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Why Hot-Dip Galvanize?

Perhaps the most critical choice made in the design of fabrication connections is how to protect the fasteners from corrosion. Hot-dip galvanizing delivers long-term, maintenance-free corrosion protection in a variety of exposure conditions. Whether used in atmospheric, concrete, soil or fresh- or saltwater applications, hot-dip galvanizing allows for maximum service-life to first maintenance. There will be no difficult field repairs and no labor and material costs associated with those repairs.

How Does Hot-Dip Galvanizing Protect Steel?


Left unprotected, steel eventually will corrode and suffer loss of mechanical properties and integrity. Hot-dip galvanizing prevents corrosion by coating steel with zinc. The galvanized coating is metallurgically bonded to the underlying steel, forming an impervious barrier between the steel substrate and the corrosive environment. The hot-dip galvanized coating also preferentially corrodes to protect the underlying steel and is able to protect small areas of steel that may become exposed when mechanically damaged. Hot-dip galvanizing is the most effective method for delivering long-term barrier and cathodic protection.

What is the Service Life Performance?

Hot-dip galvanized coatings have a proven performance under numerous environmental conditions. Zinc coatings corrosion resistance is linearly related to the thickness of the coating, which is a function of the chemistry and thickness of the fastener material. The thicker the coating, the longer the barrier and cathodic protection delivered. Galvanized coatings are much thicker than zinc-plated coatings and painted coatings offer only barrier protection. The excellent performance of hot-dip galvanized fasteners, steel products and structures has been measured since the mid1920s. For fasteners galvanized to ASTM A 153/A 153 M (Zinc Coating [Hot-Dip] on Iron and Steel Hardware) or G 164-M 92 (Hot-Dip Galvanizing of Irregularly Shaped Articles), first maintenance will not be required for many years. Should maintenance be required to ensure extended protection in an aggressive environment, a guide is provided to help plan the scheduled maintenance. (See Figure 1 Life of Protection vs. Thickness of Zinc and Type of Atmosphere.)

involves immersion in a series of solutions. The first solution is a caustic (hot alkali) solution to remove organic contaminants. Following thorough rinsing, the fasteners are pickled in a dilute acid solution to remove scale and rust. Rinsing follows again and then the third and final cleaning step, fluxing, takes place. Fluxing removes oxides and prevents further oxides from forming prior to the actual hot-dip galvanizing. In hot-dip galvanizing, fasteners are placed

What are the Steps in the Galvanizing Process?


As with any coating system, surface preparation is the key to complete coating and long-lasting performance. Galvanizing has a built-in quality control system: the metallurgical reaction between zinc and steel will not occur unless the steel is completely clean. The cleaning process for fasteners

in a perforated metal basket and completely immersed in molten zinc. Once the metallurgical reaction is complete and the fasteners are completely coated, the zinc is drained from the basket. The basket is then spun to remove excess zinc, ensuring a smooth coating and buildup-free threads. Inspection is the final step in the sequence conducted at the galvanizers plant. With proper cleaning, inspection is simple. If the coating looks good, it is good. The metallurgical reaction has taken place and the steel fasteners are completely covered with corrosion-protecting zinc.

What Makes the Galvanized Coating a Good Choice for Fasteners?


For a variety of reasons, the hot-dip galvanizing process delivers an excellent fastener. Complete & consistent coverage the complete immersion in molten zinc ensures excellent corrosion protection for 100% of the exposed surfaces, with a consistent zinc thickness. Coating thickness hot-dip fasteners, depending upon diameter, will have from 1.7 to 3.4 (43 to 86 microns) mils of impervious zinc coating. Zinc-plated fasteners have a thin zinc coating, up to only 1 mil (25 microns). Cathodic protection unlike other barrier coatings, such as paint, zinc is a sacrificial metal and preferentially corrodes to protect the underlying steel. Bond strength hot-dip fasteners have a coating bond strength in the range of 3600 psi (24.82 MPa). The coating is extremely diffiFigure 1
Service-Life Chart for Hot-Dip Galvanized Coatings
Derived from The Zinc Coating Life Predictor (fortjava.com:8080/zclp/index.html) 75 100 125 150 175 200 300 25 50

cult to damage. Painted and zincplated coatings have a typical bond strength of only a few hundred PSI and are easily scratched and removed. Hardness hot-dip fasteners have ironzinc alloy layers in the coating that are almost
(100% Zn) 70 DPN Hardness (94% Zn 6% Fe) 179 DPN Hardness (90% Zn 10% Fe) 244 DPN Hardness (75% Zn 25% Fe) 250 DPN Hardness

Eta

Zeta

Delta

Gamma

Base Steel

159 DPN Hardness

twice as hard as the base steel itself. This abrasion resistance makes the galvanized coating difficult to damage during tightening. Zincplated fasteners have only a pure zinc layer (no alloy layers) that is one-half as hard as the base steel, making damage likely during tightening. Paints are generally very soft and easily damaged during installation.

250

3.9 mils of zinc coating is the minimum thickness for 1/4" thick structural steel, as governed by ASTM A 123-01, Standard Specification for Zinc (Hot-Dip Galvanized) Coatings on Iron and Steel Products

200

Service Life* (yrs.)

Ru

ra

150

Su
Tem

bu

rba

n
arin e rial ust

a per

te M

100

Mo
50

de

ly rate

Ind

ic Trop

al Ma

rine

0 0 1 2 3 4 5 6 7 8

Average Zinc Thickness (microns top line, mils bottom line)


*Service Life is defined as the time to 5% rusting of the steel surface

Note: 1 mil ~ 1.8 oz./ft2

Temperature range hot-dip fasteners perform well across a broad temperature range from continuous exposure in the arctic climates to the extremes of 392F (200C) in processing plants. Paintable prepared according to ASTM D 6386 (Practice for Preparation of Zinc [Hot-Dip] Galvanized Coated Iron and Steel Product and Hardware Surfaces for Painting), hot-dip coatings are successfully painted, providing long-lasting underfilm corrosion protection. Zinc-plated fasteners can similarly be painted.

Applicability hot-dip galvanizing is a factory-controlled process, independent of weather conditions. Touch-up in the field is rarely necessary. However, should field touch-up or repair of the galvanized coating be needed, zinc coatings can be repaired following the guidelines of ASTM A 780 (Practice for Repair of Damaged and Uncoated Areas of Hot-Dip Galvanized Coatings). Corner and edge protection the formation of the ironzinc metallic layers is a vertical reaction; thus, all edges and corners have at least as much zinc coating thickness as flat surfaces, providing added corrosion benefits over other types of coatings. Fasteners that are zinc-plated or painted have very little zinc or paint on the edges and corners. Corrosion typically starts on these edges and corners. Outdoor applications the thicker zinc coating on hot-dip fasteners translates into excellent performance in extreme weather and atmospheric conditions. Larger connections are most commonly hot-dip galvanized. Zinc-plated fasteners, with a thin zinc coating, are well suited to inside applications and economical for very small connections and nails, but not appropriate for performance outside.

American Galvanizers Association


6881 South Holly Circle, Suite 108 Englewood, CO 80112 800.468.7732 720.554.0900 Fax 720.554.0909 www.galvanizeit.org e-mail: aga@galvanizeit.org
2001 American Galvanizers Association. The information provided herein has been developed to provide accurate and authoritative information about after-fabrication hot-dip galvanized steel. This material provides general information only and is not intended as a substitute for competent professional examination and verification as to suitability and applicability. The provided herein is not intended as a representation or warranty on the part of the AGA. Anyone making use of this information assumes all liability arising from such use.

Hot-Dip Galvanized Fasteners


AMERICAN GALVANIZERS ASSOCIATION

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