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When steel is dipped into molten zinc at a temperature of approximately 450 °C, in the process of galvanizing a layer of iron-zinc alloy with a variety of compositions and then a highly adherent layer of pure zinc builds up on the steel component as a result of inter-diffusion between the liquid zinc and the steel surface.
After the incoming inspection, the components are charged using a device, taking their shape and type into account. All dirt is removed in the subsequent wet chemical pre-treatment and the steel surface is activated using a flux solution for the following galvanizing process. Rounding out the process, a swift, steep dipping process then occurs in addition to a short, product-dependent dipping time, the cleaning of the bath surface before starting the slow, steep pulling out process and the removal of zinc runs.
The build-up of the iron-zinc alloy layers during the process can be carried out at different speeds. The chemical composition of steel with respect to silicon and phosphorus is of crucial importance, as in certain concentrations these elements accelerate the iron-zinc reaction, and thick, grey zinc coats are formed during galvanizing. In order to achieve perfect visual results, this fact should be taken into account in the planning phase.
For steel components exposed to atmospheric oxygen, hot-dip galvanizing provides highly effective corrosion protection with very long protection duration. For many applications, the protection duration and service life are actually the same. Zinc coats offer low-maintenance or even maintenance-free corrosion protection. When analyzing the costs of corrosion protection measures, including maintenance and repair costs during the service life of steel constructions, hot-dip galvanizing is by far the most economical corrosion protection available, both for steel constructions and many other steel products.
The process unbeatable for almost 150 years for the sustainable corrosion protection of steel.
We have compiled a number of useful tips for you on the manufacture and construction suitable for hot-dip galvanizing.
No paint / sprays / weld slag
No decals / markings
Openings in the base plate area
Do not weld extensively
Notches / bores in the top plate area
Position ventilation and suspension points
Weld in the sleeves in a flush manner
Introduce beading / tilting
Bores concealed / verifiable
Openings in complex construction