Process

Hot Dip Galvanizers - Ireland's premier hot dip galvanizer

Hot dip Galvanizing is the immersion of iron or steel articles in molten zinc to apply a protective coating. All material processed by Galco Steel is in accordance with I.S. EN ISO 1461: 1999

Preparation
The galvanizing reaction will only occur on a chemically clean surface. Like most coating processes the secret to achieving a good quality coating lies in the preparation of the surface. It is essential that this is free of grease, dirt and scale before galvanizing. Contamination is removed by a series of processes. Firstly we degrease using a caustic solution into which the component is dipped. The article is then rinsed and then dipped in hydrochloric acid at ambient temperature to remove rust and mill scale. Welding slag, paint and heavy grease will not be removed by these cleaning steps and should be removed before the work is sent to the galvanizer. After further rinsing, the components are then dipped in a flux solution - usually about 30% zinc ammonium chloride at around 65-80°C.

Galvanizing
When the clean iron or steel component is dipped into the molten zinc (at 450°C) a series of zinc-iron alloy layers are formed by a metallurgical reaction between the iron and zinc. Upon withdrawal from the galvanizing bath a layer of molten zinc will be taken out on top of the alloy layer. This cools to exhibit the bright shiny appearance associated with galvanized products.

Coating
When the reaction between iron and zinc has ceased and the article is taken out of the galvanizing bath complete with its outer coating of zinc, the process is complete. In reality there is no demarcation between steel and zinc but a gradual transition through the series of alloy layers which provide the metallurgical bond.

Performance
Toughness - the coating bonds metallurgically with the steel giving a much greater resistance to damage than other coatings.
Complete coverage - because it is dipped in molten zinc, all parts of the surfaces are coated - inside and out - including awkward corners and narrow gaps.

Three Way Protection - Hot Dip Galvanizing protects in three ways.

1. It weathers at a slow rate giving a long and predictable life.
2. The coating sacrifices itself to any small areas exposed through drilling, cutting or accidental damage.
3. If large areas get damaged it prevents the sideways creep of rust.