What is cathodic protection?
Cathodic protection helps prevent corrosion on a metal surface. We explain in detail what cathodic protection is, its different types, and the benefits of cathodic protection for steel, especially in the context of hot dip galvanizing.
Cathodic protection explained
Each type of metal has an different electric potential, or the amount of potential electricity it can hold. When two different types of metal come together, provided they have dissimilar potential, the metal with more electro-negative potential will “sacrifice” itself and corrode before the metal with less electro-negative potential.
There are two types of cathodic protection. One is achieved by supplying a direct current (DC) from an external source, known as impressed current cathodic protection. The other makes use of sacrificial anodes, known as galvanic anode or sacrificial anode cathodic protection.
Benefits of cathodic protection
By preventing corrosion, cathodic protection extends the lifespan of metal structures, reducing the amount of replacements or repairs needed. This helps to save time and money on refabrication.
The extended lifespan given to the steel also means that it becomes a more sustainable solution than steel without cathodic protection, by reducing emissions associated with transport and refabrication.
Cathodic protection also helps to make vital steel fabrications such as structural steel more safe to use. Corrosion poses a significant threat to steel which can, in turn, create serious safety hazards. The extended lifespan given by cathodic protection helps to ensure that the steel remains reliably safer to use for longer and saves on downtime associated with maintenance.
Galvanizing provides cathodic protection
The hot dip galvanizing process provides galvanic anode cathodic protection for steel. The fabrication is dipped into a bath of molten zinc, causing a reaction that makes the zinc bond to the underlying steel. This occurs because zinc has more electro-negative potential than iron, causing the zinc to corrode first.
The cathodic protection provided through galvanizing means that it is a much more effective and long-lasting coating method than alternatives such as paint.
A high quality coating
Although hot dip galvanizing is very effective at corrosion protection, it’s important to choose the right galvanizing company for the job.
A bad quality job may result in an uneven coating thickness, which can cause a quicker rate of corrosion than a coating with the same thickness throughout. Spikes on an uneven coating could also cause a potential safety hazard. An uneven coating also may not look as nice, which may be important to you depending on its use. A high-quality galvanizing company will ensure the galvanized finish looks smooth, shiny, and aesthetically appealing.
When you choose Joseph Ash Galvanizing, you will be working with a company that cares about quality and takes care of the process from start to finish.
- We’ll collect and deliver your steel to our site ✔️
- Comprehensive technical support, guidance and assistance at every stage ✔️
- Fast turnaround times ✔️
- Hot dip galvanized to BS EN ISO 1461 standards ✔️
- Part of a circular economy ✔️
Galvanized steel can last a lifetime, so it’s expected that it won’t stay looking like new forever. Dirt can build up from everyday mud and grime, as well as from industrial sources. Therefore, you may be wondering how to clean galvanized steel.
While you can clean steel before galvanizing it with shot blasting, the galvanized finish on the steel will be compromised if you try to shot blast it after galvanizing. Fortunately, there are ways of cleaning galvanized steel that don’t damage the coating.
Cleaning galvanized steel
There are several ways of treating stains or marks on galvanized steel. Cleaning should be conservative at first, becoming more vigorous as needed. This is to ensure you don’t damage the zinc coating.
When cleaning bulk contaminants such as dirt, ordinary soaps can be used. For more adherent contamination or for larger areas, the use of a low-pressure wash with pure water, or alongside proprietary cleaning materials such as car wash fluid, can be effective. The car and truck cleaners are formulated to minimise corrosion on the metallic parts of vehicles so are suitable for use on galvanized steel. However, it is important wash the steel with fresh water afterwards.
Many mild stains (such as those from water ponding and water runs) can be removed with the use of common household ammonia cleansers. Again, be sure to thoroughly rinse the galvanized article with fresh water afterwards.
Finally, do not use any abrasive materials on the steel, as this can wear away the zinc coating achieved from the galvanizing process. It’s best to use a water-based emulsifier; alkaline-based cleaners with a pH of 12 or lower; or organic solvents for cleaning galvanized steel.
After cleaning, rinse the area with clean water and wipe the steel with a soft cloth. Make sure that you fully dry the steel to avoid the formation of wet storage stain on the surface.
Removing cement from steel
During building or renovations, cement and mortar may be dropped onto the galvanized steel. This can be very difficult to remove from the steel once it has hardened. If this occurs, remove the large parts of the deposit as close to the surface as practicable. Oxalic acid can then be used to remove the remaining remnants from the galvanized steel, followed with a thorough rinsing. Other acids are more effective on the mortar or cement, but these can be very damaging on zinc and are not recommended.
How to remove wet storage stain
Wet storage stains, also known as white rust, are common when galvanized surfaces are exposed to moisture (such as rain, dew, or condensation) and there is limited air flow over the surface. Wet storage stains can be prevented by storing galvanized steel in ventilated areas away from moisture.
While it’s best to prevent white rust rather than remove it, you can clean it by using a diluted acidic or ammonia solution, followed by a thorough rinsing with clean water.
How to touch up galvanized steel
Over time, there may be some areas that lose their galvanized coating. This can happen if you clean your steel incorrectly, or through gradual damage that builds up from everyday movement and impact. Fortunately, patches of damaged steel can be touched up with a zinc spray.
Zinc sprays contain condensed amounts of zinc that you can spray onto affected areas, without having to re-galvanize the whole fabrication. This saves you time and money compared to re-galvanizing the whole fabrication. It also helps extend the lifespan of steel as it prevents rust from building up inside the damaged areas, which may save you from needing to rebuild the fabrication from scratch.
One brand of zinc spray you can use is Galvsafe Zinc Spray. Galvsafe Zinc Spray is safe to paint and powder coat over, making touching up your steel easy. The Zinc Spray also colour-matches steel, so it blends in seamlessly and keeps the fabrication looking like new. It’s ideal to use after cleaning your galvanized steel to help maintain its lifespan. Order yours today by contacting your nearest Joseph Ash Galvanizing site.
If you have any questions about cleaning your galvanized steel, get in touch with your local galvanizer for advice.
Ready to galvanize your steel?
Many industries rely on their steel fabrications being kept outside. From structural steel buildings to farm gates and transmission towers, steel is prone to corrosion in moist environments. Fortunately, hot dip galvanizing serves as the perfect coating method for steel that is exposed to the elements.
What happens when galvanized steel gets wet?
Normally, when steel gets wet – whether from the rain or moisture in the air – it corrodes very quickly. When metals collect moisture, an electrochemical reaction causes the steel to corrode. The corrosion process is often accelerated by dissolved salts or impurities in the water.
Rust is just one type of corrosion but it’s one of the most prevalent types to affect steel. It occurs when oxygen reacts with metal atoms, forming metal oxides. Both oxygen and moisture are required for steel to rust. However, it’s very unlikely your steel will be kept away from oxygen if it’s exposed to moisture. Therefore, it’s important to slow down the corrosion process as much as possible.
The galvanizing process involves dipping steel into a bath of molten zinc, causing the zinc particles to metallurgically bond to the steel. This bond creates a much more durable finish that surface-level coatings such as paint, meaning galvanizing is effective for protecting steel against atmospheric attack, such as heavy rain.
Is galvanized steel good for outdoor use?
Galvanized steel is good to use outdoors thanks to its corrosion-resistant properties. Structural steel, transmission poles, and agricultural equipment are all types of steel that are likely to be affected by weather conditions, among many other types of steel fabrications.
If you’re in the construction, agricultural, transport or energy sectors, galvanizing steel that is used outside means you save time and money on maintenance and replacements.
Outdoor paint for steel
Hot dip galvanizing is a reliable coating method for protecting steel against weather damage. However, you may be looking to add an extra layer over your steel such as paint.
Paint is often used to give colour to steel and add an extra layer of protection, but it can chip away easily, compromising the underlying steel. Even when using waterproof paint, it is advised that you recoat it every 5-10 years. But what if there was an alternative to paint that doesn’t need retouching so frequently?
Fortunately, there is. Powder coating is a method of coating steel that adds colour without compromising on durability.
Powder coating is the best alternative to paint. Unlike paint, which chips easily and does not protect against corrosion, powder coating is applied electrostatically to the steel. This application technique means that the layer of powder coating protects the underlying steel against corrosion. Powder coating used in synergy with hot dip galvanizing is known as a duplex coating.
Joseph Ash Galvanizing for durable steel
With nine UK sites, we’re never too far away to protect your steel.
- We’ll collect and deliver your steel to our site ✔️
- Comprehensive technical support, guidance and assistance at every stage ✔️
- Hot dip galvanized to BS EN ISO 1461 standards ✔️
- Part of a circular economy ✔️
Welding is a versatile and essential skill for steel fabricators. However, you may wonder if it is safe to weld steel after it has been galvanized. Does the zinc coating affect the welding process? Will the welding process ruin the galvanized coating? We explore whether you can weld galvanized steel, and the best practices to do so safely and effectively.
What is galvanized steel?
Prior to welding your galvanized steel, it’s crucial to understand the material you’re working with. Hot dip galvanizing involves dipping steel into a bath of molten zinc, creating galvanized steel. This zinc coating protects steel against corrosion, increasing its longevity and making it an ideal choice for fabricators.
Ungalvanized steel does not have this layer of zinc over it, which makes it more susceptible to corrosion. However, the zinc can cause problems when welding steel fabrications.
What happens when you weld galvanized steel?
When you expose galvanized steel to high temperatures during welding, the zinc coating evaporates, releasing toxic fumes and creating health and safety hazards.
Inhaling zinc fumes can cause symptoms such as nausea, chills, fever, and muscle aches. These symptoms together are sometimes known as “metal fume fever”. Prolonged exposure to zinc fumes can cause serious health issues. Welding galvanized steel can also result in increased spatter and smoke, which can be hazardous and affect the quality of your work environment.
The quality of the welding job can also be affected. The presence of zinc during welding can create defects in the weld, such as porosity or inclusions, which weaken the joint.
Can you weld galvanized steel safely?
Although not recommended, you can still weld galvanized steel. However, it requires careful preparation and precautions to ensure your safety and the quality of the weld. Here are some steps to follow:
- Proper ventilation: Welding should always be done in a well-ventilated area, but it’s even more crucial when working with galvanized steel. Use exhaust fans, open doors, or consider outdoor welding to minimise exposure to zinc fumes.
- Wear appropriate safety gear: Ensure you are wearing appropriate personal protective equipment (PPE), including a welding helmet, gloves, and respiratory protection.
- Clean the surface: Before welding, grind away the zinc coating from the areas you intend to weld. This prevents the release of zinc fumes and ensures better weld quality.
- Use low heat: Reduce heat input by using lower amperage and voltage settings on your welding equipment. This helps minimise the evaporation of zinc.
Should I weld steel before galvanizing?
You can avoid emitting zinc fumes if you weld steel before galvanizing, reducing the side effects associated with inhaling zinc fumes. However, this doesn’t mean there aren’t health and safety risks with galvanizing steel that has already been welded. Fabricators need to ensure that their steel is correctly vented before sending to their local hot dip galvanizing site. Incorrectly venting your steel can have explosive consequences.
It’s also important to ensure you weld your steel together correctly by leaving seam gaps. Without gaps, air becomes trapped in the weld joint, causing pressure between the two welded pieces. This pressure builds up until the fabrication forcible separates at high speed. To avoid this, leave seam gaps between the steel pieces so that air can escape and avoid pressure building.
If in doubt, you can download our venting tips and tricks guide here.
However, it is important to note that the welded section will no longer be corrosion resistant after welding as the zinc coating is removed. Therefore, the item will likely have to be re-galvanized after welding to ensure it is protected.
To conclude, you can weld galvanized steel, but it requires extra care and precautions due to the zinc coating created from galvanizing. Safety should always be a top priority when working with any welding project, and this is especially true when welding galvanized steel. Proper ventilation, protective gear, and surface preparation are key to ensuring you remain safe when welding steel.
Ask your local galvanizing company if you are unsure about welding or venting steel.
Ready to galvanize your steel?
Causes, types, and how to prevent corrosion
Corrosion can affect various materials, causing deterioration and damage. If left untreated, corrosion can be visually unappealing at best or an expensive safety hazard at worst. We define corrosion, its causes and types, as well as preventative measures to help you better understand and combat the steel deterioration process.
Corrosion definition
Corrosion is the gradual deterioration of materials, caused by chemical reactions with the environment. It is a natural process and is most associated with metals, but it can also affect other materials like ceramics and plastics. The corrosion process happens when a material reacts with substances such as oxygen, water, acids, or salts, leading to the breakdown of its structure.
Causes of corrosion
Several factors contribute to corrosion, mainly occurring when metal is exposed to external variables. The primary factors include:
Moisture
When metals collect moisture, an electrochemical reaction causes the steel to corrode. The corrosion process is often accelerated by dissolved salts or impurities in the water.
Oxygen
Oxygen reacts with metal atoms, forming metal oxides – otherwise known as rust. Rust is just one type of corrosion, but it’s one of the biggest types to affect steel.
Unless the steel is kept in an oxygen-free environment, it will slowly rust over time, even if you take good care of it. Both oxygen and moisture are required for steel to rust.
Chemicals
Acidic substances can corrode metals by attacking their surface. Industrial processes, pollution, and even natural sources like acid rain can introduce acids to the environment, increasing the risk of corrosion. Industrial companies, or those that work in construction or similar sectors, are at a higher risk.
Types of corrosion
There are many forms of corrosion, each with distinct characteristics and causes. The most common types include:
Uniform corrosion
This type of corrosion occurs evenly across the surface of the material, resulting in a gradual loss of material thickness. Uniform corrosion is typically caused when metal is exposed to moisture or atmospheric conditions.
Pitting corrosion
Pitting corrosion is when holes form in the metal surface. It often starts with a small scratch, which then becomes an active site for corrosion. Pitting corrosion can be particularly destructive, leading to rapid damage.
Galvanic corrosion
Galvanic corrosion occurs when two different metals come into contact in the presence of an electrolyte, such as moisture. The metal that is less resistant to corroding corrodes quicker due to the electrochemical potential difference between the two metals.
Uniform corrosion is the most common type of corrosion; fortunately, it is also among the easiest types to prevent.
Preventing corrosion
Metal corrodes very quickly without a protective coating. Preventive measures can help minimise the risk and impact of corrosion. Some effective strategies include:
Galvanizing
Hot dip galvanizing involves dipping steel into a bath of molten zinc, causing a chemical reaction where the zinc metallurgically bonds with the steel. As the zinc and steel atoms bond, it makes the steel very durable and corrosion-resistant. Galvanizing is among the most effective ways to protect steel against corrosion.
Top-layer coatings
Applying a surface coating such as powder coating or paint can protect steel against corrosion. Top-layer coatings can also be used after the steel has been galvanized to enhance the steel’s longevity.
Combining hot dip galvanizing and powder coating on the same steel structure is known as a duplex coating. You can learn about the benefits of duplex coatings here.
Environmental changes
Changing your environment can reduce the rate of corrosion. However, this may not always be possible, especially if the steel is outside or near corrosive chemicals.
How to remove rust from metal
There is still hope if your steel has started to corrode. A surface-cleaning technique such as shot blasting can remove any existing rust off the steel. While shot blasting on its own won’t prevent rust from building up again, it is a crucial step before galvanizing to make the process more effective.
If your steel is very rusty, it may not be possible to recover. In the future, book in with a reputable galvanizing company as soon as possible after steel fabrication.
By understanding the causes and types of corrosion, as well as implementing preventive measures, it is possible to minimise its impact.
Joseph Ash Galvanizing can remove rust from your steel and increase your steel’s resistance against corrosion. Find your nearest site and get a quote today.
Have you heard of galvanizing, but are unsure of what it means? Look no further, as we cover everything to know about this corrosion protection process here.
Galvanizing definition
Galvanizing, or galvanising (UK spelling) is a metal protection process that involves coating steel or iron with a layer of zinc. The zinc coating acts as a barrier for the metal, protecting it from rust and corrosion.
Hot dip galvanizing is the most established method of galvanizing. Most steel finishing providers in the UK offer hot dip galvanizing rather than its alternatives. Without galvanizing, metal corrodes quickly, as the metal is exposed to moisture and other sources of corrosion.
The galvanizing process
There are many stages to hot dip galvanizing, but in summary, it can be divided into four stages: cleaning, fluxing, galvanizing, and post-treatment.
Cleaning
First, the metal is cleaned and degreased, using an alkaline solution that is heated with the residual heat from the galvanizing furnace. The cleanliness of the alkaline solution is maintained, as it continuously flows through an oil separation unit to remove residual oils.
After this, acid cleaning takes place with tanks containing hydrochloric acid. Inhibitor is added to reduce chloride emissions, reduce maintenance of the facilities and improve working conditions for our employees. Spent acid – meaning acid that has become weaker from the cleaning process – is reused, neutralising alkali wastes from other processes.
Fluxing
Once the steel has been cleaned, it is dipped in a flux solution. A flux solution is made of zinc-ammonium chloride which, like the alkaline solution in the cleaning process, is heated with residual heat from the galvanizing surface. The fluxing process removes the remaining traces of oxide and helps prepare the metal for the zinc bath.
Galvanizing
After fluxing, the metal is dipped into a bath of molten zinc. This process forms a metallurgical bond between the zinc and the metal, which means the atoms between them chemically bond instead of just applying a top level coating on the metal surface. This process creates a durable, corrosion-resistant finish that can withstand extreme temperatures, harsh environments, and corrosion.
Post-treatment
Finally, an optional follow-up coat such as paint or powder coating can be applied. While not part of the galvanizing process itself, post-treatment further increases the metal’s durability and corrosion-resistance.
Post-treatment can also include quenching and passivation. These are also optional, but can help preserve the steel further and protect against wet storage stains.
We’ve created a useful animation that showcases the hot dip galvanizing process.
Different types of galvanizing
The above process applies for hot dip galvanizing, but there are numerous types of galvanizing, including:
Hot dip galvanizing
During hot dip galvanizing, metal is dipped into a bath of hot zinc, as detailed before. The heat causes a chemical reaction, causing the zinc to metallurgically bond to the steel. This process makes the metal much more durable compared to surface-level coatings such as paint.
More technically, the process creates a sacrificial anode cathodic protection layer, causing the zinc to corrode in preference to the iron.
There are many reasons to hot dip galvanize your steel, such as increased durability and low lifetime costs.
Cold galvanizing
The metal is coated with cold zinc. Unlike hot dip galvanizing, cold galvanizing does not cause the zinc to metallurgically bond to the metal as there is no heat. As a result, it is not the preferred method of galvanizing, as the zinc layer is prone to chipping. Some argue that it isn’t a form of galvanizing at all.
Spin galvanizing
Spin galvanizing is a method for coating metal that is too small to be dipped directly into a bath. To stop the small pieces getting lost in the bath, they are placed inside a perforated basket first. After being withdrawn from the bath, the basket is spun at high speeds to remove the excess zinc. Like hot dip galvanizing, spin galvanizing has many benefits, as it is the same process but for smaller sized pieces.
Joseph Ash Galvanizing offers a range of galvanizing services to meet your needs, from small components to large structures. Our team of experts use state-of-the-art technology and equipment to ensure that your products are galvanized to the highest standards. Galvanizing is also environmentally friendly, using minimal energy and producing no hazardous waste.
Galvanizing services throughout the UK
No matter your size or sector, Joseph Ash Galvanizing can provide you with a high-quality galvanizing service that will protect your metal products and increase their lifespan.
- Nine sites across the UK ✔️
- Protect steel from rust and corrosion ✔️
- Quality Systems approved to BS EN ISO 9001 ✔️
- Quick turnaround times ✔️
- On-site storage facilities ✔️
Incorrectly venting your steel fabrications before sending them to your local hot dip galvanizing facility can lead to explosive consequences. It’s critical to ensure you follow correct venting procedures to keep your fabrication intact and galvanizing operatives safe. It will also help you achieve the best quality zinc coating.
We’ve created some helpful videos and documents on what could happen if you don’t vent your steel correctly, as well as the correct measures to take.
Video 1: Super-heated steam in hollow structures
Process chemicals and air can become trapped in open-ended hollow structures when they don’t have vent holes. The trapped chemicals create super-heated steam when submerged in the molten zinc. If the zinc makes direct contact with the steam through the open end of the fabrication, it will eject out of the bath with extreme force.
Vent holes on the closed end of the steel mean the process chemicals can escape, avoiding the build-up of steam.
Video 2: Trapped air during welding
When welding steel together, it is important to leave seam gaps in the steel to avoid air becoming trapped. If large steel pieces are welded together without gaps, air becomes trapped between them. When dipped in the galvanizing bath, this causes the pressure between the two pieces to build up until they become forcibly separated at high speed.
To avoid this, leave seam gaps between the steel pieces so that air can escape and avoid pressure building.
Video 3: Incorrectly-placed vent holes
We’ve covered briefly why vent holes are needed – to release trapped air and process chemicals. But it’s important to make sure they’re correctly placed to ensure they do their job.
Remember, when welding fabrications that cause closed-off sections, there should be vent holes both internally and externally, as required, to avoid any air or chemicals becoming trapped.
Video 4: Not enough vent holes
Even if you take the previous precautions onboard and add vent holes, you need to make sure you have enough of them to release the air and process chemicals. Both the placement and amount of vent holes are crucial for ensuring there are no explosive results at the galvanizing bath.
If in doubt, always contact your local galvanizing service provider for advice before booking your collection. They can help you determine the correct venting requirements for your individual needs.
Alternatively, you can view our venting tips and tricks poster for more information.
Next pageWhat’s the difference between shot blasting and sand blasting?
Shot blasting and sand blasting are surface preparation methods used to remove corrosion, paint, or other imperfections from metal. Both surface preparation methods leave a metal surface with a smoother, cleaner finish – an essential first step in the metal protection process. These cleaning methods make any subsequent treatment last longer and provide a higher quality finish.
But what’s the difference between the two services?
What is sand blasting?
Sand blasting traditionally uses silica sand which is blasted onto the metal to clean it. In more recent times, this has also included glass. The high-velocity sand particles strike the surface, removing coatings, rust, scale, and other contaminants. The texture of the surface after sand blasting depends on the size and type of abrasive material used.
Sand blasting is effective for cleaning and surface preparation, but leaves a smoother finish than shot blasting. While smoothing the steel is an important step for surface preparation, the durability of secondary coatings such as paint may be compromised if the surface is too smooth. Surface coatings need to be able to adhere to the steel, which is harder when the steel is completely smooth.
Unlike shot blasting, sand blasting can have negative impacts on health. This is because the fine dust residue created from the process could be inhaled (even when following the correct health and safety measures), as the particles remain in the air for several days. And this is without wind, so imagine how far these particles can travel on bad weather days!
Dust residue from sand blasting can result in dangerous amounts of respirable crystalline silica for both the operator and the consumer. Consequently, sand blasting with silica sand is banned in the UK.
What is shot blasting?
Shot blasting uses small amounts of metal, such as aluminium oxide or carbon grit, which is propelled onto the steel. The small particles are known as “shot”, hence the process’s name. The main difference between shot blasting and sand blasting is the material used. Because of this difference, shot blasting does not result in inhaling any residue when using the correct PPE and is, therefore, not forbidden.
Metallic shot can also be re-used multiple times, reducing material costs. The ability to reuse material also means shot blasting is more environmentally friendly than sand blasting.
Shot blasting also results in a slightly different finish compared to sand blasting. Sand blasting creates a fully smooth profile, whereas shot blasting creates a slightly textured surface profile. The added texture allows for any secondary coatings to adhere to the steel more, increasing the coating’s durability.
In summary, shot blasting and sand blasting use different materials, resulting in slightly different surface finishes. Sand blasting poses a health and safety risk and is not the preferred method of surface cleaning.
At Joseph Ash Galvanizing we take pride in our health and safety measures, following health and safety laws and regulations when carrying out shot blasting, galvanizing, powder coating and duplex coatings projects. We also follow BS EN ISO 1461 and BS EN ISO 9000 quality assurance specifications. Our commitment to health and safety is also evidenced by the fact we’ve won RoSPA Gold awards for excellent health and safety standards, nine years running.
Contact us today to discuss your shot blasting requirements.
Next pageWhile hot dip galvanizing is a common metal treatment method, spin galvanizing is key for galvanizing small pieces. We cover what spin galvanizing is, how it works, and the benefits it offers here.
What is spin galvanizing?
Spin galvanizing is a process used to coat small metal parts with zinc. It is particularly useful for coating small, complex parts that may be difficult to dip into a galvanizing bath. The process involves placing the pieces in a basket, which is then submerged in molten zinc, withdrawn, and spun at high speeds. Spin galvanizing is used to increase the lifespan of steel by making it more robust, durable, and rust-resistant.
How does spin galvanizing work?
Spin galvanizing involves several steps. First, the parts that need treating are cleaned and prepared for galvanizing. This involves removing any dirt, grease, or other contaminants by using a method such as shot blasting.
Next, the parts are placed in a basket which is then submerged into molten zinc. The basket acts as a barrier, stopping the pieces from being lost in the bath. Once a zinc/alloy layer forms, the basket is withdrawn and spun at high speeds. The spinning action distributes the zinc evenly over all parts and removes any excess, creating a uniform coating.
Finally, the coated parts are removed from the basket and inspected to ensure that the coating is even and free of defects.
Benefits of spin galvanizing
Spin galvanizing has numerous distinct benefits:
Protect small pieces: One of the main benefits of spin galvanizing is that small parts can be galvanized without being dipped directly into a bath. You gain the benefits of hot dip galvanizing without losing any pieces. This makes it an ideal solution for protecting fasteners, fixings, hinges, and chains.
Increased durability: Unlike surface-level coatings such as paint, the zinc layer used with galvanizing chemically bonds to the metal, making it stronger against corrosion. The zinc coating is also thicker than alternatives, further contributing to its durability. The increased durability enhances the metals lifespan, saving you time and money on repeated coatings.
Environmentally friendly: Galvanizing produces less waste compared to other methods, as it only uses the amount of zinc needed. This makes it an environmentally friendly option, fitting into a circular economy.
Save money: You can expect to see a greater return on investment with spin galvanizing. Spin galvanizing makes the metal more durable, reducing the frequency of maintenance needed, and reducing the associated labour costs such as transportation. It is also a fast process with a short turnaround time, so the parts are returned to you quicker.
Spin galvanizing is a cost-effective, efficient, and environmentally friendly method for coating small parts with zinc. It offers enhanced adhesion, consistency, and reduced material waste compared to other steel protection methods. It is the ideal choice for protecting your small metal pieces.
At Joseph Ash Galvanizing, we offer spin galvanizing at our Telford branch. We can collect your small metal parts and return them to you with our BS EN ISO 9001:2015 quality finish. Contact us today to learn more about how we can help you protect your metal from rust and corrosion.
Next pagePowder coating is a popular alternative to paint that serves many benefits that paint cannot. While the two coating methods may seem similar, powder coating has numerous benefits compared to paint. We cover what powder coating is and what benefits it brings. We will also explore why powder coating is better than paint, and its relevance for various industries.
What is powder coating?
Powder coating is a process that involves applying a dry powder to a metal surface. The powder is sprayed on the surface with a spray gun, and the fabrication is then cured in an oven under a high temperature to form a tough, durable skin. It can be applied over galvanized metal to make it even more durable.
Like paint, powder coating is used for protecting the material underneath, and enhancing the steel’s visual appeal with a wide range of possible textures and colours. However, powder coating is superior to paint as it is cheaper, quicker, more durable, and more environmentally friendly.
Benefits of powder coating
Powder coating offers several benefits over traditional paint, including:
Durability: Powder coating is more durable than traditional paint. It is resistant to chipping, scratching, and fading, leaving the fabrication looking nicer for longer. Because powder coating reduces how often the steel needs to be treated, maintenance becomes cheaper overall.
Time-saving: Paint needs several days to dry after it has been applied. It also needs multiple coats to achieve the desired result. In contrast, a powder coat can be completed in one sitting and has a quicker drying time. This means you get your fabrication back quicker and spend less time waiting.
Environmentally friendly: Powder coating is an environmentally friendly alternative to traditional paint. It produces less waste, and the powder can be recycled. Additionally, paint contains toxic solvents that damage the environment. The powder coating solution does not contain toxic solvents and is safer for operators to apply, provided the correct PPE is used for the job.
Versatility: While paint and powder coatings are both available in many colours, powder coating also comes in a wide range of textures and finishes, including metallic, glossy, and matte. This versatility allows for greater customization and design options.
Cost-effective: Powder coating is a cost-effective alternative to traditional paint, thanks to its increased durability and recyclability. It is also less labour-intensive, meaning your service provider can complete the job for a lower price.
Powder coating for steel
Powder coating is beneficial for steel in a wide range of industries. The automotive industry can benefit from powder coating as it can coat everything from cars and trucks, to motorcycle parts and trailers. It can also be used in the aerospace and marine industries to coat aircraft parts and marine equipment.
The construction industry can coat structural steel, fencing, gates, and other building components. Similarly, it is also used in the architectural industry to coat window frames and doors. Powder coating is most beneficial for industries that require a durable, long-lasting coating that can withstand harsh environments. It is ideal for increasing the visual impact of your metal and helping it stand out. You can view our photo gallery if you’d like to see some examples.
Powder coating is a durable, versatile, and cost-effective alternative to traditional paint. It offers several benefits, including greater durability, customisation options, and environmental friendliness. Powder coating is relevant in a wide range of industries and is most beneficial for markets that require durable, long-lasting coatings that can withstand harsh environments.
Joseph Ash Galvanizing can powder coat your steel fabrications. Contact us today for a quote or to book a collection.
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