Standard Procedure

HOT DIP GALVANIZING

Jl. Kapt. Subijanto Dj.

German Centre 3rd Floor – Suite 3300
BSD – Tangerang
INDONESIA
Tel: +62 (0) 21 5315-9154/9155
Fax: +62 (0) 21 5315-9153
e-mail: austrindo@zinkpower.com
company profile: www.zinkpower.com
 Table of Content
1 Preparation of Goods 3
1.1 Paints, Protective Coatings, Welding Slag……............................ 3
1.2 Ventilation ................................................................................... 3
2 Incoming Control 3
2.1 Unloading ................................................................................... 3
2.2 Completeness of delivery ........................................................... 3
2.3 Marking of materials ................................................................... 3
2.4 Compliance of materials.............................................................. 3
3 Preparation 4
4 Pre treatment 4
4.1 Stage 1 – Washing of materials ................................................. 4
4.2 Stage 2 – Surface treatment....................................................... 4
4.3 Stage 3 – Fluxing ....................................................................... 4
5 Hot Dip Galvanizing 5
6 Quenching 5
7 Take off and final inspection 6
7.1 Taking down of materials ........................................................... 6
7.2 Sorting and finishing touch ......................................................... 6
8 Quality, outgoing control and invoicing 6
8.1 Quality control ............................................................................ 6
8.2 Weighing .................................................................................... 6
8.3 Invoicing...................................................................................... 7
9 Process Documentation 7
9.1 Materials Received ..................................................................... 7
9.2 Material Inspection....................................................................... 7
9.3 Material Identification TAG .......................................................... 7
9.4 Dipping Report ............................................................................ 7
9.5 Galvanizing Report....................................................................... 7
9.6 Outgoing Materials Report .......................................................... 7
9.7 Delivery Note / Surat Jalan.......................................................... 7
10 Flow Chart 8
11 Attachments 8
11.1 ASTM A123 Standard for Hot Dip Galvanizing
11.2 EN ISO 1461 Standard for Hot Dip Galvanizing
11.3 Material Data Sheets 1 to 4 about Sodium Dichromate

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Jl. Kapt. Subijanto Dj. German Centre 3 – Suite 3300 BSD – Tangerang 15321, Indonesia
Fax: +62 (0) 21 5315 9153; e-mail: austrindo@zinkpower.com ; profile: www.zinkpower.com
1 Preparation of Goods
It is important that the materials, such as steel structures, pipes, gratings, pipe spools,
handrails, flanges, elbows, etc. (nuts & bolts are not processed in our plant) are being
prepared for galvanizing in a proper manner to fit our kettle size 10 meters long x 1,5
meters wide x 3 meters deep:

1.1 Paints, Protective Coatings, Welding Slag

All paint, paint marks, varnish or other protective coating has to be removed prior to
sending materials for galvanizing.
Please note that lacquer or oil paint marks also need to be removed, while calk marks are
no problem and will dissolve during pretreatment.
Also welding slag has to be removed completely to avoid blank galvanizing surfaces.
All surfaces must be clean, (eg: free of paint, varnish or other protective coating, clean of
welding slag, splatter, etc.) prior to being delivered to the galvanizer!

1.2 Ventilation
All structures, especially pipes need proper ventilation! The larger the ventilation the
better. As a rule of thumb you may say that pipes below 1” should have at least 8mm if
not 12mm holes, pipes above 1” should have at least 12mm holes!
But not only pipes and profile need ventilation also H-Beam, U-Beam and C-Channel
structures need ventilation openings where zinc might not run off.
If you are not sure contact us prior to delivery or production and we will gladly assist your
Team to prepare properly.

2 Incoming Control
Upon arrival of materials we will check:
2.1 Unloading
The delivered goods are unloaded with forklifts or cranes (whatever suits best).

2.2 Completeness of delivery

We check in accordance with Delivery Note provided by the forwarder and/or sent prior
by the customer the completeness of the delivery.

2.3 Marking of materials

Right away the received materials will receive a tag identifying the client, delivery date
and time and if available the project name.

2.4 Compliance of materials

We then survey the materials whether they are in compliance with galvanizing
requirements as mentioned in EN ISO 1461 annex A and C.1 as well as ASTM A123
chapter 3 and 4.
If some materials fail to comply we will notify the client to clarify next steps to remedy the
situation.

Page 3 of 8
Jl. Kapt. Subijanto Dj. German Centre 3rd – Suite 3300 BSD – Tangerang 15321, Indonesia
Fax: +62 (0) 21 5315 9153; e-mail: austrindo@zinkpower.com ; profile: www.zinkpower.com
3 Preparation
Once the incoming inspection is complete and the material in compliance with EN ISO
1461 and/or ASTM A123 requirements they will be attached to a jig, girder or placed in
racks by hand or utilizing forklifts or cranes (whichever suits best) and lifted with cranes
to the treatment section.

4 Pre treatment
Proper and right pre treatment is crucial for successful galvanizing, since only clean and
well prepared surfaces will allow for the zinc to form the desired metallurgical bond.
Painted, marked or other wise coated surfaces (see also point 1 Preparation of Goods)
will not be properly covered!

4.1 Stage 1 – Washing of materials

First the materials are being dipped into caustic soda where grime, oil, grease, calk
markings and other dirt is being removed.
Please note: paints, paint marks or other protective coatings are NOT being removed!

4.2 Stage 2 – Surface treatment

After rinsing with water the materials are dipped into HCL (hydrochloric acid) where it is
maintained until all rust and mill scales are removed and the surface is in accordance
with EN ISO 1461 and/or ASTM A123 requirements.
Treatment times may vary from a few minutes up to an hour depending on the surface
condition of the materials.

4.3 Stage 3 – Fluxing

After rinsing in water the materials are now dipped into flux. The flux provides a coat
which will burn of during dipping, thus providing the final surface cleaning during dipping
process and therefore ensuring the desired metallurgical reaction between steel and zinc.
5 Hot Dip Galvanizing
The pretreated and dried materials are now being dipped as fast as possible into molten
zinc.
Upon immersion the steel reacts with the zinc and exchanges particles 24 zinc particles
to 1 steel particle thus forming the desired metallurgical bond.
The materials then remain within the zinc bath until the required coating thickness in
accordance with EN ISO 1461 and/or ASTM A123 standards are reached (main indicator
is when the cooking – bubbling – process stops).

6 Quenching
When the material allows it, it will be cooled inside the quench tank which is filled with
water that also removes some ash residue. Please note that certain structures can not be
quenched in order to avoid undesirable distortions.

6.1 Sodium Dicromate / Sodium Bicromate

Since it is only providing a temporary cosmetic surface protection by inhibiting or delaying
the required reaction of the zinc with CO² in the atmosphere we are NOT using Sodium
Dicromate / Sodium Bicromate or similar products!

Not only would such solutions base a threat to our staff (highly toxic) but also to the
environment and the people living near by especially considering that no proper waste
water disposal facilities are available (only concentrations below 5 mg/m³ are considered
harmless while fumes, consumption and direct contact are considered highly toxic)!

Please also see attached material data sheets: Attachment 11.3 – 1 to 4

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Jl. Kapt. Subijanto Dj. German Centre 3rd – Suite 3300 BSD – Tangerang 15321, Indonesia
Fax: +62 (0) 21 5315 9153; e-mail: austrindo@zinkpower.com ; profile: www.zinkpower.com
7 Take off and final inspection
Once the galvanizing process is finished we take off the materials and do the final
inspection:

7.1 Taking down of materials

Some materials require to be taken down right away and to be placed on a straight
surface to avoid distortions but most can be quenched and taken down immediately when
finished.

7.2 Sorting and finishing touch

After being taken down the materials are sorted (per truck delivered or as requested by
customer) and zinc tips removed.
Please note that we do NOT allow any grinders for the final touching, but only use hand-
file as allowed and specified in EN ISO 1461 and ASTM A123.
Bare spots are treated in strict compliance with EN ISO 1461 and ASTM
A123.

8 Quality, outgoing control and invoicing

Quality inspection and outgoing control is of utmost importance to ensure overall
compliance and customer satisfaction:

8.1 Quality control

Our independent (in house) inspectors are checking ALL galvanized materials to ensure
that minimum EN ISO 1461 and ASTM A123 standards are always met.
For thickness testing we use a “FISCHER DELTASCOPE MP30E” thickness
tester.
Valid calibration certification for both the thickness tester and the calibration standards for
the thickness tester are available upon request.
In case of shortcomings the materials is sent back to the proper procedures for either
additional touch-up or regalvanizing.

8.2 Weighing
When everything is in compliance the finished white material is then weight and the result
sent on for further processing (scale calibration record is available on request).

8.3 Invoicing
Once the galvanizing report is completed, quality control and weighing passed the
customer will be informed and the invoice issued.

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Jl. Kapt. Subijanto Dj. German Centre 3rd – Suite 3300 BSD – Tangerang 15321, Indonesia
Fax: +62 (0) 21 5315 9153; e-mail: austrindo@zinkpower.com ; profile: www.zinkpower.com
9 Process Documentation
To ensure our quality and overall compliance we have a thorough internal documentation
system:

9.1 Materials Received

Includes: Customer Name; Project Name; Material description, Weight and Contract/PO
number.

9.2 Material Inspection

Filed in case material is not in conformity with EN ISO 1461 or ASTM A123 and used to
inform the customer (used prior or after galvanizing whenever applicable).

9.3 Material Identification TAG

All received materials receive a ID TAG stating Customer; Project; date & time of arrival.

9.4 Dipping Report

Every dip, incl. all important parameters, is recorded.

9.5 Galvanizing Report

Once the material is taken down and inspected a Galvanizing Report is filed and
includes: Customer; Project; Contract/PO Number; Weight and Delivery Details.

9.6 Outgoing Materials Report

Registers the outgoing material and should be in conformity with 9.1 Materials Received
report.

9.7 Delivery Note / Surat Jalan

Required for any material, goods or tools that leave our premises.

Page 7 of 8
Jl. Kapt. Subijanto Dj. German Centre 3rd – Suite 3300 BSD – Tangerang 15321, Indonesia
Fax: +62 (0) 21 5315 9153; e-mail: austrindo@zinkpower.com ; profile: www.zinkpower.com
10 Flow Chart

11 Attachments
1. 11.1 ASTM A123 Standard for Hot Dip Galvanizing
2. 11.2 EN ISO 1461 Standard for Hot Dip Galvanizing
3. 11.3 Material Data Sheets 1 to 4 about Sodium Dichromate

Page 8 of 8
rd
Jl. Kapt. Subijanto Dj. German Centre 3 – Suite 3300 BSD – Tangerang 15321, Indonesia
Fax: +62 (0) 21 5315 9153; e-mail: austrindo@zinkpower.com ; profile: www.zinkpower.com