UNITED METAL GALVANIZING SERVICES Issue: 1 | Rev: 04 Date: 12/04/2023, wi WIG74:2:22 TLE: HOT DIP GALVANIZI METHOD STATE! u 1 SCOPE This Work Instruction covers the steps for Galvanizing of Structural Steels/Pipe Spools/Handrails/Fasteners 2 REFERENCE Specification for Zinc (Hot-Dip Galvanized) Coatings on Steel Products: ASTM A 153/ ASTM A 123/ BSEN ISO 1461. Practice for Safeguarding against embitterment of Hot-Dip Galvanized Structural Steel Products and Procedure for detecting embitterment: ASTM A 143, Practice for Safeguarding against war page and Distortion during Hot-Dip Galvanizing of Steel Assemblies: ASTM A 384, 3 METHOD OF STATEMENT GALVANIZING PROCESS, The galvanizing procedure and its requirement are in accordance with equivalent international standards. Whenever specified in work order, the requirement of customer is met for quality of galvanizing. Galvanizing can also be carried out as per specified requirement. The procedure for surface treatment / preparation and galvanizing of material, which is generally in line with ASTM A 153, ASTM A 123 & BSEN ISO 1461 is followed. 3.1 VISUAL INSPECTION OF BLACK MATERIAL After receiving black material visual inspection is carried out. Surface of material is checked for contamination of oil / grease / paint on the surface, Surface condition of material is observed, whether surface is reasonably smooth or having rusty appearance to decide retention time. Itis also checked whether the article has proper arrangement for vent and drainage of air liquid and zine, Prepared by UMGS: 7 Reviewed & Approved By: Name : Mohammad Al Jilani__| Name : Renjith nr Rgeon ite”) x —__IUNITED METAL GALVANIZING SERVICES Issue: 1 | Rev: 04 Date: 12/04/2023 wi WIG74:2:22 HOT DIP LVAl METHOD STATEMENT For hollow section and closed sections in order to avoid blasting while dipping required arrangement is made for drainage of zinc and air vent by providing additional holes etc. Holes can’t be closed by welding after galvanization as it will affect the nearby galvanized areas. In case if welding is carried out to close the area, same should be cleaned and recoated with Carboline and zine spray For welded material, it is checked whether welding slag is removed. Items shall be blast cleaned if specified by Client / Contract, Surface preparation of the product is carried out to the specified degree of cleaning as indicated in ISO — 8501 — 1 — 1988: Pictorial Surface Preparation standards for Painting of Steel Surfaces. Normally to avoid material roughness after galvanizing SA 2.5 degree of cleaning is applied, Visual Inspection is done to ensure that the items is free of rust & mill scales 3.2 DEGREASING IN ACIDIC DECREASING TANK ‘The material is dipped in degreasing solution to remove oil and grease on the surface of material, Material will kept in solution for 30 minutes and if not cleaned properly, same process will be continued. ‘The PH value of degreasing solution is checked monthly 3.3 PICKLING Hydrochloric acid is used for pickling at room temperature to remove rust corrosion and scales ‘The articles are kept in acid tank for 10 minutes or more depends upon the degree of contamination, Hydrochloric acid solution is prepared by dilute technical grade acid 32 % with an equal volume of water. The strength of hydrochloric acid is checked weekly with PH meter and Acid solution is replaced monthly Retention time is decided on the surface condition of material. Mild agitation of material shall be done during pickling so as to optimize pickling time. Prepared by UMGS : - | Reviewed & Approved By: & Name : Renjith Name : Mohammad A\ Jilani -|-st STATUS aN‘UNITED METAL GALVANIZING SERVICES Issue:1 | Rev: 04 Date: 12/04/2023 WIE: WIG74:2:22 TTL HOT DIP GALVANIZI ETHOD STATEMENT. 3.3.1 ACID STRIPPING In case the steel received is pre-galvanized, then the same has to be stripped in a stripping tank containing Hydrochloric acid to chemically remove all the Zine coating prior to acid pickling. 3.4 RINSING ‘The material shall be rinsed in running water after pickling. ‘This tank should be cleaned on every weekly off. 3.5 PRE-FLUXING The rinsed material after pickling shall be dipped in pre-fluxing solution having almost equal weight of zine chloride and ammonium chloride dissolved in it. The Ph value should be checked monthly and should be maintained between 4 to 5.5 36 DRYING Before dipping of articles in zinc bath it is kept on hot plate for mainly drying of surface and also to increase the temperature of material. Visual inspection is carried out to check whether surface of material to be galvanized is free from rust and impurities or unpicked spot. If impurities / rust are found on the surface of material, material is either re-dipped in pre-flux solution or pickling in HCL acid. 37 GALVANIZING DIPPING IN ZINC HATH ‘The molten metal in the galvanizing bath should contain not less than 98.0% by mass of zine. ‘The bath temperature is essentially maintained to get the quality of the product. Prepared by UMGS : Name : Mohammad Al Jilani Reviewed & Approved Name : Renjith NR TS STAMP STATUS , yUNITED METAL GALVANIZING SERVICES Issue: 1 | Rev: 04 Date: 12/04/2023, Wi: WIG74:2:22 TITL HOT DIP GALVA’ ETHOD STATEM! The bath temperature may vary from 440 deg C to 460 deg C and working temperature of 450 deg Cis commonly used ‘Temperature of the bath is reduced / increased depending upon the thickness of the article. Aluminum added in galvanizing bath 0.005% (0.007% Max.) for reducing threat of oxidation of molten metal and brightens the appearance of the articles. Lead is also added in the form of Zn-Pb alloy to provide spangle on the surface. Lead content should be in the range of 0.8-1%, The article should be immersed uniformly in the galvanizing bath taking into consideration operator safety. ‘The speed of immersion also influences the uniformity of coating. The time of immersion in general the article is left in the zinc bath until it reaches the temperature of the bath, which is usually indicated by the stopping of the boiling action. Articles are withdrawn through a bath of clear zinc to avoid contamination. Surplus zine is removed by manually wiping. Finally material is dipped in quenching tank for cooling. Sodium dichromate is added to prevent white rust. 3.7 FINAL INSPECTION & TESTING 3.21 SAMPLING & TEST METHOD Test specimens shall be selected at random from each lot as per ISO 1461 table 1 or as per ASTM A 123 Clause no. 7.3 eee SNo. ~_No. OF PIECES IN LOT No. OF SAMPLES 1 —__ Sor less All 2 #10 500 3 3 501 to 1200 3 4 1201 to 3200 8 3 3201 to 10000 13 6 10000 to Over 20 Prepared by UMGS: Reviewed & Approved By: = ay See stam Stratus a ; Name : Mohammad Al Jilani Name : Renjith NR2~ |UNITED METAL GALVANIZING SERVICES ] Issue: 1 | Rev: 04 Date: 12/04/2023, [WE : wiG74:2:22 TTL HOT DIP G) UUZIN' |ETHOD STATEMENT Visual inspection of each lot is carried out to segregate the rejected pieces which are having galvanizing defects like bare/black spots, heavy flux, ash and dross inclusions, lumpiness, blisters and flaking off due to adequate adhere of zinc coating. The coating shall be continuous smooth & uniform in thickness. Zine coating shall be checked by elcometer (thickness Gauge) on the randomly selected pieces. Defective pieces are taken back by the Production (galvanizing) Dept. for rectification and re-offer. Coating requirements as per ISO 1461 Table 3 or as per ASTM A 123 ASTM A123 TABLE 1 Minimum Average Coating Thickness Grade by Material Category "Al Specimens ested ate Category ‘Sta Tess Range Meas) (rn) (8) YO HSNA KOMI) KOK IS!) eh (ebd) ‘Sturt Shapes ad Pe 6 ® 5 ® io Stipa ar 6 6 % ® 10 Pe and Tubing 6 6 is a B Wee s 9 cy a 0 on samples that are not centrifuged “Smomess” | “SSmsss'™ | “Smiccness” | “mass ‘Antiole and it thickness inary? (eninirmarn? nimi) (inne)? ue om mn ‘ome Equvalent coating mass uring a nominal coating dansty of7.2afem? (eae Annex 0). Prepared by UMG! Reviewed & Approved By: Name : Mohammad Al JilaniUNITED METAL GALVANIZING SERVICES Issue: 1 | Rev: 04 Date: 12/04/2023, wi WIG74:2:22 /ETHOD STATEMENT. Components shall be free from blisters, flux deposits acid, black spots & dross inclusions. ‘The zine coating shall withstand handling consistent without peeling or flocking. 3.9 STORAGE AND HANDLING ‘The galvanized material shall be stored in such a way that will avoid wet storage strength i.e. white rust. This shall be achieved by ensuring ventilation within the packed lot using wooden packing blocks to allow free air circulation. Galvanized material shall be stored in finished goods yard away from flux and acid fumes. Galvanized material should not be stored in too large piles. In case large are used, spacer shall be provided. Loading / Stocking shall be done only when galvanized material is dry. While loading and stocking, slings of crane should be pve sleeved to protect the material from dent and damages. 4 TOSAFEGUARD AGAINST WARPAGE OR DISTORTION OF STEEL OVERLAPPING SURFACES - Overlapping surfaces, narrow gaps and back-to-back angles and channels should be avoided as far as possible. If overlaps are completely sealed by welding there is a hazard, if they are not completely sealed there is danger of pickled acid entering the cavity and then weeping out so damaging the coating in service. = movable parts and treads should be avoided for galvanizing. As after dipping zine will stick into these surface and will be difficult to remove DISTORTION - Some fabricated assemblies/large plates have a tendency to distort at galvanizing temperature. Like plate with more than I meter length and width. This caused mainly by: Prepared by YMGS : “STAMP stares (eR: Name: Mohammad Al Jilani___| Name : Renjith NRO"UNITED METAL GALVANIZING SERVICES Issue: 1 Date: 12/04/2023, wi WIG74:2:22 TITLE: HOT DIP GALVANIZING ~ METHOD STATEMENT Thermal stresses set up in the material by differential expansion and contraction due to joining parts of unequal thickness or the use of non-symmetrical sections. ‘The relief of residual internal stresses set up during fabrication. The risk of distortion can be minimized by attention of following points: a, Design the fabrication as that it can be quickly and completely immerse in a single dip b. Use symmetrical sections in preference to unequal angles or channels. c. Use section of nearly equal thickness. d. Accurately pre-form parts to avoid force or restraint during joining. ¢. Bend members to the largest ratio. £, Continuously weld if possible, intermittent welding if permissible 5. REPAIR USING ZINC RICH EPOXY PRIMER Preparation of the damage surface will be influenced by the type of paint selected and the anticipated service conditions. Experience shows that in general organic zinc-rich systems are more tolerant of surface preparation ‘The following general guidelines shall apply. Surface to be reconditioned / touch-up repair shall be cleaned, dry and free of oil, grease and corrosion products. Surface to be reconditioned / touch-up repair is to be carried out by using ZINC RICH EPOXY PRIMER/ CARBOLINE with 70-80 micron DFT Apply additional coat to achieve original system thickness. Where anticipated, field service conditions include immersion, blast clean the surfaces in accordance as per SA? grade cleaning, Where circumstances do not allow blast cleaning, it is permissible to power disk sand areas to be effected; surface preparation shall extent into the undamaged galvanized coating. ‘The method and extent of surface preparation shall be mutually agreeable to the contracting parties. | Prepared ee Name : Mohammad Al Jilani aN | STAMP a isUNITED. METAL GALVANIZING SERVICES Issue: 1 | Rev: 04 Date: 12/04/2023, WI: WIG7.4:2:22 TITLE: HOT DIP GALVANIZING ~ METHOD STATEMENT. If the area to be reconditioned includes, welds, first remove all flux residue and weld spatter of a size or type that cannot be removed by blast cleaning by mechanical means, that is chipping etc. Spray or brush-apply the zinc-rich epoxy primer to the prepared area. Apply the primer as recommended by the primer manufacturer in a single application employing multiple spray passes to achieve a dry film thickness to be agreed up on between the contracting parties. Take thickness measurements with either a magnetic or electromagnetic gauge to ensure that the applied coating is as specified. 6 GREY COATING ON GALVANIZED SURFACE Protection is equal and often better with dark grey coatings than with light grey. When rimmed or aluminum killed steels are hot dip galvanized, compact zine-hon alloy layers are formed and covered by zinc which has a light bluish grey metallic luster. In some cases the zino can form randomly oriented crystals to give a sponge finish but this is not a sign of either good or poor hot dip galvanizing nor does spangle affect the corrosion resistance of the zine coating. icon, which is sometimes added to still as a de-oxidant during its production, speeds up the reaction between the steel and molten zinc. When the steel part is removed from the galvanizing bath but still remains hot, the reaction may continue and convert all or part of the surface zine layers to zine-iron alloys. Zinc-alloys are dark grey compared with the light grey of zinc. Usually zinc-iron alloy coatings from more thickly and hence give longer life than the coatings on rimmed or aluminum killed steels. The zinc-iron alloys in any case have at least as good corrosion resistance as zine thickness and can have better intrinsic corrosion resistance in acid industrial environments. The dark grey coatings surface may develop iron oxide staining on atmospheric exposure, even in mild condition when moist. This is only a surface effect and does not develop into nodular or flaking rust; the galvanized coating remains intact to protect the steel. 8 RECORD Prepared byUMG Name : Mohammad Al Jilani Name : Renjith NRUNITED METAL GALVANIZING SERVICES TITLE: HOT DIP GALVANIZING ~ ME STATEMENT Zinc Coating Certificate with coating thickness - UMGS-QC-F-01 R.0 er Colaall.g ie Gletal 51a ial) Iso UNITED METAL GALVANIZING SERVICES L.L.C ‘as Aci: Da anni Yi nig Cargo A Ses 9001:2015 \Wrcluding: Bond Guarsrad, Lighting Poles. Electrical Poles, Elecivical Towerx, Cable Wray Fasteners a — [Link]-401 Ro| ZINC COATING CERTIFICATE INSPECTION AND TESTING FOR COMPLIANCE WITH ASTM A 123/ BS EN ISO 1461:2009 [Certificate No lunes/zcy bate [client liob wo project Details Joo No ‘COATING THICKNESS AND MASS OF ZINC COATING iz Maas of Zine se. erage [C SF | stuteriat Description | OTY Coating = , ‘hicknes er Note: COATING THICKNESS HAS BEEN MEASURED WITH DFT GUAGE MAKE: ELCOMETER, SERIAL NO CALIBRATION CERTIFICATE NO... JADHESION TesT:~ [Coating does not lift off in large flakes and same found satistactory as per ISO 1461 JVISUALINSPECTION OK NOT OK, 1) smoorn x ‘ok Ja) conmmuous, ok 2) FREE FROM GROSS SURFACE IMPERFECTIONS ok ‘We certify that aforesaid material has been hot dip galvanizing to ASTM A 123/ BS EN ISO 14612009 Standard and same found satisfactory Quality Control inspector Quality Control Manager Chent Prepared by [JMGS Reviewed & Approved By: \ (47 Six Sta Stars Name : Mohammad Al Jilani Name : RenjithUNITED METAL GALVANIZING SERVICES issue: | Reve 04 | at: 242003 we: wia7s:2:22 | TITLE: HOT DIP GALVANIZING ~ METHOD STATEMENT Data sheet for carboline arboline. Carbozinc 858 PRODUCT DATA SHEET SELECTION & SPECIFICATION DATA ‘Generte Type | Two-components zinc Miled, crane-ned epoxy primer. ‘Cocene 858 5 9 Noh sate organic ane cpoay pres aesigred Be comeson promecson Deconpton | Suctral tie! in sal and weatherng encrarmares. The pat il ent) lo apet ata protects steel (Govanicaly, Prowaes ugh and soreaion reste ae ‘Wet Fim Teloknees: | £0-250 um per coat. Dey Fim Truokneee | S0- 150 microns (1.95~5'9 mis) per cout ‘By vemme: 65 2 24 ‘semeaes Content | Se nent nary 88% [3 at 50 ur hirer bum ‘Aim tren ming and sepscation, “Tiorstinat Coverage Toes LUmitalions | Not recommended tr direct expatugs to stong aces and aikates, “Tepsoate | May be topccated wan epoxy polyurethane or ethers as recommended by Carbaine, SUBSTRATES & SURFACE PREPARATION ‘surface munthe ean and ary Employ adequate memoas io remere ct ss, cl and tober oe | Se es sin | Serres eae Maxine & THINNING ste | Pn nec ben EB RE Aa on COS OO NOTH Pee | emer tay tar re fn |2:sAn nwa | Prepared "k MGS : Reviewed & Approved By: ee rare Name : Mohammad AI Jilani Name : Renjith NR ) 2