Coil Processing Galvanizing Lines Explained - Part 1

(Coil galvanizing processing - Ca Steel Co.)

Coil slitting lines generally work with mild steels, often with low-alloy content, that lend themselves to rust over time.

Unless the steel is eventually painted, coated, or treated in such away that rust cannot gain a footing on the substrate, rust will eventually ruin either the appearance or the mechanical properties of carefully produced metal forms from metal slitting lines.

Producers developed the process of galvanizing low alloy steels for preserving them under general environmental conditions.

Galvanizing does provide atmospheric protection equal to higher cost processes such as mehanite coatings, chrome plating, or stainless steels, but it is sufficient for most outdoor applications.

The primary purpose of galvanizing is preventing metal from exposure to air with a low cost, long lasting coating. Galvanizing simply means a form of hot dipped zinc coating applied precisely to a metal material for preventing air, or oxygen specifically, from rusting the underlying material.

Continuous Coil Galvanizing Operation

Some firms specialize in continuous metal coil galvanizing systems that supply industries such as road guards, outdoor building materials, and industrial fabrication or building materials.

Metal coils or rolls are loaded onto a pair of Pay-Off Reels, with the head of the charged coil being lap seam welded to the tail of the coil being processed. High voltage copper wheels above and below create a continuous lap along the material, preparing it for the Entry Loop Car or accumulator.

Cleaning and Preheating

This phase relieves the metal coil material of any rolling oils, shavings and dirt. Brushes combined with diluted sodium hydroxide prepare the surface.

Preheating the steal to a moderate temperature allows the cleaning process to strip the surface of the metal, and speed up the next heat treatment step. Heat treating takes the metal to annealing temperatures for the hot dip procedure.

Even though this is not a full heat treatment, gas burners are running at 2250 degrees Fahrenheit. The high-speed coil galvanizing lines run the prepped metal through in a few seconds, preventing pre-annealing of the material.

Heat Treatment

Most feed-stock coils for the galvanizing lines come in Full Hard, and sufficiently cleaned and heated to allow the zinc to bind firmly to the metal.

Once the zine adheres sufficiently, the now galvanized metal can be formed easily by the customer while still maintaining strength and rust proof properties.

Referred to as the “reducing zone” for annealing, this section achieves formability requirements in a precisely calibrated atmosphere. 1 part hydrogen to 3 parts nitrogen ensures the process will avoid creating scale while “reducing” light surface oxide back to iron.

With heat treatment temperatures at 1650 degree Fahrenheit, the metal reaches temperatures ranging from 1300 degrees to 1500 degrees Fahrenheit.

The thickness or gauge differences in the metal coils undergoing the galvanizing process  require different annealing times. The times can vary up to about 1 minute and are controlled by computers with operator input.

Up to this point, the metal coil material has been cleaned, preheated, heat annealed or reduced, and is getting ready for the actual process of galvanizing.

We will cover the chemical annealing process and further heat treating processes, forming adjusting processes, and the final phase prior for completing production in the Coil Processing Galvanizing Lines Explained - Part II.

We will cover the chemical annealing process and further heat treating processes, forming adjusting processes, and the final phase prior for completing production in the Coil Processing Galvanizing Lines Explained - Part 2

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Top 3 FREE Tips

to increase efficiency

  1. Use appropriate technology and by-pass manual labor where possible for the roll and coil changeovers.
  2. Coil cars can also cut transition and changeovers.
  3. Consider material handling elements such as coil storage racks if there is not a crane installed for keeping a coil car active.
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