Handbook of Hot–dip Galvanization

Hot–dip galvanization is a method for coating steel workpieces with a protective zinc film to enhance the corrosion resistance and to improve the mechanical material properties. Hot–dip galvanized steel is the material of choice underlying many modern buildings and constructions, such as train stations, bridges and metal domes.
Based on the successful German version, this edition has been adapted to include international standards, regulations and best practices. The book systematically covers all steps in hot–dip galvanization: surface pre–treatment, process and systems technology, environmental issues, and quality management. As a result, the reader finds the fundamentals as well as the most important aspects of process technology and technical equipment, alongside contributions on workpiece requirements for optimal galvanization results and methods for applying additional protective coatings to the galvanized pieces.
With over 200 illustrated examples, step–by–step instructions, presentations and reference tables, this is essential reading for apprentices and professionals alike.


Spis treści:
Preface to the Third German Edition.
Acknowledgment.
Preface to the Second German Edition.
List of Contributors.
1 Corrosion and Corrosion Protection IPeter Maaß).
1.1 Corrosion.
1.2 Corrosion Protection.
Appendix 1.A.
2 Historical Development of Hot–dip Galvanizing (Peter Maaß).
References.
3 Surface–preparation Technology (Peter Peißker).
3.1 As–delivered Condition.
3.2 Mechanical Surface–preparation Methods.
3.3 Chemical Cleaning and Degreasing.
3.4 Rinsing of the Parts.
3.5 Pickling.
3.6 Hot–dip Galvanizing Fluxes.
References.
Standards.
Lifting Devices.
4 Hot–dip Galvanizing and Layer–formation Technology (W. –D. Schulz and M. Thiele).
4.1 Process Variants.
4.2 Layer Formation in Hot–dip Batch Galvanizing Between 435 °C and 620 °C.
4.3 Liquid–metal–induced Embrittlement (LME).
4.4 After–treatment.
References.
5 Technical Equipment (R. Mintert and Peter Peißker).
5.1 Preliminary Planning.
5.2 Layout Variants of Plants.
5.3 Pretreatment Plant.
5.4 Drying Furnaces.
5.5 Galvanizing Furnaces.
5.6 Galvanizing Kettle.
5.7 Zinc Bath Housings.
5.8 After–treatment.
5.9 Unloading Area.
5.10 Crossbeam Return.
5.11 Crane Units.
5.12 Filtration Plants.
5.13 Semiautomatic Galvanizing Lines for Small Parts.
5.14 Galvanizing Furnace with Ceramic Trough.
5.15 Automatic Galvanizing Line for Small Parts.
5.16 Pipe Galvanizing Line.
5.17 Application of Vibrators.
5.18 Energy Balance.
5.19 Commissioning and Decommissioning of a Hot–dip Galvanizing Kettle, Kettle Change, Method of Operation.
References.
6 Environmental Protection and Occupational Safety in Hot–dip Galvanizing Plants (C. Kaßner).
6.1 Rules and Measures Concerning Air–pollution Control.
6.2 Measures for the Control of Air Pollution.
6.3 Measuring Systems.
6.4 Waste and Residual Materials.
6.5 Noise.
6.6 Occupational Safety.
6.7 Practical Measures for Environmental Protection.
References.
Further References.
7 Design and Manufacturing According to Hot–dip Galvanizing Requirements (G. Scheer and M. Huckshold).
7.1 General Notes.
7.2 Requirements Regarding Surface Quality of the Basic Material.
7.3 Dimensions and Weights of Material to be Galvanized.
7.4 Containers and Tubular Constructions (Hollow Bodies).
7.5 Steel Profile Constructions.
7.6 Steel Sheet and Steel Wire.
7.7 Constructions of Hot–dip Galvanized Semifinished Products.
7.8 Avoidance of Distortion and Crac k Formation.
7.9 Welding Before and After Hot–dip Galvanizing.
7.10 Hot–dip Galvanizing of Small Parts.
7.11 Reworking and Repair of Zinc Coatings.
7.12 Hot–dip Galvanizing of Cast Materials.
7.13 Local Avoidance of Zinc Adherence.
7.14 Standards and Guidelines.
7.15 Defects and Avoiding Defects.
References.
8 Quality Management in Hot–dip Galvanizing Companies (G. Halm).
8.1 Why Quality Management?.
8.2 Important Criteria.
8.3 Structure of the QM System according to DIN EN ISO 9001:2000.
8.4 Short Description of QM Elements Sections 4–8 294.
8.5 Introduction of QM Systems.
8.6 Trends.
Acknowledgment.
References.
9 Corrosion Behavior of Zinc Coatings (H.–J. Böttcher, W. Friehe, D. Horstmann, C.–L. Kruse, W. Schwenk, and W.–D. Schulz).
9.1 Corrosion – Chemical Properties.
9.2 Corrosion Caused by Atmosphere.
9.3 Corrosion through Water.
9.4 Corrosion in Soils.
9.5 Corrosion Resistance to Concrete.
9.6 Corrosion in Agricultural Facilities and Caused by Agricultural Products.
9.7 Corrosion through Nonaqueous Media.
9.8 Corrosion Protection Measures at Defective Spots.
9.9 Examination of Corrosion Resistance and Quality Test.
References.
10 Coatings on Zinc Layers – Duplex–Systems (A. Schneider).
10.1 Fundamentals, Use, Main Fields of Application.
10.2 Definitions of Terms.
10.3 Protection Period of Duplex–Systems.
10.4 Special Features of the Constructive Design of Components.
10.5 Quality Requirements for the Zinc Coating for Protective Paint Layers.
10.6 Surface Preparation of the Zinc Coating for the Protective Paint.
10.7 Coating Materials, Protective Paint Systems.
References.
11 Economic Efficiency of Hot–dip Galvanizing (Peter Maaß).
References.
12 Examples of Use (Peter Maaß).
12.1 Building Construction.
12.2 Civil Engineering.
12.3 Traffic Engineering.
12.4 Sport/Leisure.
12.5 Plant Engineering.
12.6 Mining.
12.7 Energy Supply.
12.8 Agriculture.
12.9 Component Parts/Fasteners.
12.10 Environmental Protection.
12.11 Handicraft.
12.12 Art.
12.13 Continuous–sheet Galvanizing.
12.14 Conclusion.
13 Appendix (Peter Maaß).
Appendix A Defect Occurrence on Zinc Coatings and at Hot–dip Galvanized Workpieces.
13.1 Requirements for the Zinc Coating.
13.2 Assessment Criteria for Hot–dip Galvanized Coatings on Steel Structures.
13.3 Major Defects in the Zinc Coating or at the Hot–dip Galvanized Workpiece.
Components.
Appendix B Information Centers in the Federal Republic of Germany.
Appendix C Hot–dip Galvanizing Companies in Germany as of 15/8/2005 Source: Institut für Feuerverzinken GmbH.
Appendix D Worldwide Galvanizing Associations.
Index.

Nota biograficzna:
Peter Maass is a specialist engineer for corrosion protection. In addition to his engineering degree, he holds a PhD in economics. In his professional career he headed the central office for hot–dip galvanization of the German Democratic Republic for twenty years. Later Peter Maa? became head of the northeastern branch of the Institute of Hot–Dip Galvanization, Ltd., in Dusseldorf, Germany. He edited three German editions of the handbook of hot–dip galvanization that became the de facto standard for vocational training.

Okładka tylna:
Hot–dip galvanization is a method for coating steel workpieces with a protective zinc film to enhance the corrosion resistance and to improve the mechanical material properties. Hot–dip galvanized steel is the material of choice underlying many modern buildings and constructions, such as train stations, bridges and metal domes.
Based on the successful German ve rsion, this edition has been adapted to include international standards, regulations and best practices. The book systematically covers all steps in hot–dip galvanization: surface pre–treatment, process and systems technology, environmental issues, and quality management. As a result, the reader finds the fundamentals as well as the most important aspects of process technology and technical equipment, alongside contributions on workpiece requirements for optimal galvanization results and methods for applying additional protective coatings to the galvanized pieces.
With over 200 illustrated examples, step–by–step instructions, presentations and reference tables, this is essential reading for apprentices and professionals alike.