MMG

GALVANIZING PROCEDURES
HQ : 5th Floor, West Wing, Quattro West
No.4, Lorong Persiaran Barat
46200 Petaling Jaya, Selangor

Balakong Plant :

Lot 5207, Taman Balakong Jaya Industrial Area

Off Jalan Balakong, 43300 Balakong, Selangor.

Meru Plant :

Lot 5039 & 5057, Jalan Teratai, Batu 5 1/2, Jalan Meru
41050 Klang, Selangor

INDEX
GALVANIZING PROCEDURES :1)
2)
3)
4)
5)
6)
7)
8)
9)
10)
11)
12)
13)

SCOPE OF WORK
WORKING PROCESS
HANDLING OF STEEL WORKS
PRE-INSPECTION
DEGREASING AGENT
ACID PICKLING
PRELUX CHEMICAL
HOT DIP GALVANIZING
WATER QUENCHING
GALVANIZED FINISHING
PRE-DELIVERY INSPECTION
DELIVERY
REPAIRS

SCOPE OF WORK

Hot-Dip Galvanizing process mentioned hereafter is in compliance to EN ISO 1461 : 2009(E)

"Specification for Hot-Dip Galvanized coating on iron and steel articles" published by British
Standard Institution or ANSI / ASTM A123-84 "Standard specification for Zinc (Hot-Galvanized)
,(Low -lead galvanizing as required under coating specification, SHDS-CPLATING-SPEC)
coating products fabricated from rolled, pressed and forged steel shapes, plates, bars and strips".

WORKING PROCESS

a)

Receiving articles and confirmation.

Kettle size :
Balakong Plant
: 8.0m (L) x 1.3m (W) x 2.1m (D)
Meru

Plant

: 1.0m (L) x 1.0m (W) x 1.0m (D)

: 12.5m (L) x 1.8m (W) x 1.0m (D)

Jigging Process
Centrifugal or known as Spinning process

Jigging Process

On receipt if steel works and articles, the Store Supervisor shall issue a Factory Order, check
and confirm the following :b)
c)
d)
e)

Actual items, size abd quantity against client's Delivery Order.

Cropped gussets, vents and drainage holes to allow proper zinc flow in steel works.
Non water base painting or identification markings, tars, heavy oil patches or glue
and stickers or labels.
During delivery and transportation handling effects.

Traceability of goods depends on handling methods and how steel works are dispatched and
received. The Client shall ensure that all goods are sorted and bundled in a manner where it can
be unloaded in bundles and allow accountability. Proper methods of delivery allowing traceability
and prevention of any damaged during transportation, loading and unloading should agree with
the client before commencement if work.
Should there by any defects as mentioned in (a), we will notify the client as soon as possible.
Upon receipt of a client's confirmation and/ or instruction from the client to proceed, the
Plant Manager shall make adjustments to adopt corrective adjustments as deem necessary and
if required seek further consultation with the client. Thereafter he shall commence hot dip
galvanizing process.

HANDLING OF STEEL WORKS

a)

Unloading from trucks and handling of the steel structure to and from the storage
yard shall be by forklift or crane hoist.
The articles ashall sorted out in batches at the jigging Station and at the preparation
area movement of steel thereafter shall be by an overhead crane.
The condition for pre-treatment and cleaning of each steel structure and steel works
shall be maintained in the same working condition at all times.

b)
c)

PRE-INSPECTION

Steel structures and all steel works shall be inspected as follows :a)

Length, width and height to determine if the steel works will fit into the zinc bath in a
single dip.

b)

Paint or identification marking, lacquer, grease and heavy oil may require abrasive
sweep blasting as epoxy or oil based paint and heavy oil such as tar and grease may
not be chemically removable. The client shall be informed if such problems arise and
it is recommended that in the client's Pre-Inspection Report prior to dispatch of goods
to the galvanizing plant that steel surface should be free from insoluble paint and
extreme contamination.

c)

Rust scars, rolled in impurities, laps, seams and mill scales if found chemically not
removable shall be recommended for abrasive sweep blasting especially for cast
iron products.

d)

Welded areas shall be checked for welding defects, welding slag and welding
splatter.

e)

Steel structure shall be checked for suspension holes (for articles not suitable for
handling with chain and baskets)

f)

Vessels, hollow sections including small diameter tubular fabrications ( e.g.

handrails) shall be checked for venting atmosphere to prevent superheated steam
generated during molten zinc dipping which may cause explosion in the zinc bath.
Ventilation and drain holes must be provided prior to dipping any steel works in
the zinc bath.

g)

Welded strengthening gussets, webs on columns or beams and strengthening

gussets in members fabricated from channels section shall be checked for cropped
corners and drainage holes.

DEGREASING AGENT

a)

Chemicals used : -

b)

Condition of degreaser :b.1)

Concentration is 15 ~ 20 %
b.2)
Temperature is above 80C.
b.3)
Immersion time shall be 20 ~ 30 mins.

Liquid Sodium Hydroxide ( Caustic Soda)

c)

Inspection and Maintenance of Degreaser :c.1)

The concentration and the temperature of the degrease must be checked
recorded daily.
c.2)
The concentration of the degreaser shall be maintained in the above
condition at all times.
c.3)
The degreaser shall be free of undesirable substance.

d)

Handling procedure :d.1)

The steel works shall be lifted into degreaser by overhead crane.
d.2)
Before transfer to the next chemical tan, the steel works shall be water
blasted and checked for any unclean surface.
d.3)
Stubborn stain or areas where thechemical degreaser fail to clean or remove
will be power brushed or removed by grinders.

ACID PICKLING

a)

Chemicals used : -

b)

Conditions of acid :b.1)

Concentration shall be below 15%
b.2)
The pickling acid shall be an ambient temperature.
b.3)
Immersion time shall be less than 15 minutes.

c)

Maintenance of Chemical :c.1)

The concentration of the acid must be checked and recorded daily.

d)

Handling Procedure :d.1)

The steel works shall be lifted into the acid pickling tanks by overhead
crane.
d.2)
Stubborn stains or areas where the acid pickling fail in cleaning and
removing shall be power brushed or removed by grinders.
d.3)
Before being transfer to the next chemical tank, the steel works shall be
checked for any unclean surface.

PREFLUX CHEMICAL

a)

Chemical used :-

b)

Condition of the Preflux Chemical :b.1)

Concentration shall be between 23 ~ 25 %
b.2)
Temperature shall be maintain at 70
b.3)
Immersion time shall be less than 5 minutes.

c)

Maintenance of Prelux Chemical :c.1)

The concentration of the Preflux Chemical shall be checked and recorded.

Hydrochloric Acid (HCL)

Zinc Ammonium Chloride Solution (ZnC12:NH4 CI).

HOT DIP GALVANIZING

a)

Material used - Zinc Slab - zinc content not less than 99.995 % (PWG)

b)

Condition of Molten Zinc :b.1)

Temperature of the zinc bath shall be maintained at 450C ~ 455C.
b.2)
The zinc content must be analysed and recorded weekly.

c)

Handling Procedure :c.1)

Immersion time shall be between 1 ~ 2 minutes which depends on material
size.
c.2)
Splashing of zinc must be avoided and kept within an enclosed chamber.
c.3)
Galvanizing fume shall be extracted and filtered through fume exhause
system.
c.4)
The zinc surface must be skimmed prior to withdrawal of galvanized work
from the zinc bath.
c.5)
Upon withdrawal, molten zinc will be allowed to drain off the steel work
by aided of a mechanical vibrator.

WATER QUENCH

a)

Chemicals used :-

b)

Conditions of water quench :b.1)

Concentration shall be 0.15 %
b.2)
Immersion time shall be between 3 ~ 5 minutes

c)

Maintenance of the Quenching solution

c.1)
The concentration of the quenching solution shall be check and recorded
daily.

Sodium Dichromate Solution

d)

Quality Check
d.1)
Low lead content's in the galvanizing bath shall be demostrated by the
periodical check of the HD Bath. Laboratory test shall be available for JHC
inspector to review on SHDS-Coating Spects R3

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GALVANIZED FINISH

a)

Appearance of the article must be carefully checked for :a.1)

Sharp zinc drips
a.2)
Excessive roughness
a.3)
Bare spots
a.4)
Ash stain

b)

Handling procedure:b.1)
Sharp zinc drips, excessive roughness, ash stain shall be remove lightly
with a mechanical grinder.

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PRE-DELIVERY PROCEDURE

a)

Production Weight :a.1)

All steel works shall be weighted on a production scale and the weight
recorded in the factort order by computerised weight bridge.

b)

Zinc Thickness Test :b.1)

On a daily basis, the QA supervisor shall condust coating thickness test with a
SIRIM approved magnetic gauge on randomly selected goods.
b.2)
Upon request, thickness reading shall be conducted specifically for the
customers and test certificates shall be used.
JGC QC : DFT records shall be avaible for JGC inspector to review and
complied into MDR.
Final Check Before Delivery :-

c)

Prior to delivery, the store Supervisor wll check and confirm the folliwing :i)
Item and quantitiy
ii)
Packing
iii)
Documentation

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DELIVERY

a)

Complete article shall be lifted to the customer's transport by forklift.

b)

The loaded vehicle shall be weighed and weighing slip shall be issued together
with a Delivery Order.

c)

All Delivery Order / Purchase Order issued by the customers will kept for record
purposes.

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GALVANIZING REPAIR

Repair procedure to be in accordance with EN ISO 1461 : 2009(E)

a)

If repair on galvanized items required, the effected area shall be smoothed up by

grinding.

b)

The area shall be free from oil and grease prior to applying the zinc coating.

c)

Zinc coating or galvanizing for the repair shall be done by cold galvanizing method.
This area shall be sprayed by using CRC-Zinc- IT until it is fully coated.

d)

After completion of this process, the area shall be visually insoected to make sure no
bare metal is exposed.

PROCEDURE TO SPECIFY TYPE OF TEST METHOD

a)

Peeling and flaking test (adhesion)

b)

Hammer test ( wt of 200 gms)

c)

Bending or wrapping test ( only for thin steel material)

d)

Knife test ( sharp edge) visual

e)

Thickness test

f)

Pierce test

g)

Hydrogen evolution test

h)

Stripping test

Kindly please refer to the Galvanizing Procedure reference for the above
and refer to the below Galvanizing Operation Process.
1. Hot Dip Galvanizing: The hot dip galvanizing process involves at least 5 operations.
Plant design and layout will determine the maximum size of fabrications that can be galvanize

2.

Centrifuge processing of small parts. Hot dip galvanizing of small parts is done using the
centrifuge process, where the pre-treated parts are galvanized in baskets that are spun
at high revolutions after withdrawal from from the molten zinc to remove excess zinc
from their surfaces

3. End plate design.

Base plates and end plates need to be designed for adequate venting and draining..
Simple detailing during fabrication, as shown here, will produce good galvanizing results

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4. The Sandelin Diagram.

Steel chemistry determines the rate at which the steel will react with the molten
zinc alloy in the galvanizing bath to form the galvanized coating. Silicon is the most
significant reactive alloying element in structural steels. This graph shows the
reaction rate of steel with zinc at various steel silicon levels, and will give
an indication of the likely galvanized coating characteristics of a steel of known
silicon composition.

5. Welding and weld metal.

Weld metal composition and welding techniques can affect the finished
appearance of fabrications.Weld metal is normally high in silicon content and will
react with the molten zinc alloy at a higher rate that the parent metal. Weld areas
ground flush prior to galvanizing may thus appear raised above the metal surface
after galvanizing. Weld splatter will not be removed in the pre-treatment process
and will be galvanized on the surface, creating an unsightly appearance.

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6. Zinc drainage off large items.

The angle with which large fabrications can be withdrawn from the bath
will determine the effectiveness of the drainage of excess zinc from its surfaces.

7. Orientation and surface finish.

The steeper the angle at which a fabrication can be withdrawn from the
galvanizing bath, the smoother the finish is likely to be. The flatter the surface is
with respect to the molten zinc, the more drips, drainage spikes and feathers will
occur on the edges. Provision of lifting points to allow the optimum orientation
will produce the most consistent surface finish.

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8. Venting and draining of structural sections.

Beams, columns and channels that contain gussets, splice plates or stiffeners in
their design will not galvanize satisfactorily unless both zinc and air can get free
access to all surfaces of the sections. Cropping of gussets and stiffeners fabricated
into these sections will ensure a good galvanizing outcome.

9. Design detailing
Simple detailing will ensure that adequate venting and draining of fabricated assemblies will
deliver a good quality hot dip galvanized finish.

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9. Design detailing
Simple detailing will ensure that adequate venting and draining of fabricated assemblies will
deliver a good quality hot dip galvanized finish.

10. Design details for angle fabrications.

1-, 2-, or 3-dimensional angle fabrications need to be designed to consider their venting and
draining characteristics during hot dip galvanizing. Using outward facing angles, rather than
conventional inward-facing angles, in 3-D fabrications can eliminate the need for any special
venting or draining requirements.

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11. Detailing complex fabrications.

For complex fabrications, advice should be sought from the galvanized to ensure that
adequate lifting points and venting and draining requirements are incorporated into the
fabrication.

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12. Zinc buildup and clearances.

The surface tension and fluidity of molten zinc will result in thickening of the galvanized
coating at low points on solid and hollow circular sections. Where clearances for the fitting
of mating parts is requires, this thickness variation needs to be accommodated in the design,
particularly on internal surfaces of hollow sections where removal of excess zinc is difficult.

13. Draining larger hollow sections.

Larger hollow sections used for structural applications have a significant internal volume so
venting and draining of base plates and end plates needs to accommodate the flow of larger
volumes of pre-treatment chemicals and molten zinc. The location of drain holes in base
plates and end plates will be determined by the orientation of the section during galvanizing.

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14. Pipe spools and other 2-D and 3-D hollow section fabrications
require careful detailing to ensure safe and satisfactory galvanizing. Moisture trapped inside
the fabrication is an explosion hazard, and air trapped inside will prevent the item from
sinking into the molten zinc.

15. Venting and draining of handrails.

Stanchions and handrails fabricated from hollow sections need to be vented and drained on
the underside or inside to prevent ingress of rainwater and hazards to the pedestrians using
the handrails.

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16. Vent and drain hole size.

Vent and drain holes that are too small in hollow sections increase immersion time and may
cause unsightly excessive zinc drainage runs as the zinc freezes during the draining period.

17. Back-to-back sections.

Where back-to-back angle or channel fabrications need to be hot dip galvanized, welding
to create large overlapping surface areas should be avoided. The use of packers between
the sections, or using channels toe-to-toe will ensure a good galvanizing outcome.

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18. Minimizing distortion in thin sections.

Thin plate or sheet sections are prone to distortion during galvanizing. This can be avoided or
eliminated by folding, creasing or corrugating the sheet sections

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19. Design for fence panels and balustrade.

Where hollow sections are used in the fabrication of fence panels and balustrades to be hot dip
galvanized, the pre-treatment chemicals and molten zinc must be able to flow freely into and
out of the fabrication. Venting and draining on the underside of fence panels and balustrade
will not effect their appearance and will not allow weather to enter the panels.

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Centrifugal or known as Spinning process

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