WHY SPECIFY HOT-DIP GALVANIZING
▹Corrosion Protection
▹Durability
▹Longevity
▹Availability/Versatility
▹Aesthetics
▹Sustainability
▹Environmental
▹Economical
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GOVERNOR MARIO M.
CUOMO BRIDGE
Tarrytown, • 2017
HOT-DIP GALVANIZING
Surface Preparation, Galvanizing
SURFACE PREPARATION
▹Thorough cleaning is necessary
as zinc will only react with clean
steel
▹Three cleaning solutions:
▹Degreasing – removes dirt, oils,
organic residue
▹Pickling – removes mill scale and
oxides
▹Fluxing – mild cleaning, protective
layer
▹Unclean areas will not grow zinc Galvani
coating ze It!
GALVANIZING
▹Steel immersed in bath (kettle)
of molten zinc (~830 F)
▹Bath chemistry >98% pure zinc
▹Up to 2% additives (Al, Bi, Ni)
▹Molten zinc reacts with iron in
steel to form metallurgically-
bonded coating
▹Reaction is complete when steel
reaches bath temperature
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HDG SPECIFICATIONS
ASTM STANDARDS OTHER GALVANIZING STANDARDS
▹Requirements for coating ▹Canadian Standards
thickness, finish/appearance, Organization
and adherence ▹CSA G164
▹ASTM A123 ▹International Organization for
▹General iron/steel products Standardization (ISO)
▹ASTM A153 ▹ISO1461
▹Fasteners/small parts ▹American Association of State
centrifuged or spun Highway Transportation
▹ASTM A767 Officials (AASHTO)
▹Reinforcing steel (rebar) ▹AASHTO M111
▹Also has bend diameters ▹AASHTO M232
SUPPORTING SPECS (PRE-GALV) SUPPORTING SPECS (POST-GALV)
▹ASTM A143 ▹ASTM A780
▹Safeguarding against ▹Touch-up and repair of
embrittlement galvanized products
▹ASTM A384 ▹ASTM D6386
▹Minimizing warpage/distortion ▹Surface preparation for
painting over HDG
▹ASTM A385
▹Practice for high-quality HDG ▹ASTM D7803
coatings ▹Surface Preparation for powder
coating over HDG
▹ASTM A1068
▹Life-cycle cost analysis for steel
corrosion protection
DESIGN & FABRICATION
COMMUNICATION IS KEY
▹Steel Chemistry & Surface
Condition
▹Size & Shape
▹Process Temperature/Heat
▹Venting & Drainage
▹Welding
▹Threaded Parts/Connections
▹Post Galvanizing Design/Use Galvani
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DESIGN DATA DETAIL SOFTWARE
▹SDS/2 has incorporated
galvanizing details
▹Automated vent/drain locations
and sizes
▹Designate at set up or as each
member is designed
▹Checks for kettle size fit, dissimilar
materials, vents/drains, welds
▹Defaults to AISC Standards
▹Visit [Link] for details
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SUITABLE MATERIALS FOR GALVANIZING
▹Ferrous Metals
▹Carbon steel
▹Weathering steel
▹Stainless steel
▹Fasteners
▹Centrifuged to remove excess
zinc
▹Castings
▹Special cleaning/design is
important
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STEEL CHEMISTRY
▷ Recommended Steel
Chemistry for
Hot-Dip Galvanizing (ASTM
A385)
▷ Silicon <0.04% or
0.15%-0.22%
▷ Phosphorous <0.04%
▷ Carbon <0.25%
▷ Manganese <1.30%
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SURFACE CONDITIONS
▹Varying surface conditions lead to
varied appearance
▹Old/New Steel
▹Combining materials
▹Different chemistries
▹Rusted/pitted steels vs. new/machine
surfaces
▹Fabrication methods
▹Process needs/time
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SIZE & SHAPE
▹Variety of sizes/shapes
▹Average kettle is 40 feet
▹Many kettles 50-60 feet
▹Weight can also be an important
factor
▹Overhead hoists/cranes move
the steel
▹Chains, wires, racking systems, or
perforated baskets hold materials
▹Lifting points where possible
▹Design large structures in
modules
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or sub-units and connect after
galvanizing ze It!
PROCESS TEMPERATURE & MECHANICAL PROPERTIES
▹HDG Temperature does not change
▹Steel chemistry
▹Tensile strength
▹Yield strength
▹Bend properties
▹Impact properties
▹Micro-structure
▹HDG process does not “weaken”
high
strength steel
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COLD-WORKING
▹Severe cold-working increases
possibility of strain-age
embrittlement
▹Heat of HDG can accelerate the
affects
▹Keep bend radii as large as
possible before HDG
▹At least 3x the section thickness
▹Refer to ASTM A143 for
recommendations and stress-
relieving procedures
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COPE CUTS
▹Flame cut copes often have
residual stress and rough surface
▹Can lead to cracking after HDG
▹Minimizing risk for cope cracking:
▹Thermal treatment
▹Weld bead applied directly to, and
extending out one inch from the cut
▹Cracks can be repaired after
galvanizing by welding, followed by
an application of zinc per one of
the methods described in ASTM Galvani
A780 ze It!
HEATING/COOLING RATES
▹Heat of process can relieve stresses
▹Can lead to distortion and warping of
parts/assemblies
▹Common design causes of
Warpage/Distortion
▹Inherent stresses within steel
▹Cold working or cold rolled steel
▹Welding before hot-dip galvanizing
▹Asymmetrical design
▹Thin/thick material within assembly
▹Progressive dipping
▹Poor drainage/venting and lifting
points
Galvani ▹Process causes (for galvanizer to
control)
ze It! ▹Long immersion time
BEST PRACTICES TO AVOID WARPAGE/DISTORTION
▹Communication between
galvanizer, designer, & fabricator
early in design process
▹Follow guidelines in ASTM A384
▹Sheets/plates >1/4 in
▹Checkered/diamond plate
▹Thermal treatment after cold
working
▹Symmetrical design
▹Equal/near equal thickness in
assemblies
▹Overlapping joints
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VENTING & DRAINAGE
▹Cleaning solutions & zinc need
to flow into, through, out of
articles for effective galvanizing
▹Vent/drain holes allow air to
escape, immersion, and draining
of excess zinc
▹Extremely important for
personnel safety and to avoid
damage to fabrication/equipment
▹Reference ASTM A385 for
Galvani
recommended venting/drainage
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designs and sizing
GUSSET & BASE PLATES
Cropped Corners Holes Close to
(preferred) Corners
(alternatively)
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HOLLOW & ENCLOSED STRUCTURES
Ven
Internal t
baffle
Drain Galvani
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WELDING BEFORE GALVANIZING
▹Two items influence the
quality/appearance
▹Cleanliness of the weld
▹Flux/slag must be removed by
fabricator
▹Weld Rod Chemistry
▹As similar to the steel chemistry
as possible
▹Silicon acts as a catalyst for
coating growth
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OVERLAPPING SURFACES
▹Zinc viscosity prevents it from
entering gaps less than 3/32”
▹Cleaning solutions penetrate
smaller gaps – may weep out
▹Stitch-Welding with 3/32” gap
▹Complete Seal Welding
▹Large overlap requires venting to
prevent moisture trapping
▹Reference ASTM A385 for venting
requirements
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VENTING OVERLAPPING SURFACES
Steels ≤½ in. (12.75 mm) Steels >½ in (12.75 mm)
Overlapped Area in Thickness in Thickness
in2 (cm2) Unwelded Unwelded
Vent Holes Vent Holes
Area Areas
under 16 (103) None None None None
16 (103) to >64
One 3/8in (1 cm) 1 in (2.5 cm) None None
(413)
64 (413) to >400 One ½in (1/25 One ½ in (1.25
2 in (5.1 cm) 2 in (5.1 cm)
(2580) cm) cm)
>400 (2580) One ¾ in (1.91 One ¾ in (1.91
Galvani
each 400 (2580) 4 in (10.2 cm) 4 in (10.2 cm)
cm) cm)
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THREADED & MOVING PARTS
▹Threaded Parts
▹Zinc coating pickup makes threads
thicker – affecting fit-up between
male/female threads
▹Overtapping of Galvanized Nuts –
ASTM A563
▹Zinc on male thread will protect both
components
▹Clearance Holes
▹Bearing connections – no oversizing
▹Slip-critical connections – + 1/8 inch
to nominal bolt diameter
▹Maximum oversizing – AISC LRFD
Manual
Galvani ▹Moving Parts
▹Must accommodate for zinc
ze It! coating thickness
MASKING
▹Treating an area of the steel
to prevent coating growth
▹Threads
▹Areas to be welded
▹Studs
▹Not 100% Effective
▹Add significant labor in
application and removal
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MARKING
▹Temporary
▹Metal/Barcode Tags
▹Markers
▹Permanent
▹Weld Beads
▹Stamping
▹Deep Stencil
▹Refer to ASTM A385 for
recommended sizing
▹Oil-based markings should be
avoided Galvani
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HOT-DIP GALVANIZED AESS
▹A123 quality often not enough to
meet aesthetic requirements
▹Additional detailing required before
& after HDG
▹Learn A123 requirements
▹Explicitly state responsibility for
additional detailing
▹Pre-job meeting with all parties
GC/Fabricator/Galvanizer critical to
success
▹Use Custom Category Matrix
▹AISC categorical approach
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▹Optimizes cost
ze It!▹Minimizes detailing
INSPECTION, TOUCH-UP
& REPAIR, AND STORAGE
INSPECTING GALVANIZED STEEL
▹Inspections
performed/scrutinized on all
HDG
▹Coating thickness
▹Finish & Appearance
▹Referee Tests (only when a
question arises)
▹Adherence – stout knife test
▹Run knife point along surface
smoothly
▹No gouging/whittling Galvani
▹Not on edges/corners
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COATING THICKNESS FINISH & APPEARANCE
▹Checked by magnetic ▹Visual inspection with naked
thickness gauge eye
▹ASTM E376 for guidance ▹Some surface imperfections
▹ASTM A123, A153, A767 have are allowed according to
minimum coating thickness ASTM specifications
requirements (no max) ▹If they do not affect corrosion
▹Based on type of material protection
(category) and thickness of the ▹OR intended use of product
steel ▹Specification notes different
▹Sampling requirements for appearances (shiny, matte,
inspection based on lot size & mottled) are not cause for
surface area of the parts rejection (not interfere with
▹Information on maximum protection)
allowable area for touch-up ▹Touch-up/repair is done
and repair (in-plant)
APPEARANCE & WEATHERING
Photo 12/18/02
Shiny Matte
Gray
Spangled Shiny &
Galvani
Dull
Photo 03/28/03 ze It!
TOUCH-UP & REPAIR
▹ASTM A780 identifies acceptable
forms
▹Zinc-based solder
▹Zinc-rich paint
▹Zinc-spray (metallizing)
▹Main ASTM standards A123,
A153, A767 give restrictions on
size
▹Size limits only for in-plant repair
▹Touch Up & Repair video series
Galvani
on YouTube
ze It!▹[Link]/repair
PROPER STORAGE & HANDLING
▹Promote free flowing air around
parts
▹During storage & shipping
▹Wood spacers to avoid nesting
▹Avoid collection of moisture
▹Stack at angles
▹Keep away from vegetation/dew
▹May want/need to cover during
shipping
▹Refer to AGA Publication Wet
Storage Stain for additional info &
Galvani
cleaning recommendations ze It!
DESIGNING FOR HOT-DIP GALVANIZING
▹Communication amongst all
parties is key
▹Following best design practices
from the specifications leads to
best quality coatings
▹Inspection is simple, focusing
mostly on coating appearance
and thickness
▹Duplex systems are another
area for communication and
surface preparation is most Galvani
important to success ze It!
AGA RESOURCES
▹Galvanizer Locator/GalvaSource
▹[Link]/galvanizers
▹Technical Assistance/Expertise
▹[Link]
▹aga@[Link]; 720.554.0900
▹Dr. Galv KnowledgeBase
▹[Link]/knowledgebase
▹AGA Project Gallery
▹[Link]/project-gallery
▹Galvanizing Insights quarterly
newsletter
Galvani
▹Technical Library
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