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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…mehr
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.
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 Maaß became head of the northeastern branch of the Institute of Hot-Dip Galvanization, Ltd., in Düsseldorf, Germany. He edited three German editions of the handbook of hot-dip galvanization that became the de facto standard for vocational training.
Inhaltsangabe
CORROSION AND CORROSION PROTECTION Corrosion Corrosion Protection HISTORICAL DEVELOPMENT OF HOT-DIP GALVANIZING SURFACE-PREPARATION TECHNOLOGY As-Delivered Condition Mechanical Surface-Preparation Methods Chemical Cleaning and Degreasing Rinsing of the Parts Pickling Hot-Dip Galvanizing Fluxes HOT-DIP GALVANIZING AND LAYER-FORMATION TECHNOLOGY Process Variants Layer Formation in Hot-Dip Batch Galvanizing Between 435°C and 620°C Liquid-Metal-Induced Embrittlement (LME) After-Treatment TECHNICAL EQUIPMENT Preliminary Planning Layout Variants of Plants Pretreatment Plant Drying Furnaces Galvanizing Furnaces Galvanizing Kettle Zinc Bath Housings After-Treatment Unloading Area Crossbeam Return Crane Units Filtration Plants Semiautomatic Galvanizing Lines for Small Parts Galvanizing Furnace with Ceramic Trough Automatic Galvanizing Line for Small Parts Pipe Galvanizing Line Application of Vibrators Energy Balance Commissioning and Decommissioning of a Hot-Dip Galvanizing Kettle, Kettle Change, Method of Operation ENVIRONMENTAL PROTECTION AND OCCUPATIONAL SAFETY IN HOT-DIP GALVANIZING PLANTS Rules and Measures Concerning Air-Pollution Control Measures for the Control of Air Pollution Measuring Systems Waste and Residual Materials Noise Occupational Safety Practical Measures for Environmental Protection DESIGN AND MANUFACTURING ACCORDING TO HOT-DIP GALVANIZING REQUIREMENTS General Notes Requirements Regarding Surface Quality of the Basic Material Dimensions and Weights of Material to be Galvanized Containers and Tubular Constructions (Hollow Bodies) Steel Profile Constructions Steel Sheet and Steel Wire Constructions of Hot-Dip Galvanized Semifinished Products Avoidance of Distortion and Crack Formation Welding Before and After Hot-Dip Galvanizing Hot-Dip Galvanizing of Small Parts Reworking and Repair of Zinc Coatings Hot-Dip Galvanizing of Cast Materials Local Avoidance of Zinc Adherence Standards and Guidelines Defects and Avoiding Defects QUALITY MANAGEMENT IN HOT-DIP GALVANIZING COMPANIES Why Quality Management? Important Criteria Structure of the QM System According to DIN EN ISO 9001:2000 Short Description of QM Elements Sections 4-8 Introduction of QM Systems Trends CORROSION BEHAVIOR OF ZINC COATINGS Corrosion - Chemical Properties Corrosion Caused by Atmosphere Corrosion through Water Corrosion in Soils Corrosion Resistance to Concrete Corrosion in Agricultural Facilities and Caused by Agricultural Products Corrosion through Nonaqueous Media Corrosion Protection Measures at Defective Spots Examination of Corrosion Resistance and Quality Test COATINGS ON ZINC LAYERS - DUPLEX SYSTEMS Fundamentals, Use, Main Fields of Application Definitions of Terms Protection Period of Duplex-Systems Special Features of the Constructive Design of Components Quality Requirements for the Zinc Coating for Protective Paint Layers Surface Preparation of the Zinc Coating for the Protective Paint Coating Materials, Protective Paint Systems ECONOMIC EFFICIENCY OF HOT-DIP GALVANIZING EXAMPLES OF USE Building Construction Civil Engineering Traffic Engineering Sport/Leisure Plant Engineering Mining Energy Supply Agriculture Component Parts/Fasteners Environmental Protection Handicraft Art Continuous-Sheet Galvanizing Conclusion APPENDIX Requirements for the Zinc Coating Assessment Criteria for Hot-Dip Galvanized Coatings on Steel Structures Major Defects in the Zinc Coating or at the Hot-Dip Galvanized Workpiece
CORROSION AND CORROSION PROTECTION Corrosion Corrosion Protection HISTORICAL DEVELOPMENT OF HOT-DIP GALVANIZING SURFACE-PREPARATION TECHNOLOGY As-Delivered Condition Mechanical Surface-Preparation Methods Chemical Cleaning and Degreasing Rinsing of the Parts Pickling Hot-Dip Galvanizing Fluxes HOT-DIP GALVANIZING AND LAYER-FORMATION TECHNOLOGY Process Variants Layer Formation in Hot-Dip Batch Galvanizing Between 435°C and 620°C Liquid-Metal-Induced Embrittlement (LME) After-Treatment TECHNICAL EQUIPMENT Preliminary Planning Layout Variants of Plants Pretreatment Plant Drying Furnaces Galvanizing Furnaces Galvanizing Kettle Zinc Bath Housings After-Treatment Unloading Area Crossbeam Return Crane Units Filtration Plants Semiautomatic Galvanizing Lines for Small Parts Galvanizing Furnace with Ceramic Trough Automatic Galvanizing Line for Small Parts Pipe Galvanizing Line Application of Vibrators Energy Balance Commissioning and Decommissioning of a Hot-Dip Galvanizing Kettle, Kettle Change, Method of Operation ENVIRONMENTAL PROTECTION AND OCCUPATIONAL SAFETY IN HOT-DIP GALVANIZING PLANTS Rules and Measures Concerning Air-Pollution Control Measures for the Control of Air Pollution Measuring Systems Waste and Residual Materials Noise Occupational Safety Practical Measures for Environmental Protection DESIGN AND MANUFACTURING ACCORDING TO HOT-DIP GALVANIZING REQUIREMENTS General Notes Requirements Regarding Surface Quality of the Basic Material Dimensions and Weights of Material to be Galvanized Containers and Tubular Constructions (Hollow Bodies) Steel Profile Constructions Steel Sheet and Steel Wire Constructions of Hot-Dip Galvanized Semifinished Products Avoidance of Distortion and Crack Formation Welding Before and After Hot-Dip Galvanizing Hot-Dip Galvanizing of Small Parts Reworking and Repair of Zinc Coatings Hot-Dip Galvanizing of Cast Materials Local Avoidance of Zinc Adherence Standards and Guidelines Defects and Avoiding Defects QUALITY MANAGEMENT IN HOT-DIP GALVANIZING COMPANIES Why Quality Management? Important Criteria Structure of the QM System According to DIN EN ISO 9001:2000 Short Description of QM Elements Sections 4-8 Introduction of QM Systems Trends CORROSION BEHAVIOR OF ZINC COATINGS Corrosion - Chemical Properties Corrosion Caused by Atmosphere Corrosion through Water Corrosion in Soils Corrosion Resistance to Concrete Corrosion in Agricultural Facilities and Caused by Agricultural Products Corrosion through Nonaqueous Media Corrosion Protection Measures at Defective Spots Examination of Corrosion Resistance and Quality Test COATINGS ON ZINC LAYERS - DUPLEX SYSTEMS Fundamentals, Use, Main Fields of Application Definitions of Terms Protection Period of Duplex-Systems Special Features of the Constructive Design of Components Quality Requirements for the Zinc Coating for Protective Paint Layers Surface Preparation of the Zinc Coating for the Protective Paint Coating Materials, Protective Paint Systems ECONOMIC EFFICIENCY OF HOT-DIP GALVANIZING EXAMPLES OF USE Building Construction Civil Engineering Traffic Engineering Sport/Leisure Plant Engineering Mining Energy Supply Agriculture Component Parts/Fasteners Environmental Protection Handicraft Art Continuous-Sheet Galvanizing Conclusion APPENDIX Requirements for the Zinc Coating Assessment Criteria for Hot-Dip Galvanized Coatings on Steel Structures Major Defects in the Zinc Coating or at the Hot-Dip Galvanized Workpiece
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