Comparison of three galvanizing processes

Liquid Dip Process Electrolytic

Immersion in liquid Zinc/Zinc-Aluminium Process
F S V
G

Process standard
Hot Dip Galvanizing (HDG) after fabrication Continuous Strip Galvanization Electrolytic Galvanizing (Electroplating)
according to Din EN ISO 1461 (Sendzimir Process) according to DIN EN ISO 19598 / DIN EN ISO 2081
(DIN EN ISO 10684 for hardware) according to DIN EN 10 346 (DIN EN ISO 4042 for hardware)

Structure and composition of the coating

Alloying with the Alloying with the Laminated coating
base material base material

Usual thickness of the zinc layer

Depending on the thickness of the Layer thickness Z 140: 10 μm ± 3 μm Approx. 2.5 to 20 μm, in
material to be galvanized, Layer thickness Z 275: 20 μm ± 5 μm undercuts and recesses
up to 1.5 mm thickness approx. 45 μm, according to DIN EN 10 346 (thread flanks) the layer thickness
up to 3 mm thickness approx. 55 μm, is less than on open surfaces
up to 6 mm thickness approx. 70 μm

Special features
Each component is individually dipped The corrosion protection layer The zinc layer is deposited from an aqueous
in the liquid zinc bath. is applied to the surface by passing electrolyte by means of DC current.
The zinc washes over the entire surface. the steel as a continuous ribbon through Post-treatment is generally applied
Hollow sections are protected on the in- and a bath of molten zinc. to improvethe protective effect.
outside. Rigid corrosion protection. Decorative visual appearance,
smooth surface with no edges and burrs.

Distinguishing features
The surface is relatively rough, Smooth surface depending on the Iridescent shimmer,
and solidified zinc may block process, slightly greased. Holes and cut edges bright and shiny surface
small holes. Newly galvanized expose “bare metal”. Corrosion protection of after passivation.
surfaces are bright shining; high “bare” edges up to 2 mm material thickness is
temperature galvanized part provided by the by cathodic protection effect.
such as screws are grey. 1

Usage - Application
Welded components, Non-welded components up For parts in almost all shapes and sizes,
equipment exposed to 2 mm thick, especially for corrosion protection and decorative finish.
to the weather. interior building work. Recommended for dry, indoor areas only.

Corrosion Protection Corrosion Protection

(typical annual degredation for Central Europe)
Depending on the atmospheric Annual degradation almost Salt spray tests according to
conditions and the local environment. unmeasurable in dry indoor areas DIN EN ISO 9227 NSS show up to
Rural 0.1 - 1.0 μm without pollution. 360 hours before rusting depending
Suburban 1.0 - 2.0 μm on the thickness of the zinc layer and the
Marine 2.0 - 4.0 μm passivation method.
2

! 1

2
Components over 2 mm in material thickness are hot dip galvanized at Niedax.
Local environmental conditions would be for instance the direct corrosive effect of a chimney with CO2 flue gases.
Galvanizing

Batch galvanizing F

(Hot-dip galvanisation) according to DIN EN ISO 1461 (DIN EN ISO 10684 for hardware)
By immersion in liquid zinc (hot-dip process, ca. 450° C), the entire surface, including all corners and edges lapped. On
the steel is an iron-zinc alloy layer forms with an overlying layer of pure zinc. The layer thickness depends on the material
thickness and is according to DIN EN ISO 1461 to 1.5 mm material thickness 45 microns, up to 3 mm thick 55 microns and
up to 60 mm material thickness 70 microns. Due to the very hard iron-zinc alloy layer can batch-galvanized components,
without damaging the zinc surface, not deformed.

Application examples from the Niedax program:

All components with welded joints, for example, suspension struts, cable and pipe clamps as well as products with more
than 3 mm thick, cable trays / ladders, wide span cable trays / ladders and many more, as far as increased demands on
the corrosion resistance (weathering without rain shield).

Strip coating S

(Sendzimir Process) according to DIN EN 10 346

The zinc coating is on both sides, applied by a zinc bath on broadband in the run. The project uses the modified Sendzimir.
On the steel is an iron-zinc alloy layer forms with an overlying layer of pure zinc. The layer thickness of the Sendzimirbandes
used for Niedax cable laying systems is under consideration of the test method according to DIN EN 10346 according to
three surface sample depending on the product group 10 - 20 microns.

Strip galvanisation is used for components up to max. 2 mm material thickness, as up to this strength, a sufficient edge
protection is achieved by “cathodic protection”. The process-related “bare iron” interfaces of the components are in use in
dry interiors, by the cathodic protection effect is not a disadvantage. Strip galvanized components can be formed without
damaging the zinc surface.

Application examples from the Niedax program:

Cable trays / ladders, wide span cable trays / ladders, cable ladders, cable protection ducts, light boom, rails up to 2 mm
thickness. In dry indoor areas without aggressive media, the strip galvanizing provides permanent corrosion protection.

Zinc coating V G

Selon DIN EN ISO 19598 / DIN EN ISO 2081 (DIN EN ISO 4042 for hardware)
The zinc coating is applied in aqueous electrolytes by means of direct current. To improve the corrosion protection can be
carried out by an aftertreatment thick layer passivation and blue passivation according to DIN 50961.

The zinc coating is 2.5 to 20 microns. Parts with undercuts, such as C-shaped armature rails, due to the process less
heavily coated inside than outside (Faraday cage).

Application examples from the Niedax program:

Small parts (screws, washers up to max. 6 M), mounting rails and screws for distribution board, but with additional thick
layer passivated.
Galvanizing

Additional plastic coating C COLOR

Strip galvanized components with plastic coating
Strip galvanized components according to DIN EN 10 346 can be additionally equipped with a plastic coating. Niedax uses
exclusively the electro static powder coating process. Besides aesthetic reasons or individual colour scheme requests,
there are many more reasons to coat strip galvanized steel. For example the marking of the cable trays (High voltage,
medium voltage, low voltage, communication-/EDP-lines etc.). The coating does not represent extra corrosion protection.

The COLOR-coating is applied according to the electro static powder coating process. The particular characteristics of this
high quality powder coating process are excellent resistance against detergents as well as against highest thermic and
mechanical stress. The material for the coating process is free of halogen. The inner surfaces of the COLOR-ducts remain
blank from zinc; this means a well contact for protective conductors at any position. The outer surfaces are just coated
in the field of view, with good wrap-around to the rear. If the COLOR-ducts are supposed to be applied freestanding, for
example as energy columns, it needs to be indicated along with the order.

For the COLOR-coating, exclusively coating powder is applied according to the RAL-colour chart. With processing clearly
defined colour shades and the use of latest process engineering, colour deviations are avoided to the greatest possible
extent. Regardless these precautions it is not excluded, especially for additional deliveries, that there might be some lower
colour deviations (DIN 6175 Part 1). We understand by colour deviation the track of colour differences according to DIN
EN ISO 3668, chart B.1, evaluation 2.

Hot Dip Galvanizing components with a polyester epoxy resin coating C1

The products marked with C1 are hot-dip galvanized and polyester resin with an epoxy coating in a thickness of 60 - 80
microns provided. When using indoors this plastic coating ensures excellent corrosion protection as well as high mechanical
resistance and is resistant to most chemicals.

The zinc coating is thus protected by the overlying coating from atmospheric and chemical influence. A removal of metallic
zinc is avoided, so that the zinc coating remains intact for a long time under the coating in mint condition.

For special use in the outdoor area, we are pleased to offer other coatings.

Coat with zinc dust paint

The zinc-rich paint shall be such that in the dry film more than 90% zinc is included. To avoid the formation of cracks in the
coating, the coating is applied in several steps.

Application examples from the Niedax program:

Improvements, particularly assembly-related injuries of the zinc surface by welds or the like.

!
For detailed information about the zinc can be found in the cited standards as well
as in a voluminous literature offer.