Hot Dip Galvanizing Distortion

If steel fabrications distort throughout galvanizing, it is all because of ‘built-in’ stresses being discharged. At that time, the steel is heated to the galvanizing temperature. Steel tends to suffer from stresses on its own, but stresses can also be introduced by cold forming, welding, and hole punching. 

What is galvanization and its associated risks? 

When it is decided to hot-dip galvanize, it is the responsibility of a design engineer to ensure that all the pieces can be appropriately fabricated for the best quality galvanizing. An engineer should adopt the best practices, which recommend that the steel to be galvanized should have similar thickness and symmetry. 

During the process of hot-dip galvanization, steel progresses via a temperature cycle while immersing and withdrawing from the bath. It is due to the fact that parts are dipped at an angle, it gives rise to uneven heating and a temperature profile along that part, which is being galvanized. These stresses may show a change in shape and/or alignment that is defined as distortion or warping. 

How to stop distortion like risks? 

With some precautions, Hot Dip Galvanization Distortion can be reduced, these are:

  • Use parts in an arrangement of equal or similar thickness, particularly at joints. 
  • Try to use symmetrically rolled sections as compared to channel or angle frames, wherever possible. I-beams are the best option. 
  • Include reinforcing or temporary bracing on asymmetrical and thin-walled designs. 
  • Do not use those designs that need progressive dip galvanizing. This way, it will help to build assemblies and subassemblies in appropriate modules. Using this procedure, they can be dipped quickly and galvanized under a single dip. It leads to the expansion of the entire fabrication in a uniform manner. In any case, if a progressive drip is needed, you must consult your galvanizer. 
  • Bend members to the biggest adequate radii to reduce local stress concentration. 
  • Pre-build members of an assembly in an accurate manner. This way, you eliminate the need for forcing, springing or bending them to position while joining. 
  • Adopt a balanced welding procedure to stabilize stresses so that distortion can be stopped or avoided.

A Safe & Cost Effective Alternative to Hot Dip Galvanizing 

If the hot dip galvanising method is a problem for you due to delays, logistics, cost etc you now have a choice. There are service providers, which can provide protection to traditional galvanizing with no need for topcoats. This process is called the Film Galvanising System as pioneered over 40 years ago by Belgian company ZINGA.

ZINGA provides active/galvanic/cathodic protection. Film Galvanising can be done in house at your own plant or even out on site. More information about the film galvanising system is available on www.zinga.ie

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