Summary for galvanizing chipping Discussion
Galvanizing chipping is the issue raised here: Geoff Crowley of Crithwood Ltd. says bridge rails that were originally rejected for discoloration and a visible double-dip line were repaired, re-inspected by a third party, and passed, but two years later the customer claimed the zinc was literally chipping off. Geoff notes there is evidence the rails were damaged and scrapped by a snow plow crossing the bridge, which suggests the later coating loss may be tied to impact damage rather than an original galvanizing defect. The excerpt provided does not include any replies, so there is no further technical diagnosis or consensus in the thread text shown. Based on the question alone, the practical issue is whether the coating failure is being blamed on the galvanizing process when the rails may have been mechanically damaged in service.
June 18, 2014
Q. Several years ago we galvanized some bridge rails that, in the customer’s eyes were unacceptable due to discoloration and a visible double dip line. I traveled to site, repaired the dip line, the rails were inspected by a third party and passed. Recently this customer has returned saying that the zinc on these rails was literally chipping off for no reason. There is evidence that these rails were damaged and scrapped by a snow plow crossing the bridge.
The customer insists that the chipping is occurring in other areas of the rails that were not damaged, but the evidence I have seen seem to be consistent with the plow damage. Is there any way that zinc can simply start chipping several years after install for no reason?
Any help is appreciated
Thanks
Jeff Boychuk
– Delta, BC, Canada
July 3, 2014
A. There are 2 basic reasons for chipping or peeling off of Zinc from parent surface:
1. The surface is over coated, kept in Zinc Bath for more than the required time.
2. The parent material might be having high Silicon.
Now check what is the problem. If it is because of material chemistry, you cannot do anything.
Dalela, Umesh Chandra
– Abu Dhabi, UAE
A. I agree with Dalela.
But most galvanizers don’t want a job in the zinc long time, that costs money. The reason for long immersion times is almost always due to insufficient vent / drain holes in hollow sections.
The chipped edge looks thick. If it looks thick it usually is – perhaps 500 to 1000 µ.
There is a scrape mark right through the middle of the chipping. Almost surely mechanical damage then.
The zinc doesn’t come off spontaneously, you have to mechanically chip / hit it.
Geoff Crowley
Crithwood Ltd.
Westfield, Scotland, UK
July 3, 2014
July 3, 2014
A. Jeff,
How thick is the zinc coating? Anything over 6 mils likely chips. What is the steel chemistry and what is the zinc chemistry?
Regards,
Dr. Thomas H. Cook
Galvanizing Consultant – Hot Springs, South Dakota, USA
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