Skip to main content
Category

NEWS & PICS

SAVE TIME AND MONEY- Grab this handy wall chart

Avoid the pitfalls when designing for galvanizing with this handy wall chart for your office. APG has had over 55 years experience, so when it comes to Galvanizing- our motto is DO IT ONCE, DO IT RIGHT!

Don’t?get caught out with stupid unavoidable mistakes, grab your handy wall chart below and of course our experiences sales guys are always happy to assist with any queries you may have. 07 4040 7000

APG_Design-for-Galvanizing-Wall-Chart

NEW Design guidelines for Hot Dip Galvanizing

It is important to consider the corrosion protection of ferrous articles when they are being designed. The key factors to consider when designing for hot dip galvanizing are the design’s impact on:

– Safety during the process

– Quality of the coating

– Aesthetics

This guide provides general information on basic design and detailing practice, including venting and draining, to assist in the safe and quality hot dip galvanizing of articles.

APG_Design Guide for Hot Dip Galvanizing – Best Practice Venting and Draining

If only they Galvanized! Paint means maintenance.

20 million annual maintenance!

The Sydney Harbour Bridge’s use of ferrous alloy presents a significant challenge in terms of protecting the structure from the ravages of corrosion. It is indeed a cruel irony that our most-used alloy for structures, steel, is also the one most damaged by exposure to the atmosphere. Steel, unlike many other metals, does not exhibit passivity. Passivity occurs when a metal or alloy reacts with the oxygen in the atmosphere to create a non-porous oxide film that protects the material from further oxidation. Unfortunately, steel oxidises to form rust, a corrosion product that is porous, which means that the rust exposes more metal to oxidation. On large panels, this rust may simply be surface corrosion which is really more an aesthetic problem in the short term and a minor problem in the long term.

Where this lack of passivity becomes a huge problem is in places where water can pool or seep into. A riveted structure like the Sydney Harbour Bridge is fertile ground for crevice corrosion to occur through concentration cells.

Crevice corrosion occurs when a small cavity or gap is created which allows water to pool. This then brings about a concentration cell. A concentration cell is where there is an electrolyte (a fluid capable of carrying current) with differing levels of aeration or concentration of oxygen. Areas of high oxygen concentration become the cathode while areas of low concentration become the anode.

The diagram below illustrates why this is a problem for a riveted structure. The rivet when exposed is not sealed against the entry of water; this means that water may seep into the small space between the rivet and the rivet hole in the plate. Any water in this area is likely to suffer differentials in aeration levels and we now have a situation suited to corrosion. If water is drawn into areas A and B, A would have more oxygen and become the cathode, while B would become the anode. This means part B, hidden from inspection, would slowly degrade and weaken the joint. Moreover, the gap between the plates, part C, could also become filled with water and create a concentration cell between the plates.

As the corrosion process continues, the corrosion product (iron oxide) takes up a greater volume than the original metal. Thus, as the corrosion cell grows, significant forces develop to tend to force the joint apart.

A rivet holding two steel plates together

A rivet holding two steel plates together.
While the gaps are exaggerated for this illustration, water can certainly seep into such places and create concentration cells.

How can this be avoided? In modern structures, we could circumvent this by galvanising the steel. By coating the steel with zinc we protect the structure from rusting because zinc will corrode in preference to steel. This is why galvanised steel is so common in steel structures nowadays.

As the Harbour Bridge is not galvanised, our only other solution is to take the approach used for cars: paint it. The paint effectively seals the steel from the atmosphere and alleviates rust formation. The problem with paint is that, unlike galvanising, it does not protect the steel if the steel becomes exposed. Additionally, the paint is degraded by ultra-violet radiation and weathering, so it must be continually replaced. Unlike a car, which is garaged and often well cared for, the Sydney Harbour Bridge?s paint takes a beating and must be continually replaced.

The original paint primer was lead oxide based with the finishing coats based on micaceous iron oxide. Both these paints are deleterious to the environment and the RTA is removing original paint layers and using modern coating materials in their place.

The initial three coats of paint placed on the bridge used 272 000 litres of paint. The replacement of the paint is a regular part of maintenance and an ongoing cost.

 

article?from :https://sydney-harbour-bridge.nesa.nsw.edu.au/engineering-studies/corrosion.php

Hot-dip Galvanizing – Do it once, Do it right.

There seems to be a lot of confusion about the sustainability and longevity of galvanizing –

Galvanizing Process. Hot-dip galvanizing is the process of immersing iron or steel in a bath of molten zinc to produce a corrosion resistant, multi-layered coating of zinc-iron alloy and zinc metal. The process is inherently simple, which is a distinct advantage over other corrosion protection methods. This Cathodic protection prevents corrosion by converting all of the anodic (active) sites on the metal surface to cathodic (passive) sites by supplying electrical current (or free electrons) from an alternate source. Usually, this takes the form of galvanic anodes, which are more active than steel.

Build it and forget it!

When looking to build a new structure galvanizing makes sense, painting steel creates an ongoing maintenance scenario. With galvanizing it’s an almost build it and forget it scenario, because of the longevity of the galvanized coating and the way it performs for 50, 75 to 100 years or more, without maintenance means using fewer resources throughout the life of the structure to maintain it, both from an environmental standpoint and economic standpoint. Your not spending money on maintenance or wasting resources to replace it.

Creating a maintenance free structure that is both environmental and economical makes galvanizing the most sustainable product created out of natural materials. both Zinc and iron are natural metal that is 100% recyclable without losing any properties. So can be used again and again, creating an infinitely renewable resource.

Hot-dip galvanized steel is a sustainable infinitely renewable building material that improves the quality of life of the project is both durable for generations without constant maintenance programs, saving both time and money in both the private and public sectors. It uses Zinc – the healthy metal and we need to encourage builders, and those who specify gal – that if they want to do it once and do it right – choose Galvanizing.

GAA Conference _ Gold Coast 2018

Above: Stephen Pollard, Ron Pollard and Brian Coates of APG Galvanizing

The annual Australian Galvanizers Association (GAA) conference was once again held to present new innovations in Hot- dip galvanizing to the industry and of course relax with colleagues and associates for a few days as we draw closer to the end of another year. As well as a few coldies we are also there to announce the winner from the submissions for the 2018 Excellence in Hot-Dip Galvanizing Sorel Award.

Presented annually, the Excellence in Hot-Dip Galvanizing Awards honour the finest achievements in the use of hot-dip galvanizing in an ideal, creative, innovative or monumental fashion.

Hot-dip galvanized steel is used in myriad applications throughout various industries. The Sorel Award is presented to a stand out application and design featuring Hot-dip galvanizing at the core of the project. This year’s award was one by Kingfield for Borals Concrete batching plant. Congratulations!

 

 

Local family business Celebrates 50 years

Pollards Galvanizing was founded by Ron Pollard in 1966 in the industrial suburb of Bungalow, Cairns. From day one, the mission was to “treat everyone like family” whilst providing a service of the highest quality. Some 20 years later moved to Kenny Street, Portsmith where the APG offices still sit today. They expanded the Galvanizing component to Townsville in 2010, And changed the name to Australian Professional Galvanizing (APG) streamlining the process of operations and expanding their reach from Rockhampton to Cairns and inland to Mt Isa.

Stephen Pollard CEO of APG today, “Our decision to expand our premises and move the Galvanizing component to Townsville was our commitment to bring our quality, customer-first mindset to more FNQ buying customers. Our quality management systems and lean manufacturing disciplines within our culture, help bring the best possible prices to our customers so we can continue in the business of galvanizing for another 50 years!”

We have continued to grow and our workmanship meets the minimum of AS/NZS 4680/2006 quality standard. We are also members of the Galvanizers Association of Australian giving our customers further assurances.

For any further information regarding Hot-dip Galvanizing contact, the team-APG are willing to enter into a quoting arrangement for larger scale projects and actively encourage our customers to negotiate with us.

Do it once. Do it Right – Galvanize.

The benefits of after-fabrication galvanizing

No other protective coating for steel provides the long life durability and predictable performance of hot dip galvanizing:

THA’S WHY THOSE IN THE KNOW – HOT DIP!

BENEFITS:
Competitive first cost: For many applications, the first cost is lower than alternative coatings
Long Life: Often exceeding 30 years
Lowest Lifetime cost: Low initial cost and long life make galvanizing the most versatile, economical method of protecting steel
Reliability: Specified at AS/NZS 4680 and equivalent World Standards
Speed of application: A fully protective coating can be applied in minutes
Complete Coverage: All exposed steelwork is completely coated both internally and externally
Ease of inspection: The nature of the process is such that if the coating looks continuous and sounds it is so
Coating toughness: Alloy layers are harder than the steel on which the coating is formed.
Adhesion: Metallurgically bonded to steel ( basically means the metal reaction joins the zinc and steel together making it stronger) painting doesn’t do that.
Coating thickness: Galvanized coatings are distinctly thicker at corners and edges, an important advantage over most organic coatings which thin out in these critical areas
Cathodic protection: Electrochemical protection of damaged areas
Faster construction: An off-site finish, geared to fast-track construction. Requires no -site repairs other than weld damage
Top Coats: Top coats can provide – Colour | Chemical resistance | synergistically – extended life
IMAGE DETAILS: Steel fabricated by Entegra Signatures Victoria
Transported to APG from Victoria
Galvanized by APG
Transported to Cairns by APG for delivery to site on the Atherton tablelands

BISON TRAWL DOORS – Increase your catch

Since 1967 APG has listened to you the fisherman, to come up with the most efficient trawl door on the Australian market today. The Bison trawl door will save you around 15% on fuel costs, it can be trawled at optimum speed a lower engine RPM with maximum net spread with less drag enabling you the fisherman to cover more ground each night thus increasing you catch. The Bison door spreads your nets to maximum efficiency, which means you miss less product per shot. Due to superior design in the hydrodynamics, the Bison door has approximately 75% of the surface area of an equivalent wooden otter or V door and maintains its spread with the product in the cod-end. The Bison door is fabricated from steel and then HOT Dip Galvanized, this extended the lofe of the door and practically eliminates maintenance. The refurbishment of the Bison trawl door is a simple and inexpensive operation, they can be galvanized as often as you require, wear plates are easily replaced from APG and can be fitted using a hammer and shifting spanner.

Setting up the boards for your particular needs is an easy exercise, all towing parts are adjustable and doors can be fine-tuned to suit your trawl nets and vessel, additional weights are available on request, which shows you how to adjust an setup the boards to give maximum performance. APG Pty. Ltd. has the facilities to individually meet your requirements, whether to fulfil orders for new doors or refurbishments. The Bison trawl door was designed after extensive testing at the Australian Marine College using a scaled-down model of the doors and working with fisherman on their trawlers. The Bison trawl door comes in various sizes from Try doors up to 11’s and 12’s with such a large range to choose from we can cover all vessel /net combinations. At present, over 70 fishing companies are using Bison trawl doors, these include Raptis & Sons, New Fishing, Australian Tiger fisheries and many from overseas. Eg; Argenova SA from Argentina, Penwarden Holdings & Sanford Pty. Ltd for New Zealand.

10 Tonne Gantry Crane Refurb Project

 

An extensive structural modification to APG’s galvanizing process facility at Stuart in Townsville modifying the back wall of the pickling line now allows easy change out of any of the 10t capacity 28m span crane beams.

Apg General Manager Trevor Raiteri said “Any of the 4 crane beams in the process line can now be lifted out within an hour to the ground for major service. The investment will significantly cut our downtime and enhance scheduled maintenance.”

Safety concerns over fabricated Chinese steel flooding Australian market

The ABC ran a news story about the fact the the Australian Steel Industry has issued a warning over the quality of the steel coming into Australia and being used on large infrastructure projects. Many industry expects are unfortunately predicating a failure in some low quality steel, and could cause a catastrophe. As budgets tighten, companies are more and more looking to China to source steel for their projects. This looks good on paper, save a buck now, but could lead to a massive accident down the track. With the drop in the Aussie dollar, surely buying Australian steel is becoming a more viable option. Be Australian, buy Australian, look after our industry.

 

Read the full article here.

APG galvanized 2 bridge head stock beams for PNG bridge

Earlier this year (April 2015)?APG galvanized 2 bridge head stock beams for PNG bridge.

These beams weighed 19.08 Tonne each. The?Beams were made in Newcastle and transported to Townsville for galvanizing.
Modern galvanizing plants require 2 key abilities to attempt a dip of the nature.?Galvanizing bath size and overhead crane capacity.?APG is the only one in Australia with both of these capacities.
The heaviest dip done in Australian was done in 1982 at the Hexham plant – 26.5 Tonne.?This plant was closed down on the 90’s.
APG currently holds the Australian heaviest dip record of current day galvanizing plants.

 

APG Add Additonal Capacity to Plant

On the October long Australian Professional Galvanizing perform some critical weekend shutdown work. An upgrade of main dipping crane 2 with new hoists ,increased our crane lifting capacity up from 6.5T to 12.0T. We have a project planned for late 2015 to replace the beams.

Australian Professional Galvanizing Townsville, Mackay, Cairns, Rockhampton, provide high quality galvanizing and transport options for the qld construction and steel industry.

Trust APG to do the job right.

APG Galvanzing Truck Fleet

Australian Professional Galvanzing Cairns, Townsville, Mackay and Rockhampton, have a modern transport fleets servicing these areas and anywhere between.

Our transport managers ensure you steel arrives ontime and is retunred with no fuss.

Trust APG for your next steel galvanzing project

 

APG Galvanizing Plant Tank Upgrade

Over the Easter / ANZAC day period, APG undertook a shutdown which included the change out of 100,000 lt – 20 Tonne pickling tank – Major part of a $ 200,000 plant maintenance program.
Photo of new tank (Coated in blue chemical rhino lining) being lifted into position. (New tank weight = 16.3T) .
Australian Professional Galvanizing provides hot dip galvanizing services to Cairns, Townsville, Mackay and Rockhampton.

Australian Professional Galvanizing Rockhamptom

APG is spreading it wings into central QLD. With the addition of our Inspection and Transport depot at 1 Monier Rd Parkhurst Rockhampton QLD 4701.

We offer a weekly service from Rockhampton to Townsville return.

APG provide prompt professional Hot Dip Galvanizing services to Rockhampton, Mackay, Townsville and Cairns.

We would like to welcome Nathan Cowie to the APG team. if you have any questions or want to engage us for your galvanizing needs, please call Nathan on?0477 407377

APG Sponsor Charitable Cause

Australian Professional Galvanizing have help a great cause by sponsoring a team in the Variety SeeDoo Trip – Cooktown to Townsville

We galvanized their special made SeeDoo trailer for the event.
They also asked if we could supply stickers for the support vehicle.
[nggallery id=8]

Tech Update – Use Paint to Mask Galvanizing

APG recently trialled paints to mask steel from galvanizing during process.

A recent project required sections of structural steel to remain ‘uncoated’ for ease of welding on site.

The paint shown is a 2-pac Jotacote …. which prevented the pickling process in the pre-treatment and then burnt off when immersed in the molten zinc.

The result as shown protects the painted surface from galvanizing leaving the original ‘black’ finish. Provided the steel was free of oil and solvents so the paint ‘keyed’ to the steel the outcomes were consistent.

We would suggest any 2-pac paints would produce the same result.

Applications : bearing faces, pipe joins, flanges, Threads ( free of cutting oils).
Benefit ?: ease of application, minimum prep work after galvanizing
[nggallery id=7]

Galvanizing Steel Process – Video time lapse

We loaded up a head rack after the day shift cleared out of the plant and we decided to strap a camera to it and record the process of galvanizing steel.

The black steel is loaded onto the head rack and the cranes manoeuvre the head racks through each stage of the steel galvanizing process.

Galvanizing Tip – Masking Internal Threads

“Masking Internal Threads”

Photo 1 Galvanizing a mower deck with internal threads
Photo 2 Pack the internal thread with ‘office blue tack’ prior to process prevents galvanizing of the thread
Photo 3 removal of bluetack after process is easy
Photo 4 thread is left relatively clean (un-galvanized) to accept bolt.
[nggallery id=6]

Inadequate Venting for Galvanizing Steel

It is imperative to adequately vent all hollow steel sections prior to galvanizing. As you can see from the photos below, failing to do this can not only be dangerous, but it also reduce the quality of the finished product.

Photo 1 shows ‘steam burn’ . As the vent holes are small air is trapped , super heated then burns the preflux off creating ‘miss’.
Photo 2 shows same as above from another angle
Photo 3 this end immersed 1st shows no issue
Closed section steel requires 25% end section ventilation.
[nggallery id=5]