Hot-dip galvanising

Processes

Hot-dip galvanising

The highest corrosion protection for your steel. Hot-dip galvanising guarantees perfect all-round protection of your components.

In hot-dip galvanising, the pretreated steel parts are immersed in a molten zinc liquid that is heated up to approx. 450 °C. This results in a metallurgical reaction, which makes steel and zinc inseparable at their interface and provides a pure zinc coating on the surface. The dipping process allows components to be coated on the inside, outside and even in inaccessible places. The result is an impact resistant, highly corrosion resistant and durable surface with long-term protection that requires no maintenance. These properties are indispensable wherever the most difficult general conditions and weather conditions prevail: The locksmith’s trade, steel and plant construction, vehicle manufacturing and agriculture. The thickness of the zinc coating depends on the material and process.

At our Bludesch, Bürmoos and Judenburg locations, we galvanise in compliance with DIN EN ISO 1461, DASt Guideline 022, DIN EN 1090 and based on customer-specific requirements.

Inquiry Technical data

Advantage

Advantages at a glance

Design - Surface creates.
Collini surface technology makes it possible to create products in such a way that they appeal to the varying aesthetic requirements and wishes of consumers. Design is more than the form and functionality of an object. In many cases, it is the aesthetics that adds to the value. The look, colour or structure of identical materials can be changed through different surfaces.

Powder coatings with its almost infinite possibilities in terms of colouring, degrees of glossiness and structures give products their true character. It is irrelevant whether it concerns machine cladding, vehicle components or architectural design elements.

High quality metal surfaces can be created with electroplating, the properties of which distinguish it clearly from that of the base material. Hence, products are refined and the required effects in finish and structure of the respective product
are created.

Hot-dip galvanised structural components with its crystalsilver surfaces are, besides the corrosion protection, often specifically included as design elements.
Corrosion - Surface protects.
The natural state of metals is an oxide. In the metalworks the oxide is extracted by using oxygen and energy and the pure metal is obtained. However, the metal is “predestined” to return to its original state at exposure to oxygen and water. And the less precious the metal is, the faster it happens. That is corrosion.

Surface technology slows down or prevents this corrosion process. Protection against corrosion through innovative surface technology increases service-life and thus raises the value of the product or structural component. Collini provides numerous possibilities to combat corrosion.

By means of electro-plating, structural components can be protected against corrosion with suitable metal coatings.

Powder coatings form impenetrable barriers against oxygen and water and thus protecting the underlying structure.

Hot-dip galvanising protects steel parts by specifically inducing the corrosion process on the zinc surface. And only there!

Technical data

	Hot-dip galvanising
Processes	General-purpose galvanising by immersion in a melted solution of liquid zinc at approx. 450 °C
Coating colour	from bright glossy to dark grey, depending on the silicon (Si) and phosphorus (P) content in the base material
Base material	all common construction steel and cast iron types
Corrosion protection	Long-term corrosion protection of > 50 years under normal load, passivation with Zincomet Plus
Hardness	120 HV
Temperature resistance	up to approx. 195 °C
System technology	Trusses, hangers, custom rack construction
Conformity	DIN EN ISO 1461, DASt - Guideline 022, DIN EN 1090, lead-free variants - RoHS, REACH, 2000/53/EG (End of life vehicles)
Execution	Minimum layer thickness of zinc coatings according to EN ISO 1461: > 45 to> 85 μm depending on material thickness. Passivation with Zincomet Plus - glossy preserved surface for the prevention of white rust and water marks
From our R&D	all Collini hot-dip galvanising sites are already Pb-free
Protective properties	Corrosion protection of inside and outside surfaces, angles and cavities, including all edges
Functional properties	electrical (up to 50 V/μm) and heat insulating, adhesive, impregnable, dimensionally stable, primer for duplex coating
Decorative properties	Zinc flower, metallic silvery glossy appearance
Special properties	High mechanical load capacity, non-porous, extremely long maintenance-free use, subsequent duplex coating is possible

Details

Typical components & applications

Hot-dip galvanising has experienced very dynamic development in recent years, but its development potential is far from exhausted. The spectrum of innovations ranges from the introduction of environmentally friendly technologies, through adaptation to high-tech steels and complex components, to the development of new fields of application.

Typical components

Steel structures, façade parts, fences, gates, doors, terraces, balconies, carports, railings, lorry trailers, semi-trailers, transport racks, swap bodies, plant components, power plants, onshore and offshore installations, animal stable equipment, masts, supports, cable car seats and cable car components.

Industrial applications

Steel construction, home and garden architecture, bridge construction, mechanical engineering, agricultural engineering, vehicle manufacturing, plant engineering, cable car manufacturing

The locksmith's trade represents a traditional application of hot-dip galvanising for individually designed iron and steel structures, such as doors, gates, door frames, railings, fences, balconies and carports that are exposed to the weather.

Hot-dip galvanised structures such as scaffolding, form work, bridges, halls, multi-storey car parks, etc., offer maximum design options and represent an economical solution in the construction industry and its subcontracting areas. Hot-dip galvanising in steel construction makes an important contribution to increasing service life and sustainability.

The vehicle manufacturing and agricultural sectors offer their customers designs, equipment, machinery and vehicles for tough conditions. Dirt, deposits, stone chips, snow, rain, de-icing salts and animal excrement place high demands on corrosion protection in everyday life. It must be resistant, durable, abrasion resistant and offer the best cost-performance ratio. Hot-dip galvanised steel has proven to be excellent for use in these areas.

In plant construction, all exposed components receive perfect all-round protection with hot-dip galvanising, even in hard-to-reach places, as well as long-term protection without maintenance for many decades. There is a wide variety in terms of areas of application, which range from mechanical engineering and plant construction to cable way construction.

Collini surfaces

Hot-dip galvanising of piece goods in the dipping process

The inseparable bond between zinc and steel is unique in the hot-dip galvanising process. The steel is not simply coated with zinc (as with painting or coating). It actually undergoes a metallurgical reaction, which is the alloy formation. A pure zinc layer (Zn Eta) Zn 100% Fe 0% settles on the surface, over the alloy layers (Fe-Zn Gamma) Zn 75% Fe 15%, (Fe-Zn Delta) Zn 90% Fe 10%, (Fe-Zn Zeta) Zn 94% Fe 6% and when moving out of the molten zinc. As a result, the corrosion protection of hot-dip galvanised parts is extremely high, and the layer is extremely generally resistant and abrasion resistant.