Specification For Galvanizing

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Master Specification 000.285.85400

Date: 24Jun2015
Page 1 of 9
SPECIFICATION FOR GALVANIZING
This specification has been revised as indicated below and described in the revision record on the following
page. Please destroy all previous revisions.
Revision
No.
Date
Originator's
Name & Initials
APPROVALS
Reviewed/Checked By
Name & Initials
SIGNATURES
Pages
DATE
Lead Engineer:
Project Manager:
Client Representative:
ISSUED FOR :
Design
Copyright 2010, Fluor Corporation. All Rights Reserved.
Construction
Other
Mechanical Engineering
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Date: 24Jun2015
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Record of Revisions
Rev. No.
Date
Description
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Date: 24Jun2015
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Table of Contents
Section
1.0
GENERAL ..................................................................................................................................................... 4
2.0
REFERENCES .............................................................................................................................................. 4
3.0
DESIGN AND FABRICATION REQUIREMENTS ................................................................................. 5
4.0
GENERAL REQUIREMENTS FOR GALVANIZING ............................................................................ 6
5.0
GALVANIZING OF HARDWARE ............................................................................................................ 7
6.0
GALVANIZING OF CARBON STEEL ITEMS OTHER THAN HARDWARE ................................... 7
7.0
GALVANIZED JOINTS .............................................................................................................................. 8
8.0
REPAIR OF DAMAGED ZINC COATINGS ............................................................................................ 8
9.0
QUALITY CONTROL ................................................................................................................................. 8
10.0
ATTACHMENTS.......................................................................................................................................... 9
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1.0
GENERAL
1.1
Scope
This Specification covers the requirements for hot-dip and mechanical galvanizing of
aboveground carbon steel items with operating temperatures below 750F and are not in
immersion service.
This Specification is applicable to the following items:
1.2
2.0
Electrical: Conduit, cable trays and covers including fasteners, and light standards
Pipe supports: Anchors, cradles, guides, hangers, shoes, miscellaneous supports, nonfireproofed shop fabricated carbon steel pipe supports
Structural Steel and accessories: Beams and columns, bolts, bumper posts, chain link fence
and accessories, checker plates, floor plates, grating, guardrails, handrails, hardware, ladders
and cages, platforms, safety and guard chains, sheet metal, stair stringers, stair treads, toe
plates, and other similar items.
Terminology
FABRICATOR shall mean the party responsible for design and/or fabrication of steel
products to be galvanized.
GALVANIZER shall mean the party responsible for galvanizing the carbon steel items.
ENGINEER shall mean the engineer responsible for the development or maintenance of this
Specification.
OWNER shall mean the project owner or its authorized representative.
REFERENCES
The latest revision, including addenda, of the following references in effect on the latest date of this
Specification form a part of this Specification. Except as modified by the requirements specified in this
Specification or on the drawings, all Work performed shall comply with the following references. Any
conflicts between the following references and this Specification shall be resolved by the ENGINEER.
2.1
ASTM (American Society For Testing And Materials)

A123
Standard specification for zinc (hot-dip galvanized) coatings on iron and steel products
A143
Standard practice for safeguarding against embrittlement of hot-dip galvanized structural

steel products and procedure for detecting embrittlement
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2.2
A153
Standard specification for zinc coating (hot-dip) on iron and steel hardware
A307
Standard specification for carbon steel bolts and studs, 60,000 psi tensile strength
A325
Standard specification for structural bolts, steel, heat treated, 120/150 ksi minimum
tensile strength
A384
Standard practice for safeguarding against warpage and distortion during hot-dip
galvanizing of steel assemblies
A385
Standard practice for providing high quality zinc coating (hot dip)
A392
Standard specification for zinc-coated steel chain-link fence fabric
A875
Standard specification for steel sheet, zinc-5% aluminum alloy coated by the hot-dip
process
B6
Standard specification for zinc
B695
Standard specification for coatings of zinc mechanically deposited on iron and steel
SSPC (The Society for Protective Coatings)

SP 1
SP 8
SP 11
SP 10
2.3
Solvent Cleaning
Pickling
Power Tool Cleaning to Bare Metal
Near-White Metal Blast Cleaning
Specifications
000.285.85210
3.0
Painting
DESIGN AND FABRICATION REQUIREMENTS

FABRICATOR / GALVANIZER shall comply with the requirements of ASTM A143, A384 and A385 for
all design and fabrication requirements. Cold working of carbon steel items to be galvanized shall not be
permitted unless the items are heat treated in accordance with the recommendations of ASTM A143,
paragraph 5, or tested for embrittlement in accordance with ASTM A143, paragraph 8.
Potential problems that require a modification in design, in order to eliminate possible embrittlement or
warpage, shall be brought to the attention of the ENGINEER, by the FABRICATOR / GALVANIZER,
before proceeding with fabrication and galvanizing. It shall be the FABRICATOR / GALVANIZER's
responsibility to safeguard against embrittlement, bending, and warpage.
Floor plates and shop assembled platforms shall be limited in size so that multiple dipping is avoided when
possible.
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The following points shall be given special attention during the design and galvanizing:
4.0
Vent / drain holes shall be provided to avoid high internal pressures and air locks.
Defects in the substrate such as cracks, laminations, laps, and folds shall be removed prior to
galvanizing.
As appropriate drilling, cutting, welding, forming, and final fabrication of unit members and
assemblies shall be completed before galvanizing.
Welds shall be continuous. Where laps can not be avoided all overlaps or contacted surfaces shall be
seal welded.
Rough spots and burns shall be removed by grinding prior to galvanizing.
GENERAL REQUIREMENTS FOR GALVANIZING

Identification markings on the items to be galvanized shall be provided by welding the identifying marks
on the material, by embossing the identifying marks on a steel tag of no less than No. 12 gage
(0.105" thick) and securing to the material with a heavy wire such as No. 9 gage (0.148" diameter), or by
die stamping the identifying marks onto the material with characters 1/2 " high and a minimum of
1/32" deep.
The zinc used for galvanizing shall be at least equal to the grade designated as "Prime Western," defined in
ASTM B6, containing a minimum of 98.5 percent zinc.
Surfaces shall be cleaned to remove oil and grease by solvent or detergent cleaning per SSPC SP-1.
Prior to pickling, all welding slag and fluxes shall be removed by blast cleaning or by a wire needle gun.
Carbon steel items to be galvanized shall be pickled in inhibited sulfuric acid per SSPC SP-8.
The GALVANIZER shall not damage the materials by over pickling or by the use of excessively high
temperatures in pickling or galvanizing. Each aspect of the process shall comply with the requirements of
ASTM A143.
The GALVANIZER shall exercise the required care to safeguard against warpage and distortion during
hot-dip galvanizing of steel products in accordance with ASTM A384.
After immersion in the molten zinc, the items shall not be subjected to any process of scraping or wiping
which may reduce the uniformity or the specified weight of the zinc coating. Galvanizing practice shall
comply with the requirements of ASTM A385.
The zinc coating shall be continuous, smooth, and uniform in thickness. The zinc coating shall be free of
voids, blisters, flux spots, inclusions, dross, acid or black spots. The coating shall be adherent so it will not
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Page 7 of 9
be removed by any reasonable process of handling or erection. Lumps, globules, or heavy deposits of zinc,
which could interfere with the intended use of the galvanized item, shall not be permitted.
The thickness and/or weight of the zinc coating shall not be less than the minimum values stated in the
applicable ASTM standards.
The GALVANIZER shall submit to the ENGINEER a procedure for tagging or otherwise apply the
original piece identification marking after galvanizing. Once approved, the procedure shall then be
implemented.
5.0
GALVANIZING OF HARDWARE
ASTM A490 bolts shall not be hot dip, mechanically, or electroplated with zinc or other metallic coatings
as such bolts are subject to hydrogen embrittlement with subsequent stress corrosion cracking and delayed
brittle failure in service.
High strength bolts ASTM A325 shall be galvanized as follows:
Type 1:
Hot-dip or mechanically galvanizing.
Type 2:
Mechanical galvanizing only. Mechanical galvanizing shall be per ASTM B695,

Class 80, Type II
Common bolts, ASTM A307, shall be hot-dip galvanized per ASTM A153, Class C.
If nuts (ASTM A194 and A563) require galvanizing, only hardened grades A194-2H, A563- DH / DH3
shall be galvanized.
ASTM A563 nuts shall be tapped after hot-dip galvanizing.
Mechanically zinc-coated nuts for assembly with mechanically zinc-coated bolts shall be tapped oversize
prior to coating and need not be retapped after mechanical galvanizing.
6.0
GALVANIZING OF CARBON STEEL ITEMS OTHER THAN HARDWARE

Carbon steel items fabricated from rolled, pressed, and forged steel shapes, plates, bars and strips shall be
galvanized per ASTM A123.
Sheet steel shall be galvanized per ASTM A875, Type II (zinc- 5% aluminum - 0.1% magnesium), Class A
(minimized coating structure) to GF235 coating and phosphatized.
Carbon steel chain-link fence fabric shall be galvanized per ASTM A392, Class 2.
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Date: 24Jun2015
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7.0
GALVANIZED JOINTS
Galvanized contact surfaces, to be joined by high tensile friction grip bolts, shall be roughened before
assembly so that the defined slip factor is achieved.
8.0
REPAIR OF DAMAGED ZINC COATINGS

The procedure used to repair damaged mechanically applied zinc coating (galvanizing) shall be submitted
to the ENGINEER for approval.
Metallizing with zinc is an acceptable alternative to the following coating repair procedures.
Repairs to damaged surfaces, galvanized with the hot-dip process, shall be as follows:
All oil, dirt, and foreign matter shall be removed by solvent or detergent cleaning according to
SSPC-SP 1.
Areas of spot rust, burnt residue, weld spatter, and other solid adherent foreign matter shall be blast
cleaned in accordance with SSPC-SP 10. In the event blast cleaning is not practical, mechanical
cleaning in accordance with SSPC-SP-11 using an MBX Bristle Blaster or non-woven abrasive discs
(3M Company). Welded joints of galvanized items shall be cleaned with a non-woven abrasive cup
wheel prior to feathering with a non-woven abrasive disc.
Cleaned and prepared surfaces shall be coated with the following materials in accordance with the
manufacturer's instructions, recommendations, and guidelines.
Operating temperature is 200F and below: ZRC, Zinga, Galvacon, Galvilite or approved equal zinc
rich cold galvanizing compound (non-aerosol) coating shall be applied to a dry film thickness of 3
mils.
Operating temperature is 200F through 600F: Inorganic zinc primer, having a minimum of
80 percent zinc by weight, shall be applied to a dry film thickness of 3 mils and finish painted with
Krylon 14029 or approved equal high heat silicone spray paint to a minimum dry film thickness of 2
mils
Operating temperature is 600F through 750F: Inorganic zinc primer, having a minimum of
80 percent zinc by weight, shall be applied to a dry film thickness of 3 mils and finish painted with
silicone aluminum applied to a dry film thickness of 1 mil in accordance with the project painting
specification.
9.0
QUALITY CONTROL
Material that is warped or distorted to the extent of impairment for the use intended shall be rejected.
The adherence of the zinc coating to the surface of the base metal shall be determined by cutting or prying
with the point of a stout knife, applied with considerable pressure in a manner tending to remove a portion
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Date: 24Jun2015
Page 9 of 9
of the coating. The adherence shall be considered inadequate if the coating flakes off in the form of a layer
or skin so as to expose the base metal in advance of the knife point. Testing carried out at edges or corners
(points of lowest coating adherence) shall not be used to determine adherence of coating. Likewise,
removal of small particles of the coating by paring or whittling shall not be used to determine failure.
The distribution of the zinc coating shall be determined by visual inspection. Except for local excess
coating thickness, which may interfere with the use of the product, or make it inconvenient or dangerous to
handle (edge tears or spikes), rejection for poor distribution shall be made only for plainly visible excess
coating not related to design factors such as holes, joints or special drainage problems. If, in the opinion of
the ENGINEER, visual examination is not conclusive, the distribution of zinc shall be determined by using
a magnetic thickness gauge after a sufficient number of readings, not less than five and preferably ten are
taken at each end and in the middle of the piece being examined.
Where practical, the thickness shall be measured by using a magnetic thickness gauge. Where thickness
measurement is not feasible, the coating weight shall be determined as noted in the referenced
ASTM standards for galvanizing.
The GALVANIZER is solely responsible to implement a quality control program to verify compliance with
this Specification.
The GALVANIZER shall have in effect at all times, a quality control program which clearly establishes the
authority and responsibility of those responsible for the quality system. Persons performing quality
functions shall have sufficient and well defined authority to enforce quality requirements that initiate,
identify, recommend and provide solutions to quality problems and verify the effectiveness of the
corrective action.
The OWNER reserves the right to re-inspect the galvanized items at the project site and reject any items
which do not comply with the ASTM standards. The repair of the defective items shall be to the account of
the GALVANIZER.
10.0 ATTACHMENTS
Not applicable.
End of Specification

Specification For Galvanizing

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Master Specification 000.285.85400