Professional Documents
Culture Documents
Topics Covered
Background
Defects in Galvanised Coatings
Ungalvanised Weld Areas
Dark Staining Adjacent To Welds
Dull Gray or Mottled Coatings
Dross Pimples/Inclusions
White Storage Staining
Ash Staining See all Newsletters (/newsletters)
Background
There are a number of common types of defects arising from the hot dip galvanising process. An explanation of the causes of defects and
variations in appearance follows.
Also, anhydrous uxing salts left in the connection will absorb atmospheric moisture and leach out onto the adjacent galvanised surface.
Leaching of these salts will eventually reach equilibrium. A ected area should be washed clean to remove slightly corrosive leachate.
Dross Pimples/Inclusions
https://www.azom.com/article.aspx?ArticleID=1675 1/4
9/25/2017 Galvanised Steel - Causes and Defects in Galvanised Coatings
Dross is formed in the galvanising process in the form or zinc-iron crystals (approx 95% zinc - 5% iron) with a higher melting point than the
metal in the zinc bath. Dross trapped in the galvanised coating may give the coating a rough or gritty appearance. The presence of dross
inclusions in the coatings is not detrimental to the coatings performance as the corrosion resistance of zinc dross is identical to that of the
galvanised coating.
Ash Staining
Zinc ash is formed in the galvanising process as the work is immersed in the zinc. The ash formed is skimmed o the surface of the molten
zinc prior to withdrawing the work from the galvanising bath. Sometimes, ash is trapped inside inaccessible areas and sticks to the outside
of the coating as the work exits the bath. Ash may leave a dull surface appearance or a light brown stain after removal. It does not a ect
the performance of the galvanised coating.
Bare Patches
Uncoated areas on the surface of galvanised work are due to poor surface preparation, inadequate pretreatment in degreasing, pickling
and pre- uxing. These areas must be repaired using a recommended repair method or the item regalvanised if the defect is of su cient
size.
Rust Staining
Uncoated steel in contact with galvanised coatings will accelerate corrosion of the coating and stain the coating brown in the area of
contact. This can be removed by wire brushing.
Delamination
Very heavy galvanised coatings (over 250 microns thick) may be brittle and delaminate from the surface under impact and require more
careful handling in transport and erection. Thin, cold rolled items with very smooth surface nish and manufactured from reactive steel
may also give rise to coating delamination.
Black Spots
Scattered black spotting is due to residual galvanising ux crystalising on the surface of the work and is generally due to poor rinsing after
galvanising or ux contaminated rinse water. This defect is usually encountered from galvanising baths using the wet galvanising process
where the ux is on top of the molten zinc. Excess aluminium in the galvanising bath can also give rise to this defect.
Spangled Coatings
Some hot dip galvanised coatings exhibit a high level of spangling' caused by zinc crystal patterns on the surface. This phenomenon arises
with galvanising alloys produced in particular smelting processes and these alloys are commonly used for hot dip galvanising. There is no
di erence in coating performance.
https://www.azom.com/article.aspx?ArticleID=1675 2/4
9/25/2017 Galvanised Steel - Causes and Defects in Galvanised Coatings
About (/aboutus.aspx)
Source: Industrial Galvanizers Corp.
News (/materials-news-index.aspx)
Newsletters you may be intereste
in 3D Printing (/newsletters)
(/newsletters)
Articles (/articles.aspx) (Preview
For more information on this source please visit Industrial Galvanizers Corp (https://www.azom.com/suppliers.asp?supplierID=309).
(https://www.azonetwork.com/news
Directory (/materials-engineering-directory.aspx) ppnid=56))
Courses (/courses/courses.aspx)
Reply 0 0
Search (/search.aspx)
The opinions expressed here are the views of the writer and do not necessarily re ect the views and opinions of AZoM.com.
Submit
This site uses cookies. By continuing to browse the site you are agreeing to our use of cookies. Find out more (/cookies). x
https://www.azom.com/article.aspx?ArticleID=1675 3/4
9/25/2017 Galvanised Steel - Causes and Defects in Galvanised Coatings
(https://www.azom.com/ads/abmc.aspx?b=22648&z=183&cb=1)
Newsletters you may be intereste
in
The Advantages of Using Food-Grade Thermal Fluid in Indirectly Heated Baking Ovens
(/article.aspx?ArticleID=14485)
Ray Klim
Detecting Gas Leaks Hundreds of Meters Away with ABB Ability Gas Leak Detection System
(/article.aspx?ArticleID=14451)
Doug Baer
(/article.aspx?ArticleID=14451)
(/article.aspx?ArticleID=14211)
(https://www.azom.com/ads/abmc.aspx?b=22652&z=11&cb=1) (https://www.azom.com/ads/abmc.aspx?b=22649&z=9&cb=1)
(https://www.azom.com/ads/abmc.aspx?b=22734&z=21&cb=1) (https://www.azom.com/ads/abmc.aspx?b=22650&z=19&cb=1)
https://www.azom.com/article.aspx?ArticleID=1675 4/4