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. Many modern buildings and constructions, such as train stations, bridges and metal domes rely on a steel skeleton that needs to perform safely for decades even under detrimental influences - hot-dip galvanized steel is the material of choice.The book systematically covers all steps of the hot-dip galvanization process. The reader finds the basics such as corrosion and zinc film formation as well as the most important aspects of process technology and technical equipment, alongside with contributions on workpiece requirements for optimal galvanization results and on methods for applying additional protective coatings to the galvanized pieces.Separate chapters deal with the important topics of safety at work, environment protection, profitability considerations and quality management. With over 200 illustrated examples, step-by-step instructions, presentations and reference tables, this is essential reading for apprentices and professionals alike.

CORROSION AND CORROSION PROTECTIONCorrosionCorrosion ProtectionHISTORICAL DEVELOPMENT OF HOT-DIP GALVANIZINGSURFACE-PREPARATION TECHNOLOGYAs-Delivered ConditionMechanical Surface-Preparation MethodsChemical Cleaning and DegreasingRinsing of the PartsPicklingHot-Dip Galvanizing FluxesHOT-DIP GALVANIZING AND LAYER-FORMATION TECHNOLOGYProcess VariantsLayer Formation in Hot-Dip Batch Galvanizing Between 435°C and 620°CLiquid-Metal-Induced Embrittlement (LME)After-TreatmentTECHNICAL EQUIPMENTPreliminary PlanningLayout Variants of PlantsPretreatment PlantDrying FurnacesGalvanizing FurnacesGalvanizing KettleZinc Bath HousingsAfter-TreatmentUnloading AreaCrossbeam ReturnCrane UnitsFiltration PlantsSemiautomatic Galvanizing Lines for Small PartsGalvanizing Furnace with Ceramic TroughAutomatic Galvanizing Line for Small PartsPipe Galvanizing LineApplication of VibratorsEnergy BalanceCommissioning and Decommissioning of a Hot-Dip Galvanizing Kettle, Kettle Change, Method of OperationENVIRONMENTAL PROTECTION AND OCCUPATIONAL SAFETY IN HOT-DIP GALVANIZING PLANTSRules and Measures Concerning Air-Pollution ControlMeasures for the Control of Air PollutionMeasuring SystemsWaste and Residual MaterialsNoiseOccupational SafetyPractical Measures for Environmental ProtectionDESIGN AND MANUFACTURING ACCORDING TO HOT-DIP GALVANIZING REQUIREMENTSGeneral NotesRequirements Regarding Surface Quality of the Basic MaterialDimensions and Weights of Material to be GalvanizedContainers and Tubular Constructions (Hollow Bodies)Steel Profile ConstructionsSteel Sheet and Steel WireConstructions of Hot-Dip Galvanized Semifinished ProductsAvoidance of Distortion and Crack FormationWelding Before and After Hot-Dip GalvanizingHot-Dip Galvanizing of Small PartsReworking and Repair of Zinc CoatingsHot-Dip Galvanizing of Cast MaterialsLocal Avoidance of Zinc AdherenceStandards and GuidelinesDefects and Avoiding DefectsQUALITY MANAGEMENT IN HOT-DIP GALVANIZING COMPANIESWhy Quality Management?Important CriteriaStructure of the QM System According to DIN EN ISO 9001:2000Short Description of QM Elements Sections 4-8Introduction of QM SystemsTrendsCORROSION BEHAVIOR OF ZINC COATINGSCorrosion - Chemical PropertiesCorrosion Caused by AtmosphereCorrosion through WaterCorrosion in SoilsCorrosion Resistance to ConcreteCorrosion in Agricultural Facilities and Caused by Agricultural ProductsCorrosion through Nonaqueous MediaCorrosion Protection Measures at Defective SpotsExamination of Corrosion Resistance and Quality TestCOATINGS ON ZINC LAYERS - DUPLEX SYSTEMSFundamentals, Use, Main Fields of ApplicationDefinitions of TermsProtection Period of Duplex-SystemsSpecial Features of the Constructive Design of ComponentsQuality Requirements for the Zinc Coating for Protective Paint LayersSurface Preparation of the Zinc Coating for the Protective PaintCoating Materials, Protective Paint SystemsECONOMIC EFFICIENCY OF HOT-DIP GALVANIZINGEXAMPLES OF USEBuilding ConstructionCivil EngineeringTraffic EngineeringSport/LeisurePlant EngineeringMiningEnergy SupplyAgricultureComponent Parts/FastenersEnvironmental ProtectionHandicraftArtContinuous-Sheet GalvanizingConclusionAPPENDIXRequirements for the Zinc CoatingAssessment Criteria for Hot-Dip Galvanized Coatings on Steel StructuresMajor Defects in the Zinc Coating or at the Hot-Dip Galvanized Workpiece