Hot-Dip Galvanizing of Steel Structures

Hot-Dip Galvanizing of Steel Structures

1st Edition - February 4, 2016

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  • Authors: Vlastimil Kuklik, Jan Kudlacek
  • eBook ISBN: 9780081005385
  • Paperback ISBN: 9780081007532

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Hot-Dip Galvanizing of Steel Structures contains practical information that is useful for both researchers in hot-dip galvanizing and engineers, designers, and inspectors. The book draws from the empirical experience and research of the authors, complementing the current state of knowledge of morphological variations of the coating and causes of coating delamination. The book includes chapters devoted to qualitative tests of the coating, and to methods of making corrections. A section describing the principle of protecting steel against corrosion through zinc coating is also provided, along with an extensive chapter on the principles of good design for hot-dip galvanizing. The chapter related to the safety of hot-dip galvanized steel structures offers a new hypothesis about the mechanism of nucleation of LMAC cracks during hot-dip galvanizing, thus enriching the knowledge regarding this phenomenon.

Key Features

  • Provides practical information on hot-dip galvanizing from a scientific-disciplinary perspective, including coverage of design principles, reliability of galvanized structures, and legal aspects
  • Features chapters devoted to qualitative assessments of the surface treatment and methods for correcting problems
  • Includes discussion of hot-dip galvanizing with regard to environmental aspects and sustainable development


Researchers, engineers, graduate students, technicians, and inspectors working in the galvanization industry.

Table of Contents

    • Preface
    • Introduction
      • I.1 Zinc
      • I.2 Steel corrosion and corrosion protection
      • I.3 Steel corrosion
      • I.4 Anti-corrosion protection of steel using zinc
    • 1. List of selected zinc coating technologies
      • Abstract
      • 1.1 Electroplating of zinc
      • 1.2 Thermal spraying of zinc (metallizing)
      • 1.3 Hot-dip galvanizing (by immersion in molten zinc)
      • 1.4 Sherardizing (diffusion zinc coating)
      • 1.5 Mechanical plating
      • 1.6 Zinc coating comparisons
    • 2. Hot-dip galvanizing
      • Abstract
      • 2.1 Continuous galvanizing
      • 2.2 Batch galvanizing
    • 3. Chemical pre-treatment
      • Abstract
      • 3.1 Degreasing
      • 3.2 Pickling
      • 3.3 Rinsing
      • 3.4 Flux
      • 3.5 Drying
      • 3.6 Harmful effects of hydrogen
    • 4. Hot-dip galvanized coating formation
      • Abstract
      • 4.1 Iron–zinc system
      • 4.2 Conventional (low-temperature) galvanizing
      • 4.3 High-temperature galvanizing
    • 5. Morphology of hot-dip galvanized coatings
      • Abstract
      • 5.1 Influence of silicon (Si)
      • 5.2 Other influences of chemical composition of steel
      • 5.3 Influence of additions in the zinc bath
      • 5.4 Influence of other factors
    • 6. Phenomena on galvanized coatings
      • Abstract
      • 6.1 Coating roughness
      • 6.2 Color shade
      • 6.3 Coating on thermally cut surfaces
    • 7. Tests of hot-dip galvanized coatings and assessment of their quality
      • Abstract
      • 7.1 Order acceptance by the galvanizer
      • 7.2 Quality management system
      • 7.3 Acceptance inspections on order completion
      • 7.4 Coating thickness measurement and assessment
      • 7.5 Coating adhesion tests
      • 7.6 Zinc corrosion
      • 7.7 Coating defects and verification of an attainable quality standard
      • 7.8 Delamination of a hot-dip galvanized coating
      • 7.9 Repairs of defects of galvanized coating
    • 8. Service life of hot-dip galvanized coatings
      • Abstract
      • 8.1 Anti-corrosion action of zinc
      • 8.2 Atmospheric corrosion
      • 8.3 Duplex systems
    • 9. Proper design principles for hot-dip galvanizing
      • Abstract
      • 9.1 Drain holes
      • 9.2 Variable thermal stress during hot-dip galvanizing
      • 9.3 The galvanizing plant must be allowed to suspend parts
      • 9.4 Clean metallic surface
      • 9.5 Welds
      • 9.6 Holes for pins and screws
      • 9.7 Three-dimensional components
      • 9.8 Overlapping joints
      • 9.9 Closed cavities
      • 9.10 Asymmetric parts
      • 9.11 Deposition of dirt and debris
      • 9.12 Moving assemblies
    • 10. Maintaining the integrity of hot-dip galvanized steel structures
      • Abstract
      • 10.1 Defects caused by hydrogen
      • 10.2 Tempering brittleness
      • 10.3 Cold working and strain age embrittlement
      • 10.4 Precipitation hardening
      • 10.5 Welds
      • 10.6 Structure with an unsuitable design or poor quality
      • 10.7 Thermal stress caused by thermodynamics of hot-dip galvanizing
      • 10.8 Liquid Metal Assisted Cracking (LMAC)
    • 11. Standardization
      • Abstract
      • 11.1 Basic standards for hot-dip galvanizing
      • 11.2 Technical standards related to hot-dip galvanizing
      • 11.3 Tests
      • 11.4 Corrosivity of atmospheres
      • 11.5 Other selected standards and regulations
      • 11.6 Management systems
    • 12. Legislation
      • Abstract
      • 12.1 Evaluation of environmental influences
      • 12.2 Integrated permitting
      • 12.3 Reference documents about the Best Available Techniques
      • 12.4 Waste
      • 12.5 Atmosphere
      • 12.6 Land
    • 13. Hot-dip galvanizing and the environment
      • Abstract
      • 13.1 Degreasing solutions
      • 13.2 Pickling solutions
      • 13.3 Stripping
      • 13.4 Zinc ashes
      • 13.5 Skimmings
      • 13.6 Filter dusts from air pollution control equipment
      • 13.7 Dross
      • 13.8 HCl emissions
      • 13.9 Heat recovery
      • 13.10 Low water consumption
    • 14. Sustainable development
      • Abstract
    • References
    • Index

Product details

  • No. of pages: 234
  • Language: English
  • Copyright: © Butterworth-Heinemann 2016
  • Published: February 4, 2016
  • Imprint: Butterworth-Heinemann
  • eBook ISBN: 9780081005385
  • Paperback ISBN: 9780081007532

About the Authors

Vlastimil Kuklik

Vlastimil Kuklik has worked in the field of hot-dip galvanizing at the METALEUROP S.A., the ZINKPOWER Kopf Gruppe and the WIEGEL GROUP. He carries out professional quality assessment of zinc coatings (as a Corrosion Engineer) and he is an active functionary of the Czech and Slovak Galvanizers Association, where he organizes and conducts technical research of the phenomena and of the metallurgical process of hot-dip galvanizing. The results of his work are regularly published in professional magazines. He works as a lecturer at seminars on hot-dip galvanizing and he lectures at the Czech and Slovak universities. He regularly supplies contributions to the scientific program of conferences on metal coatings. In the Czech and Slovak Republic is he known as a reputable expert on hot-dip galvanizing who contributes to the knowledge of the process of hot-dip galvanizing. His research is carried out in collaboration with leading institutions such as the Czech Technical University in Prague or Brno University of Technology.

Affiliations and Expertise

Czech and Slovak Galvanizers Association

Jan Kudlacek

Jan Kudlacek is a Vice-head and assistant professor in the Department of Manufacturing Technology, Faculty of Mechanical Engineering - CTU in Prague. His research and professional Interests deal with surface treatment, corrosion, corrosion protection, surface pretreatment, detection of residual grease, hot dip galvanizing, electroplating, organic coatings and tribology. He is the author of numerous articles and papers (published in technological magazines and proceedings of scientific conferences). He is experienced with organizing of professional conferences (IN-TECH, Technological Forum, Quality and Risks in Production, Progressive and Innovative Surface Treatments). Vice-president of World Association for Innovative Technologies - WAIT, chief executive at Czech Center for Surface Treatment.

Affiliations and Expertise

Faculty of Mechanical Engineering, Czech Technical University, Prague

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  • Vlastimil K. Tue May 15 2018

    Hot Dip Galvanizing of Steel Structures

    A clear and richly illustrated textbook about hot-dip galvanizing for galvanizers, coating inspectors as well as users