Inspectors Course (Presentation) - 04-2012

Inspecting Hot-Dip
Galvanized Steel
American Galvanizers Association
6881 S Holly Circle Suite #108
Centennial, CO 80112
aga@galvanizeit.org
www.galvanizeit.org
1-800-HOT-SPEC
Protecting Steel for Generations
AGA Inspection Course

Designed to educate the Inspector,
Engineers and Specifiers
Topics Covered
Galvanizing Basics, a process
overview
ASTM Galvanizing Specifications
Requirements
Measurement Techniques
Rejectable Coating Defects

08/04/16
2005 American Galvanizers Association

What is Galvanizing?
Applying a
corrosion
resistant zinc
coating by
dipping
fabricated
steel into a
bath of molten
zinc.
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Why Galvanize?
Corrosion Protection
Cost Effective
Durable
Complete Coverage, inside and out
Maintenance-free Service Life
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Hot-Dip Galvanizing Process:

Surface Preparation
Surface Preparation
Degreasing
Typically an alkaline solution
Removes dirt, oil, and grease
Pickling
Sulfuric or Hydrochloric acid
Removes mill scale and
oxidation
Fluxing
Lightly acidic zinc chloride and
ammonium chloride solution
Cleans steel and provide
protective layer prior to
galvanizing
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Hot-Dip Galvanizing Process:

Galvanizing
Galvanizing Kettle
Zinc
ASTM B6 or B960
> 98 % Zn
835 o F (445 o C)
Minor Alloying
Elements
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Aluminum
Bismuth
Tin
Lead
Nickel
Post Galvanizing Operations

Quenching (optional)
Cooling
Passivation (Chromating)
Finishing
Painting
Surface Profiling
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The Galvanized Coating
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Complete Coverage
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Other Types of
Corrosion Prevention
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Paints
Weathering Steel
Stainless Steel
Aluminum
Tar/Asphalt
Oil/Grease
Polymer Coatings
Plating
Sacrificial Anodes
Impressed
Current

10
Zinc Coatings
Electroplated
Continuous Galvanized
Zinc Paint
Metallized
Mechanical Coating
Batch Hot-Dip Galvanized
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Electroplated Zinc
Coating applied by submersion in
electrolytic bath.
Coating is typically pure zinc (no
intermetallics), tightly adherent to
substrate and very ductile.
Coating thicknesses ranging up to 1 mil.
Used indoors or in mild environments.
Most commonly used on sheet and strip
or for small parts like screws and other
light fasteners.
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Continuously Galvanized Sheet

Coating applied by immersion in molten zinc.
Almost entirely unalloyed zinc making it very
ductile, most 99.8% Zn.
Continuous coating weights are affected by
steel gauge, lines speed, air knife pressure and
galvanizing bath properties.
G60 and G90 are common coating weights
(0.60 and 0.90 oz/ft2 for both sides). This is
equivalent to 0.50 and 0.75 mils of coating
thickness per side.
The coatings are thin and commonly painted or
otherwise coated for outdoor applications.
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Zinc Paint
Barrier coating applied to clean steel.
Only sometimes affords cathodic
protection.
Commonly used to repair damaged
galvanizing.
Typically does not exceed 4 mils.
Easily applied to a variety of product
types and designs; however, the coating
is typically limited to exteriors because
of the method of application.
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Metallized
Requires special equipment and training
to apply effectively.
Cathodic and barrier protection.
Can be applied in coating thicknesses
similar to hot-dip galvanized.
Coating density is less than the hot-dip
galvanized coating density.
Acceptable method of repairing hot-dip
galvanized.
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Zinc Coatings
Metallized
Batch Hot-Dip
Galvanized
Zinc Paint
Continuous
Galvanized
Electroplated
BASE STEEL SUBSTRATE
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ASTM Standards for Galvanizing

ASTM A123/A123M
Standard Specification for Zinc (Hot-Dip
Galvanized) Coatings on Iron and Steel
Products
ASTM A153/A153M
Standard Specification for Zinc Coating
(Hot-Dip) on Iron and Steel Hardware
ASTM A767/A767M
Standard Specification for Zinc-Coated
(Galvanized) Steel Bars for Concrete
Reinforcement
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Supporting ASTM Specifications

ASTM A143/A143M
Practice for Safeguarding Against
Embrittlement of Hot-Dip Galvanized
Structural Steel Products and Procedure for
Detecting Embrittlement
ASTM A384/A384M
Practice for Safeguarding Against Warpage
and Distortion During Hot-Dip Galvanizing
of Steel Assemblies
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Supporting ASTM Specifications

ASTM A385/A385M
Practice for Providing High Quality Zinc
Coatings (Hot-Dip)
ASTM A780
Practice for Repair of Damaged and Uncoated
Areas of Hot-Dip Galvanized Coatings
ASTM D6386
Practice for Preparation of Zinc (Hot-Dip
Galvanized) Coated Iron and Steel Product
and Hardware Surfaces for Painting
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Other Galvanizing Standards

CAN/CSA-G164-M92 (R2003)
Hot Dip Galvanizing of Irregularly
Shaped Articles
ISO 1461:2009
Hot dip galvanized coatings on
fabricated iron and steel articles
Specifications and test methods
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Application of Zinc onto Steel

Most commonly specified batch hotdip coating type is ASTM A123.
Covers many designs and product
types.
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ASTM A123
Products: Structural Steel and
Plate; Strip and Bar; Pipe and
Tubing; Wire; Reinforcing Bar
Both Single Parts and Assemblies
Assemblies can be made of several
product types, encompassing many
different material categories and
minimum required coating grades.
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Assembly with Multiple Coating

Thickness Requirements
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Materials & Manufacturing

Design and fabrication are
responsibility of designer and
fabricator
A143, A384 and A385 provide
guidance
Castings shall be properly heattreated as in ASTM A47
Zinc Per ASTM B6 or B960 with
additives allowed up to 2% of total
metal
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ASTM A123 Requirements

Coating Thickness material category
and steel thickness
Finish continuous, smooth, uniform
Appearance free from uncoated areas,
blisters, flux deposits and gross dross
inclusions
No heavy zinc deposits that interfere with
intended use.
Adherence should be tightly adherent

through all expected uses of article
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Coating Thickness
Coating thickness grade is microns
25 microns is 1 mil
Coating thickness is by material type
and thickness, even on assemblies
Minimum but no maximum
Thicker coatings can be requested by
the purchaser
Structural tubing is still tubing
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Coating Thickness: ASTM A123

All Specimens Tested
Steel Thickness Range (Measured), in. (mm)
Material Category
<1/16 (<1.6)
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1/16
to <1/8 (1.6 to <3.2)
1/8
to 3/16 (3.2 to 4.8)
>3/16 to <1/4 (>4.8 to

<6.4)
1/4 (6.4)
Structural Shapes and

Plate
45
65
75
75
100
Strip and Bar
45
65
75
75
100
Pipe and Tubing
45
45
75
75
75
Wire
35
50
60
65
80
Reinforcing Bar
...
...
...
...
100

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Coating Thickness Conversion
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ASTM A123: Table 1 and Table 2

Example: 1/16 thick steel bar
Coating Grade
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Finish
Continuous no breaks or holes in the
coating
Reasonably Smooth relative term, minor
roughness that does not interfere with the
intended use or roughness that is related to
the received condition of the steel is
acceptable
Uniform as the steel chemistry and
section thickness permits
Intended Use the finish of the coating will
not interfere with its intended use.
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Intended Use
The galvanized coating should not
have surface imperfections that
would impair or interfere with the
intended use of that product.
Imperfections can include lumps,
projections, globules, or heavy
deposits of zinc.
Handrails
Moving Parts
Articles to be painted after galvanization
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Appearance
Upon shipment to the customer,
galvanized articles should be free from:
Uncoated Areas
Blisters
Flux Deposits
Gross Dross Inclusion
Excess zinc that interferes with the
intended use of the product
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Appearance
Conditions allowed
Dull coating
Chain, wire marks
Small holes < inch, filled with zinc
Both bright and dull coating
Skimmings on surface
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Adherence
The zinc coating will withstand
handling consistent with the nature
and thickness of the coating and
normal use of the article without
peeling or flaking
In general the zinc coating applied to
article covered by this specification
are too heavy to permit severe
bending without peeling or flaking.
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Special Instructions
Should be stated on the purchase
order.
Examples:
Not Quenching if Painting
Removing Tough Surface
Contaminant by Grinding
Any Special Requests Agreed Upon
by Both Parties
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Galvanizers Responsibility
It is the responsibility of the galvanizer to
ensure compliance with this specification.
The material shall be inspected at the
galvanizers plant prior to shipment.
Materials rejected for reasons other than
embrittlement may be repaired according
to ASTM A780 or stripped, regalvanized,
and resubmitted for conformity to this
specification.
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ASTM A153: Hardware

Applies to hardware items that will
be centrifuged, spun or otherwise
handled to remove excessive free
zinc.
Castings
Rolled, Pressed and Forged Articles
Fasteners
Miscellaneous Threaded Objects
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Materials & Manufacture

Zinc metal per ASTM B6 or B960
Material weight or coating thickness per
material class and material thickness in
Table 1
No post-galvanizing machining on
threads unless authorized by the
purchaser
Bare spots after galvanizing can be
repaired per ASTM A780
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A153 Requirements
Coating Thickness/Weight
Threaded Articles areas with threads
are not subject to the coating thickness
requirement
Finish and Appearance
Embrittlement high tensile strength
fasteners and castings can be subject to
embrittlement
Adherence
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ASTM A153 Table 1:

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Threaded Articles
The zinc coating on threads should
not be cut, rolled, or subject to
finishing tool operations.
In order to meet overtapping
allowances, tapped holes or the
tapping of the threads of nuts after
galvanizing is permitted.
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Upon shipment to the customer,
galvanized articles should be free
from:
Uncoated Areas
Blisters
Flux Deposits
Gross Dross Inclusion
Excess zinc that interferes with the
intended use of the product
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Embrittlement
Can be caused by cold working,
degree depends on these factors:
Steel type (strength level, aging
characteristics)
Thickness
Amount of cold working
Galvanizing process
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High Quality Coatings

Select steel composition to ensure
a high quality coating:
Carbon < 0.25 %
Phosphorus < 0.04 %
Manganese < 1.3 %
Silicon < 0.03 % or
0.15 % < Silicon < 0.22 %
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Adherence
Coating should adhere tightly to
the steel throughout all reasonable
activities.
If articles covered by galvanized
coatings are bent or fabricated to
such a degree that flaking or
cracking occurs, this is not a
cause for rejection.
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Single Product Spec, ASTM A767

ASTM A123 and ASTM A153
describes a hot-dip galvanizing
process that applies zinc to a
variety of different steel products.
ASTM A767 is a specification that
describes only one unique
product; reinforcing steel (rebar).
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ASTM A767
Standard specifically for steel
reinforcement, smooth or deformed.
Includes a chromate quench step to
prevent a reaction between the
galvanized bars and fresh Portland
cement.
Does not include reinforcing wires.
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A767 Requirements
Identity The galvanizer is responsible for
consistent material tracking if necessary.
Coating Thickness
Chromating To prevent reaction between
Portland Cement and recently galvanized
material.
Finish and Adherence
Bend Diameters Flaking and cracking
due to fabrication are not rejectable.
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Identity
The galvanizer is responsible for
maintaining the identity of the
rebar through the galvanizing
process.
Direct shipment to the job-site may
be necessary and identity must be
preserved during this shipment.
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A767: Table 1
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Chromating
All galvanized rebar is required to
be chromate treated.
Chromate solution must be 0.2%
Common practice is to take
exception to this specification
requirement.
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Finish
No bare spots
Free of blisters, flux spots or
inclusions, dross and acid or black
spots.
Bars that stick together will be
rejected.
Tears or sharp spikes which make
the bars hazardous to handle are
cause for rejection
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Adherence
The coating shall be adherent so it
cannot be removed by any
reasonable process of handling or
erection.
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A767: Table 2
Minimum Finished Bend Diameters
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Bending
Damage done to the coating when
bending is done after galvanizing is
not a cause for rejection and may be
repaired.
Cracking
Flaking
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Inspection Techniques
Magnetic Coating Gauges
Optical Microscopy
Weigh-Galvanize-Weigh
Weigh-Strip-Weigh

Visual Inspection
Adherence
Stout Knife
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Inspection Techniques
Embrittlement
Similar Bend Radius
Sharp Blow
Steel Angle
Chromating
Spot test
Bending
Table
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Verifying Coating Thickness/Weight:

Measurement Techniques
Coating Thickness
Magnetic
Thickness
Gauges
Coating Weight
Weigh-GalvanizeWeigh
Non-destructive
Non-destructive
Optical
Microscopy
Destructive
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Weigh-StripWeigh
Destructive

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Magnetic Thickness Gauges

Pull-Off Gauge
Pencil style
Spring-loaded magnet
Difficult to read
Approximate Readings
Portability
Older method
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Magnetic Balance
Gauge
Banana style
Spring-loaded
magnet and dial
gauge
Accuracy 10%
Flat surfaces only
Frequent
calibration
Still Used
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Electronic Gauge
Many Styles
Temperature
compensated
magnetic
transducer
Battery powered
Accuracy 5%
Easy to read
Most common
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ASTM E376
Measuring Coating Thickness by Magnetic-Field or
Eddy-Current (Electromagnetic) Examination Methods
Measurements on large articles

should be made at least 4 inches
from the edge to avoid edge effects.
Measurement readings should be as
widely dispersed as possible.
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Reducing Error when using

Magnetic Gauge Instruments
Recalibrate frequently, using non-magnetic
film standards or shims.
Readings should not be taken near an edge,
hole or inside corner.
Readings taken on curved surfaces should
be avoided if possible.
Test points should be on regular areas of
the coating.
Take at least five readings to obtain a good,
true value which is representative of the
whole sample.
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Calibration Pointers
Magnetic thickness gauges must
be properly calibrated for accurate
readings.
Calibration is done using nonmagnetic standards of known
thicknesses.
Known standards of both above and
below the expected thickness values
should be used for calibration.
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Making Magnetic
Thickness Measurements
A minimum of five values should be
taken for each specimen.
The average of these specimen
values should not be less than one
thickness grade lower than the
required coating thickness given by
the standard.
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Coating Thickness Measurement

Optical Microscopy, ASTM B487
Destructive Technique
Cut and Cross-section
Piece of Coated Steel
Use Calibrated
Eyepiece
Five Sections Must Be
Measured for Each
Sample
Accuracy Dependent
on Methods and
Operator Skill.
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Coating Weight Measurement:

Weigh-Galvanize-Weigh
Step1: Weight After
Cleaning (pre-galvanize)
Step2: Weight After
Cooling (post-galvanize)
Determine Surface Area
for Coating Thickness
Calculation
Method Does NOT
Account for Reacted Iron
Underestimates Coating
Weight by up to 10%
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Coating Weight Measurement

Weighing-Strip-Weigh, ASTM A90
Destructive Technique
for Large Groups of
Parts
Weigh Parts, Then
Strip Coating, Finally
Weigh Again
Coating Contains Iron
and Zinc
Accurate to Within
10%
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Inspecting Finish
Visual Inspection
Unmagnified or naked eye
Observe surface conditions, both
inside and out of fabrication (tubes)
Check contact points, i.e. welds,
junctions, bent areas
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Inspecting Appearance
Visual Inspection
Unmagnified or naked eye
Observe surface conditions, both
inside and out of fabrication (tubes)
Check contact points, i.e. welds,
junctions, bent areas
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Bare Spots
- Not Acceptable
Inadequate Surface
Preparation
Welding Slag
Sand Embedded in
Castings
Excess Aluminum in
Zinc Bath
Articles in Contact
Chain and Wire
Marks
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Bare Spots
- Not Acceptable
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72
Uncoated Areas
- Not Acceptable
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Flux Inclusions
- Not Acceptable
Wet
Galvanizing
Cause Bare
Spots
Surface Defect
Clean and
Repair
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Skimmings on Surface
- Acceptable
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Skimmings versus Flux

Skimmings
Flux
Galvanized
Aesthetic Defect
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Ungalvanized
Rejectable Defect

76
Welding Spatter
- Not Acceptable
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Sand Embedded in Castings

- Not Acceptable
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Inspecting Appearance
Prefabricated Holes
Holes 1/2 inch or larger should be clean
and with minimal zinc deposit.
Marks from Handling Equipment

Marks left by handling equipment are not
cause for rejection, unless these marks
have exposed the base steel metal.
Pieces should be handled and
positioned appropriately during cooling
to prevent the freezing together of
articles.
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Chain and Wire Marks

- Possibly Acceptable
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80
Drainage Spikes
- Not Acceptable
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81
Clogged Threads
- Not Acceptable
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82
Clogged Holes
- Acceptable
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83
Oxide Lines
- Acceptable
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84
Touch Marks
- Not Acceptable
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85
Articles in Contact
- Not Acceptable
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Surface Contaminants
- Not Acceptable
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87
Fish Boning
- Acceptable
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Excess Aluminum in Bath

- Not Acceptable
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Delamination
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Flaking / Delamination
- Not Acceptable
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Dross
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Dross Inclusions
- Acceptable
Small Pimples in
Coating
Iron/Zinc Particles
Large Dross
Particles Removed
and Repaired
Small Dross
Inclusions Allowed
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Striations
- Acceptable
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Striations
- Acceptable
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Blasting Damage
- Acceptable
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Bleeding
- Acceptable
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Bleeding
- Acceptable
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Bleeding
- Acceptable
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99
Weeping Welds
Incomplete welds and unsealed
areas less than 3/32 can entrap
cleaning solutions that will bleed
out staining to surrounding areas.
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Rough Surfaces
Galvanizing will show the surface
conditions of the underlying steel.
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Rough Surface
- Acceptable
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102
Steel Surface Condition

- Acceptable
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103
Runs
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104
Blowouts
- Not Acceptable
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105
Distortion
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106
Wet Storage Stain

- Not Acceptable
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107
Wet Storage Stain

- Not Acceptable
Voluminous, white,
powdery corrosion
products resulting
from improper
material handling
and storage
practices.
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Wet Storage Stain

Susceptible Environments
Humid
Stagnant
Waterfront
Marine
Industrial
Outdoor storage
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Wet Storage Stain

Susceptible Products
Newly Galvanized Material
Tightly packed articles
Poorly ventilated
Stacked articles like sheet, plates,
angles, bar and pipe
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Wet Storage Stain

Prevention
Galvanized items should be clean and
free of flux.
Items should be stored under cover in
dry, well ventilated areas.
If stacking is unavoidable, articles
should be raised from the ground and
separated with strip spacers to provide
free moving air to all surfaces.
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Wet Storage Stain

Impact on Coating Life
Light
Medium
Heavy
Typically only scenarios of heavy wet

storage stain produce appreciable
zinc loss that can negatively affect
coating performance.
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Wet Storage Stain, Light

- Acceptable
Mild, light staining
in most cases does
not need to be
cleaned and will
weather naturally to
match unaffected
areas.
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Wet Storage Stain, Medium

- Acceptable
Most parts with a
medium layer of
wet storage stain
can be cleaned
and then put into
service.
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Wet Storage Stain, Heavy

- Not Acceptable
Some parts with
heavy wet storage
staining can be
cleaned, but most
must be stripped
and regalvanized
before being put
into service.
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Wet Storage Stain

Unpreventable Situations
In certain environments during
seasons of extreme humidity and
rainfall, wet storage staining is
unavoidable.
Most light storage staining will
weather to be indistinguishable from
unaffected areas.
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Wet Storage Stain

Natural Weathering
When an galvanized metal subject to
wet storage stain is placed into
service, exposure to free flowing air
as well as wetting and drying cycle
will produce a layer of zinc carbonate
known as the zinc patina.
Formation of the zinc patina produces
a coating that is uniform in
appearance.
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Wet Storage Stain
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Weathered Wet Storage Stain
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Wet Storage Staining

Galvanizers Responsibility
Responsible for proper storage while
on his lot.
Purchasers Responsibility
Responsible for proper storage once
the material has left the galvanizers
lot.
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Visual Inspection: Shiny vs. Dull

- Acceptable
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121
Dull and Shiny

- Acceptable
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122
Gray Coatings
- Acceptable
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123
Gray Coatings
- Acceptable
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Gray Coatings
- Acceptable
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Grey Coatings
- Acceptable
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126
Reasons for Different Appearances

Smooth versus
Rough
Shiny versus Dull
Steel Chemistry Silicon and
Phosphorus
Accelerated
Coating Growth
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127
Silicons Influence on Galvanizing

Can the coating get too thick?
What are the negatives of
excessively thick coating?
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Reactive Steel Micrograph
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129
Accelerated Growth
Typical Zinc-Iron
Alloy Layers
Irregular Zinc-Iron
Alloy Layers
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130
Two regions
of increased
coating weight
due to % mass
Silicon
(relative)
Coating Thickness: The Sandelin Curve
Phosphorus
adds to
Silicon Effects
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Phosphorus
Castings and
Cold-rolled/ColdWorked Materials
Impurity in Steel
2 Effects Typical:
Gray Areas
Striations
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Testing Adherence:
Stout Knife Test
Adhesion test
Stout knife
Push down point of
stout knife
Not at edges or
corners
Coating must not
flake off
No paring or
whittling with knife
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Inspecting Embrittlement
Parts suspected of embrittlement
shall be tested per ASTM A143.
Similar Bend Radius
Sharp Blow
Steel Angle
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Chromating
The presence of hexavalent
chromium on galvanized surfaces
is determined by spot testing using
ASTM Practice B201
The test involved dropping lead
acetate on the surface, waiting 5
seconds, and blotting it gently.
The presence of a dark deposit or
black stain is a negative test.
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Sampling
100% inspection of every galvanized
article is time consuming.
Sampling protocol has been outlined
in the ASTM specifications.
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Sampling: Key Words

Lot unit of production or shipment from
which a sample is taken for testing.
Sample A collection of individual units of
product from a single lot.
Test Article an individual unit of product
that is a member of the sample.
Specimen the surface of an individual test
article or a portion of a test article which is
a member of a lot or a member of a sample
representing that lot.
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Sampling
160 in2 (100,000 mm2)

Randomly selected test articles to be
used as individual specimens
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Sampling
> 160 in2 (100,000 mm2)

Each sample is divided into three
specimens
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Minimum Number of Specimens

For both ASTM
A123 and A153
the following
table is used to
select the
minimum # of
specimens to be
selected for
sampling from a
given lot size:
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# of Pieces
in Lot
# of
Specimens
3 or less
All
4 to 500
501 to 1200
1201 to 3200
3201 to 10,000
13
10,001+
20

140
ASTM A767: Number of Tests

Magnetic Thickness
3 Samples per lot
5 Or more
measurements
per sample
15 Measurements,
at the minimum,
comprise the
average
08/04/16
Stripping and Weighing

3 Samples per lot
Microscopy Method
5 Samples per lot
4 Measurements per
sample
20 Measurements, at
minimum, comprise
the average

141
Galvanized Coating
Inspection Results
Acceptance
Meet all the specifications requirements.
Repair
Meets most of the specifications
requirements. Unacceptable areas can be
repaired per the specification.
Rejection
Defect areas are too large or are inaccessible
to repair. May be stripped, regalvanized, and
resubmitted for inspection.
08/04/16

142
Non-conformities in
the Galvanized Coating?
If inspection turns up nonconforming areas in the coating,
the piece may be rejected.
Rejected articles may be repaired
in two ways:
In plant production repair
Damage on-site repair
08/04/16

143
In Plant Production Repairs

Area of repair is significant:
ASTM A123
One inch or less in narrowest dimension.
Total Area can be no more than of 1 % percent of the
accessible area to be coated or 36 in.2 per short ton per piece,
whichever is less.
ASTM A153
The bare spots shall have an area totaling not more than 1 %
of the surface area to be coated excluding threaded areas of
the piece.
ASTM A767
Total area in any 1 ft. length shall not exceed 1%
08/04/16

144
Renovation Thickness
Thickness of Renovation The
coating thickness of the repaired area
must match the coating thickness of
the surrounding area.
Exception Renovation done with
Zinc Paints will be 50 % higher than
required by Table 1, but not greater
than 4.0 mils
08/04/16

145
ASTM A767 Touch-up & Repair

If the coating fails to meet the
requirement for finish and adherence,
the bar may be stripped, regalvanized,
and resubmitted.
Damage done to the coating due to
fabrication or handling shall be repaired
with a zinc-rich formulation per ASTM
A780
Sheared ends shall be coated with a
zinc-rich formulation per ASTM A780.
08/04/16

146
ASTM A780
Repair of Damaged and Uncoated Areas of
Hot-Dip Galvanized Coatings
Types of Material Acceptable for Repair

Shall Provide Barrier Protection and
Preferably Anodic to Steel
One Application of the Material 2mils
Follow manufacturers directions
Possible in Shop or Field

08/04/16

147
Acceptable Repair Methods

Zinc-Based Solders
Zinc-Rich Paints
Zinc Spray (Metallizing)
08/04/16

148
Zinc-Based Solders
Zinc-Cadmium, Zinc-Copper-Tin,
Zinc-Tin-Lead
Surface Preparation
Application
Performance
08/04/16

149
Zinc Paints
Must contain between 65% and
69% zinc by weight or greater than
92% metallic zinc in dry film.
150% of the thickness specified in
ASTM A123 Table 1 for the
appropriate material category, but
not more than 4 mils.
08/04/16

150
Zinc Spray (Metallizing)

This coating is the most similar to
the galvanized coating in
appearance and composition (but
not microstructure).
Cost is higher.
More difficult to apply, requires a
trained worker.
08/04/16

151
In Summary
Galvanized steel is steel with a
corrosion protection coating
formed by the reaction between
steel and molten zinc.
The requirements for galvanizing
are outlined by ASTM A123 for
structural steel products, ASTM
A153 for hardware, and ASTM A767
for steel reinforcement.
08/04/16

152
References
ASTM Specifications
www.galvanizeit.org
08/04/16

153
Questions and comments
08/04/16

154

Inspectors Course (Presentation) - 04-2012

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Inspecting Hot-Dip

Protecting Steel for Generations

AGA Inspection Course

Rejectable Coating Defects

2005 American Galvanizers Association

2005 American Galvanizers Association

2005 American Galvanizers Association

Hot-Dip Galvanizing Process:

2005 American Galvanizers Association

Hot-Dip Galvanizing Process:

Post Galvanizing Operations

2005 American Galvanizers Association

The Galvanized Coating

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2005 American Galvanizers Association

2005 American Galvanizers Association

2005 American Galvanizers Association

2005 American Galvanizers Association

Continuously Galvanized Sheet

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2005 American Galvanizers Association

2005 American Galvanizers Association

BASE STEEL SUBSTRATE

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ASTM Standards for Galvanizing

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Supporting ASTM Specifications

2011 American Galvanizers Association

Supporting ASTM Specifications

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Other Galvanizing Standards

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Application of Zinc onto Steel

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2005 American Galvanizers Association

Assembly with Multiple Coating

2005 American Galvanizers Association

Materials & Manufacturing

2011 American Galvanizers Association

ASTM A123 Requirements

Adherence should be tightly adherent

2005 American Galvanizers Association

2005 American Galvanizers Association

Coating Thickness: ASTM A123

to <1/8 (1.6 to <3.2)

to 3/16 (3.2 to 4.8)

>3/16 to <1/4 (>4.8 to

Structural Shapes and

Strip and Bar

Pipe and Tubing

2011 American Galvanizers Association

Coating Thickness Conversion

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ASTM A123: Table 1 and Table 2

2005 American Galvanizers Association

2005 American Galvanizers Association

2005 American Galvanizers Association

2005 American Galvanizers Association

2005 American Galvanizers Association

2005 American Galvanizers Association

2005 American Galvanizers Association

2011 American Galvanizers Association