Communication among Design Engineer, Architect, Fabricator, & Galvanizer

Corrosion protection begins at the drawing board, and regardless of what protection system is specified, it must be factored into the product's design. Similarly, all corrosion protection systems require certain design details and proper planning to ensure the highest quality coating. For hot-dip galvanizing, a total immersion process in molten zinc, the design engineer will want to ensure all pieces are fabricated suitably for the process. Most design principles necessary for success throughout the galvanizing process are easily and readily followed, and in most cases, ensure maximum corrosion protection. Incorporating these design practices along with those listed in ASTM A 385 Practice for Providing High Quality Zinc Coatings (Hot-Dip), will not only produce optimum quality galvanized coatings, but also help reduce costs and improve turnaround times.

One key to providing the best design for the hot-dip galvanizing process is communication between the architect, engineer, fabricator and galvanizer. Opening the lines of communication early in the design process can eliminate potential costly pitfalls later in the process. A few discussion topics good to cover while the project is being designed include:

• Steel Chemistry and Surface Condition

• Size & Shape

• Process Temperature/Heat

• Venting & Drainage

• Welding

• Threaded Parts/Connections

• Post Galvanizing Design/Use

Understanding these aspects of the galvanizing process and how they can affect the coating and finished product's outcome will help ensure everyone's expectations are met.

Introduction - To Hot Dip Galvanizing

Hot Dip Galvanizing

The galvanizing process has existed for more than 250 years and has been a mainstay of North American industry since the 1890s. Galvanizing is used throughout various markets to provide steel with unmatched protection from the ravages of corrosion. A wide range of steel products ­from nails to highway guardrail to the Brooklyn Bridge's suspension wires to NASA's launch pad sound-suppression system - benefit from galvanizing's superior corrosion protection properties.

The uses of hot-dip galvanized steel continue to evolve, and new markets are emerging all the time. As with all materials and coatings, there are certain practices which yield better quality finished products. In order to meet the expectations and demands of many different markets, it is important to be cognizant of these best design practices for steel to be galvanized. Often no or only minor adjustments to the design are necessary, and worth the extra time and/or effort up front to alleviate certain future headaches related to the utilization of other coating systems.

Hubbell wins award for environmental energy project

Hubbell Galvanizing has won the top award for Electrical, Utility and Communications projects from the American Galvanizers Association for its work with Optiwind Inc. on a wind turbine project in Torrington, Conn.

The Klug Hill Farm windmill was designed to support the green movement, reduce cost and increase efficiency for Connecticut Light and Power. Optiwind designers wanted to create a sustainable, affordable, environmentally conscious way to generate electricity from wind for smaller markets.

The hot-dip galvanized steel that Hubbell provided throughout the structure helps the project achieve all of these goals. The structure is made entirely of galvanized steel, using infinitely recyclable zinc to protect it. The unbeatable corrosion protection means less energy or materials will be spent on routine maintenance.

Optiwind engineers briefly considered painting the structure, but realized the maintenance cost was too high. Hot-dip galvanized steel's cathodic protection is the perfect marriage of economic and environmental goals. We needed good communications to make all 100 tons of steel work. Many connection points required very tight tolerances, and we had to mask many of the movable parts. We made sure Optiwind's engineers knew what to expect from the hot-dip galvanizing process, and made modifications to ensure success.

This project breaks new ground, allowing small institutions to use wind generators for electricity. And hot-dip galvanized steel is an essential part of its success. The long-lasting, no-maintenance, and sustainable nature of galvanized steel is a crucial element of any affordable, environmentally friendly project.

We needed good communications to make all 100 tons of steel work. Many connection points required very tight tolerances, and we had to mask many of the movable parts. We made sure Optiwind's engineers knew what to expect from the hot-dip galvanizing process, and made modifications to ensure success.

This project breaks new ground, allowing small institutions to use wind generators for electricity. And hot-dip galvanized steel is an essential part of its success. The long-lasting, no-maintenance, and sustainable nature of galvanized steel is a crucial element of any affordable, environmentally friendly project