NEW KETTLE!

Hubbell Galvanizing would like to formally announce that our 

new kettle is now operational.  The new kettle dimensions

are as follows:

46'L x 5'W x 10'H

Please contact us with any questions regarding size/fit, or to 

place your next order -- we look forward to assisting you!

Hubbell Galvanizing

1-800-244-4258

(315) 736-8311

info@whyrust.com

Raised Welds After Galvanizing

Our customers take a lot of time and pride in their work, and want the completed product to

look its best.  We understand this desire, and always strive to make our customers happy.  

Quality and appearance are just as important to us as they are to our customers.  Below is

a short discussion that can aid our customers in reaching their goal, especially with products

such as handrail.

Raised welds after galvanizing are a common occurrence in the galvanizing industry, 

especially with handrail.  Many fabricators spend great amounts of time ensuring that the 

handrails and welded areas on the handrails are as smooth as possible.  These same fabricators

are then surprised when the handrails return from galvanizing and all of the welds they spent

so much time smoothing out, are anything but smooth.  Most likely, this has to do with a 

differing chemistry between the steel and the weld material -- namely the silicon level.  

Some concentrations of silicon can speed up the metallurgic reaction between the zinc and 

steel, causing rapid and large crystal growth.  This, in turn, causes the welds to become 

raised in comparison with the surrounding steel.  Fabricators need to pay close attention to

the silicon level of the weld material, to ensure that it is compatible with the steel in the parts

they are constructing.  Below is an article from the AGA discussing this issue in more detail:

     

Size & Shape

Size and shape of the fabrication is an important consideration to make, during the design process for parts to be galvanized.  Because hot-dip galvanizing is a total immersion process, the design must take into consideration the capacity of the galvanizing kettle; therefore, it is wise to verify kettle constraints with your galvanizer early in the design process.  Almost any component can be galvanized by designing and fabricating in pieces suitable for available galvanizing facilities.  Parts can also be progressively dipped by the galvanizer, to accomodate larger sizes and abnormal shapes.  For reference, the average kettle length in North America is 40 feet (13m), and there are many kettles between 50-60 feet (15.24 m - 18.28 m).

If you have any design questions relating to galvanizing, please give us a call: Hubbell Galvanizing 1-800-244-4258 (315) 736-8311 info@whyrust.com http://www.whyrust.com

Can Castings be Galvanized?

High-quality castings and forged parts are commonly and successfully galvanized. The quality of the galvanizing is strongly influenced by the quality of the casting.  As with all steel to be galvanized, cleanliness is very important to achieve completely galvanized cast iron or steel parts.  However, conventional cleaning processes employed by galvanizers do not always adequately clean castings.  This is because sand and other surface inclusions are not removed by chemical cleaning.  Thorough abrasive cleaning is the most effective method for removing foundry sand and impurities.  In fact, the preferred way to clean the casting is by abrasive blasting (either grit-blasting or a combination of grit and shot). Cleaning is traditionally performed at the foundry before shipment to the galvanizer.  However, some galvanizers are able to perform abrasive blasting at their facilities - check with your galvanizer before sending your parts.  

Sound, stress-free castings with good surface finishes will produce high-quality galvanized coatings. The following design and preparation rules should be applied for castings to be galvanized:

· Avoid sharp corners and deep recesses

·  Use large pattern numerals and generous radii to facilitate abrasive cleaning

· Specify uniform wall sections. Non-uniform wall thickness in certain casting designs may lead to distortion and/or cracking. Cracking results from stress developed as the temperature of the casting is increased during galvanizing. Uniform wall sections and a balanced design lowers stress.

As always, if you have any questions regarding this or any other galvanizing topic, please don't hesitate to contact us:

Hubbell Galvanizing

1-800-244-4258

(315) 736-8311

info@whyrust.com

Minimizing Distortion

Why do some fabricated assemblies distort during galvanizing?  

Stresses induced during steel production and in subsequent fabricating operations, are sometimes relieved when exposed to the high temperature of the molten zinc in the galvanizing kettle (generally around 840 deg. F).  Also, parts of dissimilar thicknesses that are welded together can expand and contract at differing rates, based upon their thickness.  When one of these materials tries to expand or contract and the other material is stationary, distortion can occur.  Galvanizing these types of materials separately can be of great benefit to the manufacturer, from a distortion control standpoint.  For example, with a channel frame and thin plate assembly, the frame and plate should be galvanized separately and bolted or welded together later, rather than welded together before galvanizing.

Guidelines for minimizing distortion and warpage are provided in ASTM A384,Safeguarding Against Warpage and Distortion During Hot-Dip Galvanizing of Steel Assemblies, and CSA Specification G 164, Hot Dip Galvanizing of Irregularly Shaped Articles.

Tips for Minimizing Distortion

To minimize changes to shape and/or alignment, design engineers should observe the following recommendations:

-Where possible, use symmetrically rolled sections in preference to angle or channel frames.

 I-beams are preferred to angles or channels.

-Use parts in assemblies that are of equal or near equal thickness, especially at joints (Figure 5).

-Use temporary bracing or reinforcing on thin-walled and asymmetrical designs (Figure 6).

-Bend members to the largest acceptable radii to minimize local stress concentration.

-Accurately preform members of an assembly so it is not necessary to force, spring, or bend them into position during joining.

-Continuously weld joints using balanced welding techniques to reduce uneven thermal stresses. Pinholes from welding are very dangerous in items to be galvanized and must be avoided. Staggered welding techniques to produce a structural weld are acceptable. For staggered welding of 1/8-inch(4 mm) or lighter material, weld centers should be closer than 4 inches (10 cm).

-Avoid designs that require progressive-dip galvanizing. It is preferable to build assemblies and sub-assemblies in suitable modules, so they can be immersed quickly and galvanized in a single dip. In this way, the entire fabrication can expand and contract uniformly.  Where progressive-dip galvanizing is required, consult your galvanizer.  

The last tip brings about a great point - if you have any questions regarding proper fabrication techniques to facilitate galvanizing, ALWAYS contact your galvanizer!  At Hubbell Galvanizing, we are happy to assist you with any questions you may have.  Feel free to contact us at the following:

(800) 244-4258 - Toll-free

(315) 736-8311 - Office

(315) 736-0381 - Fax

info@whyrust.com

http://www.whyrust.com

Galvanizing Appearance

A large portion of the questions we receive at Hubbell are regarding the appearance of the galvanized product.  One of the most frequent questions in the "appearance genre" is regarding a non-uniform (dull gray and shiny silver) finish.  While the contrast may look surprising and lead you to think there might be an issue with the product, we can assure you that this is a completely normal occurrence.  Most often, the non-uniform appearance results from the chemical make-up of the steel itself.  It is important to note that as the galvanized product weathers over time, the initial appearance differences you see will fade away, and the product will be a uniform matte grey.  Below is an excellent article from the American Galvanizers Association regarding this very topic:

 If you have any further questions about this, or any other topic, please let us know!  You can contact us at the following:
(315) 736-8311
(800) 244-4258
info@whyrust.com

Tubular Fabrications & Hollow Structurals Cleaning

Tubular Fabrications & Hollow Structurals Cleaning

Tubular assemblies (handrails, pipe columns, pipe girders, street light poles, transmission poles, pipe trusses, sign bridges) are commonly galvanized because corrosion protection is afforded to the interior and exterior of the product. To provide an optimal galvanized coating, hollow products require proper cleaning, venting, and draining.

Cleaning

As with all steel, pipe and other hollow materials must be thoroughly cleaned before the molten zinc will metallurgically bond with the steel. Pipe can present two special cleaning challenges. First, the mill coating (varnish, lacquer, and similar materials) applied by pipe manufacturers requires extra time and effort to remove at the galvanizing plant. Some galvanizers do not have the capability to remove this coating. Some organic mill coating formulations, both foreign and domestic, are

extremely difficult to remove with common cleaning solutions, so blasting may be required. Ordering uncoated pipe avoids costly attempts to remove these mill coatings. In some cases, it may be more cost effective to substitute tube for pipe.

Second, welding around mill coatings burns and carbonizes the varnish in the surrounding areas and cannot be removed

by the normal cleaning process at a galvanizer. This soot must be removed by blasting or other mechanical cleaning methods prior to delivering steel to the galvanizing facility.