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Facts about Zinc

Zinc has a self-healing mechanism in it. The zinc coating sacrifices itself slowly by galvanic action to protect the base steel. This sacrificial action continues as long as any zinc remains in the immediate area.

Zinc melts at 787 F (420 C), and boils at 1,665 F (907 C). Zinc comprises an estimated 0.004 percent of the Earth's crust. Zinc ranks 25th in order of material abundance in the earth. Zinc is essential for the growth and development of almost all life: between 1.4 and 2.3 grams of zinc are to be found in the average, healthy adult. Zinc is found everywhere in daily life: in every cell of the human body, in the earth, in the food we eat and in products we use (sun-block, automobiles, cosmetics, airplanes, appliances, surgical tools, zinc lozenges) Children need zinc for growth. Adults need zinc for reproduction and good health. The U.S. Recommended Daily Allowance is 15 milligrams of zinc. Zinc is 100 percent recyclable. Over 80 percent of the zinc available for recycling is currently recycled. More than one-third of the zinc consumed in North American is produced from recycled materials. The U.S. penny is 98 percent zinc, with a copper coating. Recently, zinc is found to enhance eyesight, preventing the onset of macular degeneration. Due to the long lifespan of most zinc-coated products like galvanized steel, which in some cases may last maintenance-free for over 100 years, much of the zinc produced in the past is still in use, constituting a valuable and sustainable resource of zinc for generations. Zinc occurs naturally in the earth, air & foods you eat; it is the second most common trace metal, after iron, naturally found in the body. Zinc is the third most used nonferrous metal (after aluminum & copper), of which the U.S. consumes more than one million metric tons annually; the average person will use 730 pounds of zinc in his or her lifetime, according to the U.S. Bureau of Mines Zinc is primarily used as a coating on iron & steel to protect against corrosion, which costs nearly $300 billion annually Zinc makes the average automobile last longer--17 pounds of zinc protect it from rust, 20 pounds are used to make zinc die-cast parts like door handles & locks, & each tire contains about 1/2 pound of zinc, needed to cure rubber. Zinc is essential to your health, boosting the immune system, helping cells to grow, regulating appetite & healing wounds; zinc lozenges can even cut short the common cold. Zinc is a natural insect repellent & sun screen, protecting lips & skin.

Zinc can store six times as much energy per pound as other battery systems, increasing the range of electric vehicles; zinc-air batteries have powered cars to speeds of 120 mph. Zinc combined with copper makes brass

Zinc: Essential for Life As one of nature's essential elements, zinc is required by humans throughout their life-cycles to grow & develop. Zinc occurs naturally throughout the earth in plants & animals & the food we eat. Every cell requires zinc to multiply. Zinc is required for smell & taste & helps regulate the body's immune system. It heals & protects the skin & boosts brain activity. Zinc is essential for life. Zinc & Steel Zinc's most remarkable quality is its natural capacity to protect. By protecting steel against corrosion, zinc protects buildings, automobiles, ships & steel structures of every kind from corrosion by the atmosphere, water, & soil. By protecting against corrosion & its costly effects, zinc extends the life of steel, thus protecting investments. A typical galvanized coating can now be expected to last 70 to 150 years without maintenance in most urban & rural atmospheres. Zinc & the Environment Zinc, like all metals, is a natural component of the Earth's crust and an inherent part of our environment. Zinc is present not only in rock and soil, but also in air, water, and the biosphere - plants, animals, and humans. Zinc is constantly being transported by nature, a process called natural cycling. Rain, snow, ice, sun, and wind erode zinc-containing rocks and soil. Wind and water carry minute amounts of zinc to lakes, rivers, and the sea, where it collects as sediment or is transported further. Natural phenomena such as volcanic eruptions, forest fires, dust storms, and sea spray all contribute to the continuous cycling of zinc through nature. During the course of evolution, all living organisms have adapted to the zinc in their environment and used it for specific metabolic processes. The amount of zinc present in the natural environment varies from place to place and from season to season. For example, the amount of zinc in the earth's crust ranges between 10 and 300 mg/kg, and zinc in rivers varies from less than 10 mg/L to over 200 mg/L. Similarly, falling leaves in autumn lead to a seasonal increase in zinc levels in soil and water. Zinc & Living Organisms All living organisms need zinc. For this reason, zinc is termed an essential element.

Because the amount of zinc present in nature varies widely, living organisms have natural processes that regulate their uptake of zinc. Nevertheless, deficiency occurs when the amount of zinc available is insufficient to meet the needs of a given organism. Toxicity too can occur when an excessive amount of zinc is ingested. Zinc is essential for human health. Adequate daily intake of zinc is vital for the proper functioning of the immune system, digestion, reproduction, taste, smell and many other natural processes. Analysis of diet and nutritional needs have led researchers to estimate that a staggering 49% of the world's population is at risk from zinc deficiency. Zinc is also used in a variety of medical and pharmaceutical forms, such as bandages, cold lozenges, skin treatments, sun block creams and lotions, burn and wound treatments, baby creams, shampoo, and cosmetics. For many food crops, zinc is an essential micronutrient. Zinc deficiency in agricultural soils is common on all continents and constitutes a major problem in many parts of the world because it causes serious inefficiencies in crop production. Relatively small amounts of zinc compounds, however, can cure deficiency and last for several years before they need to be repeated. This treatment is highly cost effective when the costs of the zinc application and the value of the extra yield are considered. Zinc: Recycling Zinc brings a multitude of economic and social benefits to society. Man has found a wide range of uses for this versatile natural element whose properties are valued in many industries. The most important application of zinc is protecting steel from corrosion by hot-dip galvanizing. Steel is one of the most widely-used materials on the planet and, thanks to zinc, steel's durability can be prolonged. Both steel and zinc are 100% recyclable. The zinc-steel combination has significant economic benefits in terms of life-cyle costs. Improved air quality in many industrialized countries, with diminishing levels of sulfur dioxide (SO2), means that today zinc coatings provide even longer protection for steel. Increased attention to life-cycle costing is motivating designers, specifiers and investors to opt for zinc-coated steel in many traditional and new applications, from construction to automobiles, from electricity distribution poles to safety barriers, from farm gates to ski-lifts. Zinc, the 27th most common element in the Earth's crust, is fully recyclable. At

present, approximately 70% of the zinc produced originates from mined ores and 30% from recycled or secondary zinc. The level of recycling is increasing in step with progress in zinc production technology and zinc recycling technology .

Today, over 80% of the zinc available for recycling is recycled. Zinc is recycled at all stages of production and use - for example, from scrap that arises during the production of galvanized steel sheet, from scrap generated during manufacturing and installation processes, and from end-of-life products. The pie chart below describes the percentage of recovered zinc from various products manufactured with zinc

The life of zinc-containing products is variable and can range from 10-15 years for cars or household appliances, to over 100 years for zinc sheet used for roofing. Street lighting columns made of zinc-coated steel can remain in service for 40 years or much longer, and transmission towers for over 70 years. All these products tend to be replaced due to obsolescence, not because the zinc has ceased to protect the underlying steel. For example, zinc coated steel poles placed in the Australian outback a hundred years ago are still in excellent condition.

The presence of zinc coating on steel does not restrict steel's recyclability and all types of zinc-coated products are recyclable. Zinc coated steel is recycled along with other steel scrap during the steel production process - the zinc volatilizes and is then recovered. The supply of zinc-coated steel scrap is expected to double over the next five years, as more zinc-coated vehicles enter the recycling stream. By 2005, half of the world steel output is expected to come from electric arc furnaces (EAF). As a result, growing quantities of EAF flue dust with higher zinc contents will be treated and more recycled zinc will become available. Zinc Links www.umicore.com www.tinfosnizi.com

HDG Process
Though the process may vary slightly from plant to plant, the fundamental steps in the galvanizing process are: Soil & grease removal - A hot alkaline solution removes dirt, oil, grease, shop oil, and soluble markings. Pickling - Dilute solutions of either hydrochloric or sulfuric acid remove surface rust and mill scale to provide a chemically clean metallic surface. Fluxing - Steel is immersed in liquid flux (usually a zinc ammonium chloride solution) to remove oxides and to prevent oxidation prior to dipping into the molten zinc bath. In the dry galvanizing process, the item is separately dipped in a liquid flux bath, removed, allowed to dry, and then galvanized. In the wet galvanizing process, the flux floats atop the molten zinc and the item passes through the flux immediately prior to galvanizing. Galvanizing - The article is immersed in a bath of molten zinc at between 815-850 F (435-455 C). During galvanizing, the zinc metallurgically bonds to the steel, creating a series of highly abrasion-resistant zinc-iron alloy layers, commonly topped by a layer of impact-resistant pure zinc. Finishing - After the steel is withdrawn from the galvanizing bath, excess zinc is removed by draining, vibrating or - for small items - centrifuging. The galvanized item is then air-cooled or quenched in liquid. Inspection - Coating-thickness and surface-condition inspections complete the process. The galvanizing process has existed for more than 250 years and has been a mainstay of North American industry since the 1890s.

Galvanizing primary component is zinc. This vital substance is silvery blue-gray in color and makes up an estimated 0.004% of the earths crust and ranks 25th in order of abundance. It is essential for the growth and development of almost all life: Between 1.4 and 2.3 grams of zinc are found in the average adult, and the World Health Organization has recommended a daily intake of 15 milligrams. Numerous consumer products including cold remedies, sunscreens, diaper creams, and nutritional supplements contain beneficial amounts of zinc, primarily in the form of zinc oxide. Even though galvanized steel is blue-gray, it also is green. The zinc and galvanizing industries work to promote sustainable development by enhancing zinc's contribution to society and ensuring that its production and use are in harmony with the natural environment and the needs of society, now and in the future. Zinc, as it is used in galvanizing, is a healthy metal, completely recyclable. The energy used to smelt zinc is inversely related to the amount of zinc recycled. Galvanizing delivers incredible value in terms of protecting our infrastructure. Less steel is consumed and fewer raw materials are needed because galvanizing makes bridges, roads, buildings, etc, last longer. Over time, galvanizing helps maintain steel fabrications' structural integrity: galvanized structures are safer. Additionally, because galvanized steel requires no maintenance for decades, its use in public construction is an efficient use of our taxes. Selecting galvanized steel for private projects makes a significant contribution to a company's profitability.

A AASHTO - American Association of State Highway and Transportation Officials Abrasion-resistance - the ability of the galvanized coating to resist damage caused by contact with hard, rough, or coarse media or objects Abrasive blasting - the process of using a forceful stream of particles, available in varying hardness, to remove residue and contaminants from steel surfaces to prepare for galvanizing and/or to profile steel surfaces for paint application Adherence - the act, action, or quality of zinc bonding to steel, measured in pounds per square inch (psi) or mega pascals (MPa) Aggressive environment - an environment that is particularly corrosive

Alloy layers - the interior layers of the galvanized coating comprised of iron/zinc intermetallics formed when molten zinc reacts with iron in the steel Aluminum - element found in the galvanizing bath (added to molten zinc through a product commonly called "brightener bar") that gives the hot-dip galvanized coating a shiny appearance Aluminum-killed steel - steel treated with aluminum as an oxidizing agent in order to reduce the oxygen content to such a level that no reaction occurs between carbon and oxygen during solidification Anode - the electrode of an electrolytic cell at which corrosion (oxidation) occurs, positive current flows from the anode through the electrolyte to the cathode; with respect to hot-dip galvanizing, anode refers to zinc, which corrodes sacrificially to protect steel Anodic - exhibiting the properties of an anode; zinc is anodic to steel Application - the act of putting to use; specifically, the use to which galvanized steel will be put Ash - solid byproduct formed in the galvanizing process, consisting primarily of zinc oxides, that remains on the surface of the kettle; commonly referred to as "skimmings" Ash inclusions - ash or skimmings carried out of the kettle on parts; ash inclusions remain solidified in the coating Assemblies - the fitting together of manufactured parts into a complete structure, machine, or unit of a machine; assemblies sometimes require specific design features in order to be optimally galvanized ASTM - American Society of Testing and Materials Atmosphere - a surrounding influence or environment that affects the rate of corrosion; frequency and amount of moisture, humidity, chlorides, sulfides, and wind are some of the atmospheric components affecting corrosion rates AZA - American Zinc Association

Barrier protection - the protection provided by inhibiting oxidation (rust) by an insoluble top- coating such as zinc, which isolates steel from any electrolytes that would assist the corrosion process Bond strength - the strength with which two or more items are joined; the resistance that must be overcome in order to separate the joined materials, e.g. steel and zinc-iron alloy layers of the galvanized coating, or galvanized reinforcing steel and concrete Brown staining - reaction between exposed intermetallic layers (specifically the iron portion of the layers) and oxygen, resulting in surface color changes from gray to brown Bracing - metal that is attached to a fabrication prior to galvanizing in order to provide support so that the steel does not change shape during heating and cooling; can be temporary or permanent

C Carbon - naturally occurring element commonly found in steel Cast iron - a generic term for a large family of cast ferrous alloys Cast steel - steel in the form of an object at or near finished shape, produced by pouring molten steel into a mold Casting - an object at or near finished shape obtained by solidification of a metal or alloy in a mold Cathode - the electrode of an electrolytic cell at which reduction occurs; positive current flows from the anode (zinc) through the electrolyte to the cathode (steel) Cathodic - exhibiting properties of a cathode; steel is cathodic in relation to zinc Cathodic protection - reduction or prevention of corrosion of a metal surface by making it a cathode in an electrolytic cell, using either a galvanic or impressed current; zinc cathodically protects steel, i.e. sacrificially giving up electrons to protect the steel from corrosive attack Caustic cleaning - the cleaning of steel in a solution with high alkalinity; in the hot-dip galvanizing process, organic residues are removed by immersing steel in a tank of caustic solution

Centrifuging - the process of removing excess zinc from small hot-dip galvanized parts by placing them in a perforated, rapidly spinning cylindrical container Chemical cleaning - the process of immersing steel in chemical solvents to remove (dissolve) residues that would otherwise prevent the galvanized coating from forming Chemical composition - the makeup of steel, broken down into naturally occurring elements; usually carbon, manganese, phosphorous, silicon as primary elements Chromate quenching -treating metal in a tank of containing a solution of chronium compounds to produce a conversion coating consisting of trivalent and hexavalent chromium compounds; chromate passivations sometimes are used on galvanized reinforcing bar to control reactions between zinc and concrete while the concrete cures, particularly the hydrogen evolution that adversely affects bonding; chromate quenching other galvanized articles prevents the formation of wet storage stain Chromating - chromate quenching a galvanized article Cleaning - the process of chemically or mechanically removing unwanted residue or contaminants (mill scale, rust, dirt, oil) from the surface of a steel article prior to galvanizing Cleaning solutions - liquids used to remove unwanted residue or contaminants (mill scale, rust, dirt, oil) from the surface of steel prior to galvanizing, typically alkalai caustic solution, hydrochloric or sulfuric acid, and zinc ammonium chloride flux solution Coating thickness - the thickness of the zinc coating, measured in mils (0.001 inches) or micrometers (10-6 meters) Cold-galvanizing - See zinc-rich paint Cold-rolled steel - steel that has been produced from a hot-rolled pickled coil and given substantial cold reduction at room temperature; cold-rolled steel is characterized by improved surface smoothness, greater uniformity in thickness and improved mechanical properties when compared to hot-rolled steel Cold-working -bending or forming ambient-temperature steel; this action induces stresses that may be released during the galvanizing process Containment - the act, process, or means to keep within prescribed limits Contraction - the shrinkage of steel due to cooling of the part after removal from the galvanizing kettle

Corrosion - the chemical or electrochemical reaction between a material and its environment that produces a deterioration of the material and its properties; zinc chemically reacts with elements in the atmosphere, thereby sacrificially corroding to prevent underlying steel corrosion Cracking (concrete) - the breaking of concrete due to the expansive forces caused by the formation of iron-oxide corrosion products on unprotected reinforcement bars CSA - Canadian Standards Association D Delta layer - the second layer of zinc-iron alloy growth from the base steel formed during the galvanizing process; the Delta layer's chemical composition is approximately 90% zinc and 10% iron; the Delta layer is 60% harder than the base steel it protects from abrasion and corrosion Design - to create, fashion, execute, or construct steel according to plan so that it will yield a quality hot-dip galvanized coating Diamond Pyramid Number -(DPN) system of assigning values to metals quantifying their hardness Dissimilar metals - two or more different metals in contact; due to varying surface conductivity, one or more metals may experience accelerated corrosion; because zinc is high in the galvanic series (see Galvanic Series of Metals), it preferentially corrodes to protect most dissimilar metals Distortion - any deviation from an original size, shape or contour that occurs when the application of heat during the galvanizing process releases stress from the steel induced in the fabrication process or during the steel-making process; distortion is of concern when galvanizing asymmetric structural shapes and/or fabrications Double-dipping (see progressive-dipping) - the act of dipping steel, too large in one dimension to completely fit into the galvanizing kettle, more than once in cleaning solutions and molten zinc metal in order to produce a coating that covers the entire surface of the steel Drainage - the act, process, or mode of becoming emptied or freed of cleaning solutions and/or zinc

Dross - byproduct of the galvanizing process that forms by reactions between zinc and loose particles of iron; dross may exist at all depths of the kettle, but usually sinks to the bottom Dross inclusions - dross that is carried out on the work upon removal from the galvanizing kettle Drossing - removing dross buildup from the bottom of the kettle Dry galvanizing - dipping steel in an aqueous zinc ammonium chloride solution and then thoroughly drying before immersing in the molten zinc bath Ductile iron - molten iron treated with an element such as magnesium or cerium to induce a measurable degree of ductility to the metal; these additives do not affect galvanizeability Ductility - the ability of a material to be formed without fracturing; galvanized steel is ductile within certain recommended bending radii Duplex systems - galvanized steel that has been coated with an additional corrosioninhibiting product, typically liquid or powder paint; the two separate coating systems work synergistically to provide enhanced corrosion protection E Electrical isolation - separating two conductive materials from electrical contact; galvanized steel is sometimes electrically isolated in order to prevent rapid consumption of the zinc coating Electrode - see anode or cathode, whichever is appropriate Electrolyte - an ionized chemical substance or mixture, usually liquid, that will conduct electric currents; water, soil, or many chemical solutions Embrittlement - reduction in the normal ductility of a metal due to a physical or chemical change that may occur when cold-worked steel is immersed in molten zinc in the galvanizing kettle Environment - the complex of physical, chemical, and biotic factors (climate, soil, living things) that act upon metal and ultimately affect the corrosion rate Eta layer - the fourth, outer layer of the galvanized coating solely comprised of zinc

Excess zinc - extra amounts of zinc that may accumulate on the steel because of chemical composition of the steel or the profile/design of the steel and/or fabrication External venting - holes that prevent high-pressure gas buildup in enclosed fabrications dipped in the molten zinc of the galvanizing bath F Fabrication - steel configurations constructed from diverse and usually standardized steel members Fasteners - manufactured steel products (bolts, nails, etc.) used to connect two or more steel members Fatigue strength - the maximum stress that can be sustained for a specified number of cycles without failure, the stress being completely reversed within each cycle unless otherwise stated Faying surfaces - the surface of a piece of metal (or a member) in contact with another to which it is or is to be joined Ferrous metals - metals containing iron Finishing - final stages of inspection and preparing galvanized steel so that it complies with specification(s) Flux - chemicals used to protect steel from oxidation prior to entering the molten zinccontaining kettle Flux inclusions - Flux carried out onto the work from the top flux blanket incorporated in the 'wet' process; occurs only in the 'wet' galvanizing process Fluxing - the process by which steel is dipped in aqueous zinc ammonium chloride to remove undesirable substances and to protect it from further oxide formation prior to entering the galvanizing bath Forged steels - steels formed by plastically deforming metal, usually hot, into desired shapes with compressive force, with or without dies Fresh water - sodium-chloride-free water, especially when considered as a natural resource G

Galling - a condition whereby excessive friction between high spots on two different steel parts results in localized welding Galvanic corrosion - corrosion associated with the current of a galvanic cell consisting of two dissimilar conductors in an electrolyte solution, or two similar conductors in dissimilar electrolytes Galvanic Series of Metals - a listing of metals and alloys arranged according to their relative electrode potentials in a specified environment; indicates what metal(s) will corrode first when two or more metals are in contact Galvanizing - the act of coating steel with zinc in order to provide barrier and cathodic protection from corrosion Galvanizing temperature - the temperature at which the molten zinc bath is kept in order to react with the steel; typically, this temperature is between 830 F (443 C) and 850 F (454 C) Gamma layer - the first layer of zinc-iron alloy growth from the base steel formed during the galvanizing process; the chemical composition of this layer is approximately 75% zinc and 25% iron; the Gamma layer has a DPN of 250, compared to the base steel's DPN of 159 Grinding - mechanically removing material from a work-piece with a grinding wheel or abrasive belt Grit-blasting - abrasive blasting with small irregular pieces of steel, malleable cast iron or hard nonmetallic materials H Handling - the process by which steel articles are carried throughout the galvanizing facility, by chain, wire, hook, or racked in a fixture Hardness - resistance of metal to plastic deformation, usually by indentation; the term may also refer to stiffness or temper, or to resistance to scratching, abrasion or cutting Heat-treating - heating and cooling a solid metal or alloy in such a way as to obtain desired conditions or properties High-strength low-alloy (HSLA) steel - steels with a high yield point and low percentages (<1.25%) of other alloying components

High-strength steel - steels that have a tensile strength over 150 ksi (1100 MPa) Hinges - a jointed or flexible device upon which a door, lid, or other swinging part turns Holding devices - fixtures used to connect fabrications/parts to be galvanized to handling equipment in the galvanizing facility Hot-rolled steel - steel deformed plastically at such a temperature and strain-rate that re- crystallization takes place simultaneously with the deformation, thus avoiding strain-hardening; this is the most common type of steel galvanized Hydrochloric acid - solution used in the cleaning stages of the galvanizing process and consisting of one hydrogen ion and one chloride ion (chemical formula: HCl) in mixture with water Hydrogen embrittlement - a condition of low ductility in metals resulting from the absorption of hydrogen I Identification - marking/labeling steel so that different customer products can be distinguished from one another after galvanizing Impact resistance - the ability to avoid damage due to contact with a forceful motion or object; galvanized coatings' uppermost, pure zinc Eta layer is relatively soft and absorbs impact shock, protecting the underlying alloy layers Impurities - elements or compounds in which their presence is undesired Inspection - coating thickness and surface condition verifications Intermetallic - interior layers of the galvanized coating that have distinct proportions of the alloying metals iron and zinc; e.g. Delta, Gamma & Zeta layers Internal stress - also known as residual stress, stress present in a steel member or fabrication that is free of external forces or thermal gradients Internal venting - holes on the inside of enclosed fabrications that allow cleaning solutions, zinc, and any gases to freely flow throughout the structure ISO: International Organization for Standardization. A network of national standards institutes from 140 countries working in partnership with international organizations,

governments, industry, business and consumer representatives. The source of ISO 9000 and more than 13,000 international standards for business, government and society. IZA - International Zinc Association K Kettle - molten zinc-filled tank where the metallurgical bonding of zinc and steel takes place L Lifting points - connectors (sometimes temporary) directly on the steel article that aid the galvanizer in handling the article throughout the galvanizing process M Machined surfaces - surfaces cleaned or otherwise altered by a power-driven machine Malleable iron - iron that permits plastic deformation in compression without rupture Manganese - a grayish white, usually hard and brittle metallic element found in steel that resembles iron but is not magnetic Masking - using a material to produce intentionally ungalvanized areas, typically used in areas that are to be welded, on faying surfaces, or areas where the galvanized coating is not necessary for uniform corrosion protection Matte - dull, lacking or deprived of shine; matte-gray galvanized appearance may result from steel chemistry or may be intentionally induced when the galvanized steel's use defines reflectivity limits Mechanical cleaning - removing residues or impurities from steel using mechanical force such as grinding or sand blasting Mechanical properties - the properties of a material that reveal its elastic and inelastic behavior when force is applied, thereby indicating its suitability for mechanical applications; for example, elasticity, tensile strength, elongation, hardness, and fatigue limit Metalizing - forming a metallic coating by atomized spraying with molten zinc or by vacuum deposition; also called spray metalizing; applying an electrically conductive metallic layer to the surface of another material

Metallurgical bond - the bonding of iron/zinc intermetallic layers to the base steel Mill lacquer - organic protective coating applied to steel parts, usually pipes or tubes, to protect the parts during shipping; this material cannot be removed by the usual galvanized cleaning methods Mill scale - a heavy, imbedded iron oxide layer formed during hot fabrication or heattreatment of steels N Nickel - common element found in the galvanizing kettle to suppress the reactivity of silicon and phosphorus in the steel Notching - cutting out various shapes from the edge of a strip, blank or part O Organic contaminants - surface impurities (dirt, grease, oil, paint markings) that will hinder the formation of the galvanized coating, usually removed in the caustic cleaning stages of the galvanizing process Overlapping surfaces - created when one area of a metal structure is covered by the surface of another metal structure Overtapping - cutting female fastener threads of nuts or threaded holes larger than standard to account for the increased diameter of the galvanized (male) mating part P Passivation -changing chemically active metal surfaces to a much less reactive state (see phosphating and chromating) Patina - relatively insoluble zinc carbonate layer that forms as the galvanized coating weathers, providing added corrosion protection and abrasion resistance Phosphating - forming an adherent phosphate coating on a metal by immersion in a suitable aqueous phosphate solution, commonly used to promote better adhesion of paint to galvanized steel Phosphorus - naturally occurring element commonly found in steel, particularly reactive in molten zinc metal

Pickling - removing surface oxides from metals by immersion in ambient temperature, dilute hydrochloric acid or hot (180 F/82 C) sulfuric acid Pinhole - small hole left in a weld area that allows low viscosity liquids to enter and become pressurized under the high temperature conditions of the molten zinc bath Pitch diameter - the diameter of a fastener cylinder prior to threading Pitted surfaces - areas of metal where small, sharp cavities exist, usually formed by corrosion Post-treatment - subjecting the steel to specific processes after it has been galvanized (see quenching, phosphating, and chromating) Pre-flux - the process of fluxing steel before it enters the galvanizing kettle as opposed to using a top-flux layer, which would be located on top of the molten zinc in the kettle Pre-treatment - subjecting steel to specific processes before galvanizing Progressive dipping - the act of dipping steel more than once in cleaning solutions and molten zinc metal in order to produce a coating that covers the entire surface of the steel; commonly done when the steel article/fabrication is too large to fit entirely into the kettle in one dip Q Quenching - rapid cooling by dipping galvanized steel in a tank filled with a liquid solution; usually water or a dilute chromate or phosphate solution R Racking - the process of arranging articles on a rack in order to transport them more efficiently through the galvanizing process Reinforcing steel - steel embedded in concrete to increase the concrete's load strength Repair - performing finishing work after galvanizing in order to meet standards or specifications, or coating areas of steel that have been exposed due to post-galvanizing fabrication, installation, or extremely rough handling Residue - contaminants (oil, grease, dirt, rust, mill scale) that unless removed, will prevent complete galvanizing of the steel surface

Return current path - the path through which the current in an electric cell returns to the source Rinsing - removing any active solution from the surface of steel by immersion in water Rust - corrosion product consisting of hydrated iron oxides; this term is applicable only to ferrous (iron-containing) alloys Rust - corrosion product consisting of hydrated iron oxides; this term is applicable only to ferrous (iron-containing) alloys Rust staining - reaction between exposed intermetallic layers (specifically the iron portion of the layers) with oxygen, that cause mild red or brown staining. S Salt water -water with high concentrations of sodium chloride or other salts Scale - a thick layer of imbedded oxidation (rust) products on metals Seal-welding - a weld used primarily to obtain tightness and prevent the flow of cleaning solutions and zinc into otherwise enclosed areas, to prevent flash steaming that causes localized ungalvanized areas Service-life - anticipated length of time zinc will protect steel; the amount of time until enough of the galvanized coating is consumed and 5% of the substrate steel surface area shows signs of rust Shearing - the type of force that causes or tends to cause two parts of the same body that are touching along a boundary to slide relative to each other in a direction parallel to their plane of contact Shot-blasting - abrasive blasting steel with metal shot, usually to remove deposits or mill scale more rapidly or more effectively than can be done by sand-blasting or chemical cleaning Silicon - naturally occurring element commonly found in steel; silicon is particularly reactive in molten zinc metal Silicon-killed steel - steel treated with silicon as an oxidizing agent in order to reduce the oxygen content to such a level that no reaction occurs between carbon and oxygen during solidification Skimmings (ash) - galvanizing byproduct comprised mainly of zinc oxides; skimmings are recyclable

Skip-welding - alternating the weld so that it is not continuous or complete Spalling (concrete) - the complete failure of concrete due to the expansive forces caused by the formation of corrosion products on unprotected reinforcement bars Spangle - the characteristic crystalline form exhibited by the solidified, hot-dipped zinc coating Stainless steel - type of steel alloy that contains significant amounts of chromium and/or nickel and is typically very corrosion resistant due to its ability to passivate upon atmospheric exposure Stamping - a general term covering almost all press operations, including blanking, shearing, hot- or cold-forming, drawing, bending, coining Stenciling - the process by which lettering or a design through which a substance (ink, paint, or metallic powder) is forced onto a surface to be printed; commonly used to mark steel fabrications but generally does not remain after the galvanizing process Storage - the area where galvanized articles are staged for pick-up or delivery Strain-age embrittlement - the loss in ductility accompanied by an increase in hardness and strength that occurs when low-carbon steel (especially rimmed or capped steel) is aged following plastic deformation; the degree of embrittlement is a function of aging time and temperature, occurring in a matter of minutes at the galvanizing temperature but requiring a few hours to years at room temperature Stress-relieving - heating to a suitable temperature, holding long enough to reduce residual stresses and then cooling slowly enough to minimize the development of new residual stresses Structural - steel member of specific cross-sectional dimensions used in fabrication and/or construction, (e.g. H-beam, angle, I-beam, W-flange) Structural steel shape - piece of steel of any specific design accepted as standard by the structural branch of the steel industry Sulfuric acid - solution used in the cleaning stages of the galvanizing process that consists of two hydrogen ions and one sulfate ion (chemical formula: H2SO4) in a water mixture Surface condition - state of the surface of the steel Surface preparation - stages of cleaning that prepare the steel for finishing (galvanizing)

T Tank - container for chemicals used in the galvanizing process; steel is dipped sequentially in solution-containing tanks Temporary bracing - metal that is attached to a fabrication prior to galvanizing in order to provide added support so that the steel does not change shape during heating and cooling; temporary bracing is removed after galvanizing. Thermal expansion - the process by which steel becomes larger upon heating Threaded parts - parts such as bolts and rods that allow nuts to be screwed on to one or both ends Touch-up - performing finishing work after galvanizing in order to meet standards or specifications, or coating areas of steel that have been exposed due to post-galvanizing fabrication, installation, or extremely rough handling V Venting - providing holes in fabrications to be galvanized to allow entrapped, heated liquids and gases to escape as pressure increases Vibrating - the process of removing excess zinc by rapidly shaking galvanized articles Viscosity - the property of resistance to flow in a fluid or semi-fluid state W Warping - twisting or curving of steel originally flat or straight Weathering steel - corrosion-resistant steel that initially corrodes; the presence of corrosion products then limits the further oxidation of the metal Weepage - the leaching out of trapped liquid solutions in galvanized structures, primarily through pinholes or gaps in welds that were not sealed over by zinc Weld beads - deposits of filler metal from a welding pass Weld flux - material used to prevent the formation of, or to dissolve and facilitate removal of, oxides and other undesirable substances

Weld residue - impurities left from the welding process; weld residue will inhibit localized formation of the galvanized coating. Weld slag - material resulting from the combination of weld material and weld flux; weld slag will inhibit localized formation of the galvanized coating Welding - joining two or more pieces of material by applying heat or pressure, or both, with or without filler material, to produce a localized union through fusion or recrystallization across the interface Wet galvanizing -using a liquid flux layer floated on top of the molten zinc; in the galvanizing process, final cleaning occurs as the material passes through the flux blanket before entering the molten zinc bath Wet storage stain - white surface oxide and hydroxide that forms on newly galvanized steel when excessive moisture is present in poorly ventilated storage Wheel-abrading - mechanical cleaning method used to remove small amounts of residues found on steels by means of a rough, rotating wheel White rust -white, sticky substance comprised of basic zinc carbonate; forms when galvanized surfaces are constantly covered by water or water containing sulfides or chlorides Z Zinc - major element found in the galvanizing kettle that provides both barrier and cathodic protection for steel Zinc ammonium chloride - typical component of the flux solution used in the cleaning phase of the galvanizing process Zinc carbonate patina - relatively insoluble zinc carbonate layer that forms as the galvanized coating weathers, providing added corrosion protection and abrasion resistance Zinc hydroxide - corrosion product formed in response to the presence of moisture on galvanized articles Zinc oxide - basic corrosion product formed almost instantaneously on freshly galvanized articles after withdrawal from the molten zinc metal

Zinc patina - relatively insoluble zinc carbonate layer that forms as the galvanized coating weathers, providing added corrosion protection and abrasion resistance Zinc solder - material used to touch-up and/or repair hot-dip galvanized surfaces Zinc-iron alloy layers - inner layers of the galvanized coating formed from interdiffusion reactions between iron in the base steel and molten zinc metal, (e.g. Delta, Gamma, Zeta) Zinc-rich paint - (also called "cold galvanizing") material used to touch-up and or repair hot- dipped galvanized surfaces, providing barrier protection and some cathodic protection (if the concentration of zinc is above 94% in dry film thickness) History The recorded history of galvanizing goes back to 1742 when a French chemist named Malouin, in a presentation to the French Royal Academy, described a method of coating iron by dipping it in molten zinc. In 1836, Sorel, another French chemist, obtained a patent for a means of coating iron with zinc, after first cleaning it with 9% sulfuric acid and fluxing it with ammonium chloride. A British patent for a similar process was granted in 1837. By 1850, the British galvanizing industry was using 10,000 tons of zinc a year for the protection of steel. Galvanizing is found in almost every major application and industry where iron or mild steel is used. The utilities, chemical process, pulp and paper, automotive, and transportation industries, to name just a few, historically have made extensive use of galvanizing for corrosion control. They continue to do so today. For over 150 years, hot-dip galvanizing has had a proven history of commercial success as a method of corrosion protection in myriad applications worldwide. Galvanizing standards BS EN ISO 1461: 1999 Hot dip galvanized coatings on fabricated iron and steel articles - Specifications and test methods BS EN ISO 14713: 1999 Protection against corrosion of iron and steel in structures - Zinc and aluminium coatings - Guidelines BS 7371: 1998 Coatings on metal fasteners: specification for hot dipped galvanized coatings

BS 443: 1990 Testing zinc coatings on wire BS EN 10142/10147 Hot dip zinc coatings on steel sheet BS 3083: 1988 Hot dip coated corrugated sheet for general purposes Other zinc coatings standards BS 12329: 2000 Corrosion protection of metals. Electrodeposited coatings of zinc with supplementary treatment on iron and steel BS EN 22083 Sprayed aluminium and zinc coatings BS 3382: Part 2 Electroplated zinc on threaded components BS 4921 Sherardized coatings on iron and steel articles

Other useful British standards BS 7361: Part 1 1991 Cathodic protection BS 7773: 1995 Cleaning and preparation of metal surfaces PD 6484 Corrosion at bimetallic contacts BS 7079 Surface preparation of steel substrates before application of coatings BS EN ISO 2178:1995 Measurement of coating thickness: magnetic method BS EN ISO 9000: Parts 2 & 3: 1996

Quality systems BS EN ISO 11124: Parts 3 & 4 Chilled iron shot and grit for grit blasting BS EN 23270: 1991 (2000) Paints and varnishes, terms and definitions for coating materials. General Terms BS EN 23270: 1991 (1997) Specification or temperature an humidities for conditioning and testing paints, varnishes and their raw materials BS 4395: Parts 1 & 2: 1998 High strength friction grip bolts BS EN ISO 1460 Determination of hot dip galvanizing coating mass: gravimetric method BS EN ISO 1463 Measurement of coating thickness microscopic method BS EN ISO 2064 Definition and convention concerning coating thickness method ASTM Standards A123/A 123M - 00 Hot galvanized coatings on fabricated products A 90/A 90M - 93 Test method for weight of zinc coating on iron and steel articles A 153/A 153M - 00 Hot dip galvanized centrifugal components A325 - 94 High strength carbon steel bolts A 490 - 93 High strength alloy steel bolts A 653/A 653M - 00 Hot dip galvanized steel sheet B 633 - 85 (1994)

Electroplated zinc articles A 767/A 767M - 00 Hot dip galvanized rebar

DIN Standards DIN 267 Hot dip galvanized fasteners DIN EN ISO 1461 Hot dip galvanized coatings on fabricated iron and steel articles - Specifications and test methods DIN 50978 Testing of adhesion of hot dip galvanized coatings DIN 50933 Measurement of coating thickness using dial indicator DIN 51213 Testing of zinc coatings on wire DIN 59231 Galvanized corrugated sheet DIN 50961 Electroplating zinc DIN EN 22063 Sprayed aluminium and zinc coatings Swedish Standards SS 3192 Hot dip galvanized threaded components SS 055900 Blast cleaning steel SS EN ISO 1461 Hot dip galvanized coatings on fabricated iron and steel articles - Specifications and test methods

ISO Standards ISO 1459 Protection by hot dip galvanizing: guiding principles ISO 2063 Metal spraying by zinc and aluminium ISO 2081 Electroplated zinc coatings ISO 3575 Continuous hot dip galvanized sheet Australian Standards AS/NZS 4680 Hot dip galvanized (zinc) coatings on fabricated ferrous articles AS/NZS 4534 Zinc and zinc/aluminium alloy coatings on wire AS/NZS 4791 Hot dip galvanized (zinc) coatings on ferrous hollow sections, applied by a continuous or a specialised process

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