Tips on Powder Coating on Hot Dip Galvanized Steel

Posted on October 13, 2020 by Galvanizers

Powder coating on hot dip, as can be understood from the name, is a procedure to apply a coating of a special powder on steel that is hot dip galvanized. This particular coating of powder applied on the hot dip galvanizing process provides a significant amount of flexibility as well as a long life. It is precisely the reason as to why powder coating on hot dip galvanized steek has become so popular in recent times. Now, there are three of the major problems that are usually associated with the powder coating on hot dip galvanizing.

Pin holing of the coating – It is caused by the formation of small air bubbles in the coating at the time of curing or stoving cycle. These bubbles give rise to small craters, and are unsightly. At the same time, it reduces the life and durability of the product.
Poor adhesion – In the final step of hot dip galvanizing process, water quenching is involved usually in a weak dichromate solution. If it is not done appropriately, the adhesion of the powder coating tends to be quite poor, and hence ineffective.
Incomplete curing – The powder coatings are thermosetting resins that cross link to their ultimate organic form when they are maintained at a temperature of 180 degrees Celsius for approximately ten minutes. The curing overs are designed to do the task efficiently. But if the curing is incomplete, the coating would not be perfect.

Hot dip galvanizing for corrosion control

Posted on September 21, 2020 by Galvanizers

Corrosion is an electromagnetic process. Corrosion destroys the metal, the colour changes and it becomes weak, easily breakable. Steel is at risk when it reacts with other elements such as oxygen, carbon dioxide, hydrogen, and bacteria, dirt. It forms rust over the metal and the duration of further degradation of the metal depends on the immediate climate in the surrounding. Hot-dip galvanizing controls and protects the iron from corrosion.

Why hot-dip galvanizing?

It is essential to prevent the iron from rust. To protect, a layer or a barrier has to be created or added in between the iron and the atmosphere. Then only the iron will be secured from the harmful elements and it won’t corrode. One such process that can prevent the iron from rusting, corrosion, is hot-dip galvanizing. Hot-dip galvanizing acts as a barrier between the atmosphere and iron.

Hot-dip galvanizing process

In hot-dip galvanizing, the coating of steel happens at a temperature of 449 degrees, absorbing properties of zinc which makes the steel stronger and durable. The effects of the surrounding climate and dust, bacteria are mitigated by hot-dip galvanizing.

Galvanizer provides high-quality hot-dip galvanizing services. We are an experienced team of professionals that carefully conducted the process of galvanizing. The process of Galvanizing is complicated and it requires a proper pool of professionals to carry out the task. We are proud of the quality we provide. Galvanizer provides hot dip galvanizing services in Vadodara.

Hot-dip galvanizing stages

As said earlier, the coating of steel happens at a certain temperature with properties of zinc. Before this process, it is essential to check the surface first. The surface has to be made adequate for the zinc to settle in and process.

After the hot-dip galvanizing process, proper finishing is to be given. Generally, we supply our products with the finish of Hot Dip Galvanized, Primer coated, Enameled paint coated OR Epoxy paint coated.

The inspection of the material is to be carried out. The things to be checked are thickness test, adhesion test, visual check, and uniformity of zinc coating test.

Corrosion is deadly for any metal. Rust is formed on the iron because of the immediate surrounding climate and the dust, bacteria. A barrier has to be created in order to protect from corrosion. The process of hot-dip galvanizing gives the much-needed layer on the surface that prevents iron from the climate and bacteria. Tanya Galvanizers offers top quality services because of the experienced professionals who follow the stages and process of hot dipping galvanizing in Vadodara.

For more information on hot dip galvanizing by Galvanizers, click the link:

https://galvanizers.co.in/hot-dip-galvanization.html

Difference between BATCH GALVANIZED VS PREGALVANIZED PRODUCTS

Posted on August 17, 2020 by Galvanizers

There is a general misunderstanding among common people that every zinc coating is called galvanization but this is not true as there might be many processes through which a zing coating can be applied. Hot Dip Galvanizing is a coating which is formed after immersing a steelwork in molten zinc. There are however two different processes of hot-dip galvanizing which are pregalvanizing and batch galvanizing.

Batch galvanizing is a process that is used to coat fully fabricated items and includes chemical cleaning of work before immersing it in the galvanizing bath. The item gets completely coated including internal surfaces if hollow sections. The thick coating also provides the best level of available corrosion protection.

Pregalvanization is a process where you take a specific product and galvanize them through an automated process. Steel tubes can be galvanized through an automated process. The immersion time is less and after removal, steam can be blown on the bore of the tube which gives it a good surface finish. In the case of reselling, the tubes can be cut to different sizes which creates uncoated edges.

Strands of wire can be coated using an automated process. The immersion time is very short and the wiping procedure is used to remove excess zinc and give a smooth finish to the final product. It is better to use a mesh of wires so that thicker galvanized coating can be achieved. The steel sheet is uncoiled and passed through the reduced atmosphere before immersing in galvanizing bath for a brief period.

After withdrawing the sheet from the galvanizing bath a mechanical wiper or air knife is used for removing excessive zinc so that the product has a smooth finish. The sheet after galvanizing is recoiled before the stockholder and then it is uncoiled and cut for sale which produces uncoated edges on the sheet.

Both batch and pregalvanized coating have different characteristics and some of them are being enlisted below.

The coating continuity in batch galvanizing is continuous over whole item whereas in pregalvanizing the cut edges are left uncoated
In batch galvanization, coating formation after galvanization is not recommended as it can damage the product whereas in pregalvanization coating can be normally formed without any damage
Batch galvanization offers a high level of sacrificial protection whereas a pregalvanized product has less sacrificial protection because of the thin coating due to which rust formation can happen from cut edges of the sheet
The coating appearance after batch galvanizing can be bright but variable whereas pregalvanized products the overall finish is bright without any variation
There is high resistance to abrasion in batch galvanizing due to thick and hard layer of iron and zinc alloy whereas in pregalvanization the alloy layer is very thin which can cause abrasion easily
The coating thickness in batch galvanizing is very thick as compared to pregalvanized coating
The consideration of design for galvanization is required in both batch and pregalvanized products

At Tanya Galvanizers, we offer the best hot-dip galvanizing in Vadodara. We offer both batch and pregalvanization and you can choose the one which suits your requirements and falls in your budget.

Advantages of Hot-dip Galvanized Crash Barriers

Posted on August 6, 2020 by Galvanizers

There are various types of hot-dip galvanized crash barriers available in the market by various manufacturers. They are majorly used on the side of roads or highways so that there are fewer chances of accidents. There are various advantages of hot-dip galvanized crash barriers and some of them are being elaborated below.

Durability
A galvanized crash barrier is much more durable than any other form of painting done on them. This is due to uniform protection, complete coverage and abrasion resistance. The intermetallic layers formed on galvanized steel are bonded metallurgically and are harder than base steel. The top layer of pure zinc can absorb impact and is very ductile. All these zinc layers are abrasion resistant.

The zinc coating grows parallel on the steel which is the reason why both edges and corners have the same thickness as that of flat surfaces. The total immersion process furthermore makes sure that the tubular and hollow structures are protected both outside and inside. The uniform coverage ideally means that the corrosion cannot happen easily on the surface.

Corrosion Free
A crash barrier which is galvanized is corrosion resistant. It does not get rusted easily due to weather or any other external environmental factors which makes it look new and shiny every time. Hot-dip galvanization provides three levels of corrosion resistance to steel which are cathodic protection, barrier protection and zinc patina.

The steel is first isolated from the environment by providing basic barrier protection. The layers of zinc are tightly bonded on the steel base which makes the damage difficult. Cathodic protection means that even if the coating gets destroyed the surrounding zinc will still protect the steel from corrosion.

Zinc patina is a layer formed by zinc when it is exposed to the environment so that the corrosion rate is narrowed down and an additional environmental barrier is formed. When this layer gets fully developed the corrosion of the steel reduces to a greater degree.

Availability and Versatility
Hot-dip galvanization is available in almost all parts of the world and it can be stored easily for a long time before making crash barriers. The elements used in hot-dip galvanization are readily available due to which it is preferred over other forms of painting.

Longevity
Hot-dip galvanized steel is made from the harshest materials available in the environment due to which it lasts longer. The corrosion of the steel takes place at a slower rate as compared to other forms of steel paintings.

Environmental Advantages
Zinc is available in abundance in water, air, earth and soil. It is essential to all the living beings and both steel and zinc are fully recyclable without losing their properties which makes galvanized steel a renewable material. The steel has no harmful impact on the environment when compared to other forms of painting.

Thus, we see that hot-dip galvanized crash barriers have many benefits. If you are confused about whether to go for hot-dip galvanization or painting always choose hot-dip galvanization. At Tanya Galvanziers, we make sure that you get quality galvanized barriers which are pocket friendly and last long.

Hot Dipped Galvanizing Services In Vadodara

Posted on June 18, 2020 by Galvanizers

At Vadodara, there are many providers of hot-dipped galvanizing services. However, if you want a reliable and cost-saving service then contact us at Tanya Galvanizers. We have always emphasized quality before quantity and all the services given by us to the companies have been appreciated.

We do galvanizing works for both public and private sectors like railways, telecommunication, power etc. A well-organized and highly advanced infrastructure helps us in standing apart from our competitors. The sophisticated infrastructure helps us in providing quality products and services.

The services we provide include channel sleepers, lifting barriers, clamps, cross-bracing arms, E- brackets, danger boards/clamps, top channels for pin insulators, height gates and footbridges for the railways and items like ‘V’ cross arms among others. We have modern machinery, latest technology and well-expereinced engineers who produce quality products at customized prices.

We also commission and install hot-dip galvanizing plants for our customers. We provide consultancy only to our trusted clients at present.

Maintenance of Galvanized Steel

Posted on May 22, 2020 by Galvanizers

Some of the tips for maintaining and ca ring for hot-dip galvanized products are.

Do not expose your galvanized steel product to environments where pH is below 6 and above 12 for long hours. Outside pH 6-12 range, the galvanized coating is open to quick corrosion.
Do not roughly clean your galvanized product and try avoiding rough washing of your galvanized product altogether. Galvanizing protects the steel from corrosion by developing a thin barrier film of insoluble zinc corrosion products (known as patina) on outer surface of galvanized steel through exposure to atmosphere. Frictional cleaning removes protective patina and galvanized articles have to build this barrier protection again which leads to consuming more zinc. Constant irritational cleaning will consume zinc more quickly and reduce the life of the product.
Galvanizing should be cleaned by using alkaline-based cleaners with pH of 12 or lower, water-based emulsifiers or organic solvents. The area should be rinsed with fresh water and wiped clean with a soft cloth.
Avoid direct contact of galvanized steel products with dissimilar metals, like copper and brass, in corrosive environments. In case of dissimilar metals being used together make sure that there is an insulator between dissimilar metal and galvanized products.
If a galvanizing product is situated in a highly corrosive environment like heavy, coastal, industrial, etc the product should be rinsed with potable water regularly under sheltered conditions.
Do not store a galvanized product for a long time in a damp and poorly ventilated condition. The storage location should be dry with effective ventilation.
In case of physical damage to the galvanized coating of the product, the damaged area should be repaired in accordance with AS/NZS 4680.

Cleaning Galvanized Steel

While building or renovation, cement and mortar can be dropped on galvanized steel which is very difficult to remove once hardened. Remove large parts of deposit as close to surface as practicable, after that oxalic acid can be used to remove all the remnants from galvanized steel which should be followed with rinsing. Other acids are effective on mortar or cement, but they are very aggressive on zinc and are not recommended.

Paints, like graffiti, should be removed by thinners. If scraping is required, you can use plastic or wooden scrapers. In case the paint is wet or fresh, normal thinners can be used. Once the paint gets hardened, a non-alkaline stripper can be used. Rinsing is important to remove residues that cause discoloration later or encourage corrosion.

Mild stains can be removed by using common household ammonia cleaners and being sure to rinse the galvanized article with fresh water afterward.

Water draining of other adjacent steelwork which is rusting can flow on galvanized steel and cause brown stain. It can be treated by using commercial oxalic acid or proprietary solution which is generally used for descaling pots and pans. Rinsing with water is important to remove corrosive residues of cleaner.

In order to generally clean bulk contaminants like dirt and dust ordinary laundry soaps can be used. For stubborn or large areas, the use of low-pressure wash in collaboration with cleaning materials like car or truck wash or pure water are effective. Truck and car cleaners minimize corrosion on vehicles metallic parts and are suitable for use on galvanized steel. It is important that the steel is washed down with fresh water after cleaning.

Importance Of Inspection Of Hot Dip Galvanized Products

Posted on April 28, 2020 by Galvanizers

In today’s time protection is a must. The surroundings are getting challenging with each passing day. Although, the realization of the protective shield on things that are always exposed to the outer world is from our ancient past. Hence, way back in 17th-century scientist and researchers started their work towards protecting even metals from weathers. One such protection shield found was the process of Galvanizing. One of the best processes on galvanizing is hot-dip method. The hot-dip galvanization is a very popular and successful method.

The purpose of galvanizing was to create a protective shield through zinc coating on steel. The exposure of steel can be up to 200-degree temperature and will still be strong due to galvanizing. Metals have a tendency to get rusted with extensive exposure to weather and hence creating a protective shield is one such critical requirements. As mentioned before hot-dip galvanizing is the preferred method. In this method, coating happens at a temperature of around 449 degrees. At this level of temperature when steel goes through that heat, it also absorbs few properties of zinc, making it stronger.

The process is quite assuring as it sounds and further reassuring on effective inspection. Before the coating, the steel has to be well prepared which decides the future strength of the coating. It is like when you have to polish your shoes you need to first clean them and then polish. In the same way, cleaning of steel is primary for a longer future and ensuring the efforts are worth it. Although, the coating life always depends on the amount of exposure of the metal. One can ascertain these details based on the standards that are available.

While doing inspection there are few things to consider is the uniformity of the coating. When the coating is not done in required temperature many times it has cracks. Also when steel is not cleaned properly it will result in bumps through the metal, which leads to a breakthrough for breaking the shield. Let us list down checkpoints while doing inspection of hot-dip galvanizing.

The smoothness of the surface
Edges and cuts are well ventilated
Overlapping surfaces are well taken care of
The thickness of the coating be as defined or required
Continuity of the coating
Color and uniformity of the coating

The above are the basics of inspecting hot-dip galvanized products. The inspection list can be more extensive with the nature, design and type of the structure that is galvanized. Many time even the purpose of the product plays a significant role in deciding the type of galvanizing especially in products like jewelry and food graded stuff. You can always reach us to know more about the inspection details and the galvanizing process information.

Is Hot-Dipped Galvanized The Same As Galvanized?

Posted on March 19, 2020 by Galvanizers

Galvanization is the process where steel is coated with corrosion resistant zinc. The zinc coating prevents corrosion and in case the coating is scratched, the steel is still protected. Galvanization does not change mechanical properties of steel.

Hot-dipped galvanizing is oldest and most popular form of galvanization process. Metals can be galvanized in more than one method. In hot dipped galvanizing, clean steel is dipped in molten zinc and a unique coating formation takes place that forms strong bond with the steel.

The protective outer layer is more long lasting and tough than other coatings that bond mechanically or electrically. Hot dipped galvanized makes sure that zinc coating applied to protect steel surface provides extended durability outdoors.

Electroplated galvanized steel is softer as compared to hot dipped galvanized steel, electroplated galvanized steel is prone to scratches, daily wear and tear and rough handling.

Electroplated galvanized steel will last as long as hot dipped galvanized steel if it is being used for organizing socks in your closet. An electroplated galvanized bucket if left outside and face drops, scratches and dings will last than 70 years.

Both galvanizing method and the environment it is being used in test the performance of a galvanized metal. Electrogalvanized coating is made by applying zinc to steel strips and sheets by electrodeposition. The coating thickness is less than hot dip process but gives a smooth finish.

The steel used in car bodies is galvanized through electroplate galvanizing as decorative paint can be easily applied after galvanization. Zinc is electrodeposited to steel by immersing the steel in electrolyte a solution of cyanide or zinc sulfate. Pure zinc coats iron or steel surface through electrolytic action.

If an electroplated galvanized finish cuts the steel edges or gets damaged under the zinc layer it is prone to corrosion. Zinc product reacting with oxygen and water or white rust does not occur on smoothly finished galvanized buckets.

The advantages of hot dipped galvanized are thick coatings, corrosion resistant and sacrificial protection of zinc coating. The finished product can be used outdoors in all types of weather conditions. The method is popularly used in construction industry.

Thus, we see that hot dip galvanizing is much better than all types of galvanizing process existing today. We at Tanya Galvanizers provide services in various public sectors and our latest machinery and technology gives you quality products at reasonable price.

Painting A Steel Surface Vs Hot Dip Galvanization To Protect Against Corrosion

Posted on February 17, 2020 by Galvanizers

Hot dip galvanized steel is a steel covered in zinc coating to protect the steel from corrosion. In the galvanizing process, the steel is cleaned and dipped in a bath of molten zinc solution at temperature of approximately 450 degrees.

Liquid zinc sticks to the metal and when the metal is pulled out of bath the zinc gets hardened. As a result there is a really hard outer coating of zinc which protects the inner steel core from corrosion and other types of moisture.

Barrier Protection

Barrier protection is the oldest and widely used method for protection against corrosion. It isolates the base metal from the environment. Just like paints, hot dip galvanizing coating provides barrier protection to steel. As long as the barrier is intact, there is no corrosion and the steel is protected. If the barrier gets breached, the corrosion starts.

Two most important properties of barrier protection are abrasion resistance and adhesion to base metal. The impervious and tightly bonded nature of zinc makes galvanizing a good barrier coating. Coating like paint which have pin holes can be penetrated by elements which causes rapid under film corrosion.

Cathodic Protection

Cathodic protection is an effective way for protection against corrosion. It requires changing an element of corrosion circuit by introducing a new corrosion element which ensures that the base metal becomes cathodic element of the circuit.

In case of hot dip galvanizing zinc will either corrode or protect to protect the underlying base steel. The cathodic protection ensures that even if the coating gets damaged to the point bare exposed steel, no corrosion will start until the surrounding zinc gets consumed.

Zinc Patina

Zinc patina protects zinc coating unlike cathodic and barrier protection which resist corrosion to steel. Zinc begins to corrode when exposed to atmosphere like all metals. Freshly galvanized steel can naturally wither when exposed to dry and wet cycles in the environment.

Fully developed zinc patina is passive and stable film that sticks to the zinc surface and is not soluble to water so it does not get washed off in rain or snow. Zinc patina gets corroded very slowly and protects galvanized coating underneath which brings down the corrosion rate of the steel in the same environment.

As the development of zinc patina takes place, galvanized coating turns in a matte grey color. Zinc patina formation is very important in long-lasting corrosion resistance of hot-dip galvanizing.

Hot dip galvanized coating is resistant to mechanical stress. The resistance is twenty times higher than resistance of PVC coatings and epoxy dust coatings and eight times higher than resistance of epoxy coatings.

One of the advantages of hot-dip galvanizing is there is no doubt about quality as you cannot apply zinc coating to an unclean steel surface while it is possible on the other hand when applying paint.

Thus, hot dip galvanizing is a far more lasting and better solution than paint to protect the corrosion of steel surfaces.

Materials Suitable for Hot Dip Galvanizing

Posted on January 17, 2020 by Galvanizers

Hot dip galvanizing process refers to the process of coating the base metal with zinc by dipping the base metal into a bath of molten zinc so as to enhance the durability of the base metal and at the same time prevent it from corrosion. Now, at the time when the decision for galvanizing is finally made, it is to be made sure that the base metal should be appropriately fabricated for high quality galvanizing. There are a number of rules that are required to be followed for perfectly designing the base metal for galvanizing. These rules when applied provides the intended results and ensures maximum protection from corrosion. In an addition to this, following the rules properly also makes sure that the galvanizing personnel is safe, cost of coating is lowered and certainly produces the best quality galvanizing.

At the time of hot dip galvanizing, it is to be made a point that the designer, fabricator as well as the galvanizer should necessarily work together. The proper communication between these three ensures that a wide range of problems during the entire process getting eliminated. Here is a list of the few major steps to be taken in this regard.

Removal of soil and grease from the base metal
Pickling of the base metal to remove the rust from its surface
Fluxing of the base metal for the removal of oxides for the prevention of oxidation prior to dipping into molten zinc
Now, galvanizing is done where the base metal is dipped into a bath of molten zinc to form the coating of zinc
Then comes the finishing step where the base metal is withdrawn from the bath and the excess zinc is removed by draining by vibrating and for the smaller pieces by centrifuging.
Finally, inspection is done to check for any imperfections

Materials Suitable

Almost all of the ferrous materials are suitable for the purpose of hot dip galvanizing. The structural steel metals including the high strength low allow materials are hot dip galvanized after fabrication for obtaining the long lasting protection by the zinc coating.

Here is a list of materials that are suitable for hot dip galvanizing.

Cast iron
Cast steels
Malleable iron
Hot and cold rolled steels

Though most of the ferrous materials are suitable for being hot dip galvanized, the characteristics of the galvanized coating so formed is a function of the chemical composition of the material. A reaction between the steel and the molten zinc is the basis of hot dip galvanization which results in the formation of layers of alloy of zinc and iron.

Why Tanya Galvanizers?

At any point of time, you are looking forward to the premium quality hot dip galvanization services, then Tanya Galvanizers would be the most appropriate choice in this regard. With several years of experience in this field, we aim to offer best hot dip galvanization services so as ensure complete satisfaction among each of the users opting for the same.

Galvanizers

Supplier & Consultant of Hot Dip Galvanizing Plants in India.