Service galvanizing is a process that involves coating steel or iron products with a layer of zinc to protect them from corrosion. Hot-dip galvanizing is an essential process for many industries, including construction, agriculture, transportation, energy, manufacturing, etc.
But how long does the galvanizing process take, and will the timeline enable you to meet major deadlines?
In this blog, we will take a closer look at the galvanizing process, step-by-step, and answer the question, “How long does the galvanizing process take?”
The actual action of hot-dip galvanizing—dipping steel into zinc—typically takes minutes to hours. However, this is only part of the extensive galvanizing process. Preparation, cleaning, fluxing, and rinsing are all integral parts of the project.
Turnaround time is typically around three days. This varies depending upon the scope of the project. However, South Atlantic can make arrangements to complete projects within 24 hours.
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The first step in the galvanizing process is preparation. This involves cleaning the steel or iron products to ensure that the zinc coating adheres properly. The surface cleaning process usually involves a series of steps, including degreasing, pickling, and fluxing.
Degreasing involves removing any oil or grease from the surface of the metal, which can interfere with the galvanizing process. Pickling involves immersing the metal in an acid solution to remove any rust, mill scale, or other impurities. Finally, fluxing involves applying a flux solution to the metal, which helps the zinc coating adhere properly.
How long does the galvanizing process take? The preparation process can take anywhere from a few minutes to an hour, depending on the size and complexity of the products being galvanized. For example, small parts can be cleaned and prepared quickly, while large structures such as I-beams and girders may take up to an hour to prepare.
How long does the galvanizing process take? The preparation is the most time-consuming aspect of the project. However, once the preparation process is complete, the steel or iron products are ready for hot-dip galvanizing.
Hot-dip galvanizing involves immersing the metal in a bath of molten zinc, which reacts with the iron or steel to form a layer of zinc-iron alloy on the surface of the metal. The materials used in the zinc bath is specified by ASTM (American Society for Testing & Materials) International in Specification B6. This layer of zinc provides a protective barrier against corrosion, which extends the life of the metal.
As we mentioned earlier, the actual task of hot-dip galvanizing takes minutes, but this time can vary depending on the size and shape of the products being galvanized. Small parts can be galvanized in just a few minutes, while large structures may take up to an hour to fully immerse and remove from the galvanizing bath.
After the products have been galvanized, they are removed from the galvanizing bath, and any excess zinc is removed. This can be done by draining the object or even by vibrating it at a high speed.
It’s important to remember that the hot-dip galvanizing process is complete after the materials are removed from the bath. However, all hot-dipped products have to be cooled. This is usually done by immersing the products into a solution, in water, or leaving them to air-dry.
This quenching process usually takes just a few minutes, but the exact time can vary depending on the size and shape of the products being galvanized. This is a vital step when determining how long the galvanizing process takes.
The final step in the galvanizing process is inspection. This involves checking the products for any defects or imperfections in the zinc coating, as well as ensuring that the coating is uniform and free from any drips or runs. We repair any defects or imperfections using special galvanizing repair techniques, and then we re-inspect the products to ensure that they meet the required standards.
At South Atlantic, we take pride in the fact that every piece that goes through our hot-dipped galvanizing process passes a rigorous 25-point inspection process to ensure the highest level of service.
We adhere to the most meticulous standards of the American Society for Testing and Materials (ASTM) for hot-dip galvanizing found in ASTM A123.
These standards dictate the highest quality of the entire process, including the zinc and thickness of the coating.
Galvanizing is an essential process for many industries, as it provides several advantages over other types of coatings. For example, galvanized steel is more durable and longer-lasting than painted or powder-coated steel, as it is less prone to corrosion and rust. As a result, this makes it ideal for use in outdoor applications, such as bridges, buildings, and agricultural equipment.
In addition, hot-dipped galvanized steel is also more cost-effective than other types of coatings, as it requires less maintenance and replacement over time.
We have several plants strategically located throughout the Southeast with varying kettle sizes. This means you can easily access our plants from multiple places across the country depending on your needs.
You’ll always know at what stage your product is and when you can expect it. We believe in being open and honest about our entire process. That’s why we keep you in the loop every step of the way.
Our managers have experience with “boots on the ground.” Our leadership has a keen understanding of the entire galvanizing process. This is why we can seamlessly take your project from beginning to completion.
To become and remain an industry leader for more than five decades, you have to earn trust. And perhaps even more importantly, you have to keep that trust.
We provide the best possible service to our customers. In addition, we use only the latest technology and techniques to gavlanize your products to the highest standards.
Contact us today to discuss your requirements and get a quote. Our team of experts will be happy to answer any questions you may have. We’ll provide all the information you need to make an informed decision.
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