The History of Galvanization Takes a Step Forward at AZZ

The History of Galvanization Takes a Step Forward at AZZ

Galvanizing

In 1836, a French scientist by the name of Sorel took out numerous patents on a process originally developed in 1742 by another French scientist named Melouin. This process was one in which cleaned steel was dipped into molten zinc. Because Sorel understood the electrochemical nature of corrosion and why zinc protected the steel, he named the process “galvanization,” after the Italian scientist Luigi Galvani, who had done early experiments in electricity. 

Sorel’s understanding also built on the work of Sir Humphrey Davey, who, in 1824, showed that when two different metals were electrically connected and immersed in water, one metal was protected while the other corroded more quickly. Thus was born galvanization, a process whereby zinc is sacrificed to protect steel in steel products. 

AZZ recently installed a new kettle for galvanizing steel at their facility. Jamie Atkins, Plant Manager at AZZ Galvanizing Services in Minneapolis, MN, spoke recently about the new kettle, the history of galvanization, and the implications of this new equipment for the customers.  

Atkins points out that, although galvanization is hardly a new technology, as a procedure dated back a couple hundred years, the installation of this new kettle is a huge step in efficiencies and capacity for this plant. Its comparatively simple elemental process creates a highly reliable and corrosive-resistant material. 

He further explains that the zinc has to be above 820 degrees F to be effectively galvanized, but it doesn’t need to be above 845 degrees because you don’t gain anything by being hotter. Atkins also points out that “You have to get your steel completely clean: no scale, no rust, no paint, nothing on the surface that’s a barrier to the bare steel” for galvanization to be most successful. 

When you dip the clean steel into the hot zinc, the metallurgical reaction bonding the zinc and steel creates four layers of the coating. At the bottom layer reside a mix of zinc and iron. As layers extend outward from the steel, there is increasingly more zinc with decreasing iron, so that the outer layer is a completely zinc surface. 

“In the 50s, when they started galvanizing here at AZZ, the process was not really that much different. The process still had acid that cleaned the steel. You still had a hot bath of zinc you dipped it in. Then you pulled it out, you cleaned it, and you shipped it back to your customer,” according to Atkins. Now, however, the technology has changed, creating a better product through a much more efficient process. “

AZZ, Inc. is a global provider of galvanizing, welding solutions, specialty electrical equipment, and highly engineered services. We support the power generation, transmission, distribution, and industrial markets through protection of metal and electrical systems used to build and enhance the world’s infrastructure. The new kettle is a another step forward in efficiencies and capacity for this plant. 

To learn more about what AZZ Inc. can do for your business, visit us online at AZZ.comtoday!

McKinney Aquatics Center Designed to Last for Generations Thanks to Hot-Dip Galvanized Steel Backbone

McKinney Aquatics Center Designed to Last for Generations Thanks to Hot-Dip Galvanized Steel Backbone

Galvanizing

McKinney, Texas was chosen by Money Magazine in 2014 as the best place to live in the country. When you visit, it’s not difficult to see why. This town of 161,905 people is prosperous, forward-thinking, and boasts many great events and places for families to enjoy. One of these excellent facilities is the recently constructed McKinney Aquatics Center, a sustainably built recreation center for kids and families looking to escape the Texas heat while still being active together. AZZ Galvanizing – Crowley was proud to help with the construction of such a wonderful facility, and was recently recognized for its work on the project by the American Galvanizers Association for Excellence in Hot Dip Galvanizing.

This new center was constructed after several years of dreaming, planning, and coordinating. Featuring a gymnasium, sports court, elevated track, child care area, classrooms, locker rooms and a 10,000-square foot pool—the $30 million, 80,000-square-foot facility is an incredible asset to the community. Project leaders expect it to be fully self-sustaining in three years.

One particularly exciting aspect of the project is the sustainable manner in which it was built. The core of the center is formed by hot-dip galvanized steel to ensure several generations of McKinney citizens will be able to enjoy it. This zinc-coated material is long-lasting, offering corrosion protection as well as consistent, rust-free beauty. Vastly superior to paint that would deteriorate consistently over time and need to be frequently reapplied, hot-dip galvanized steel is maintenance-free. 

AZZ Galvanizing – Crowley is very pleased to have played such a central role in the construction of this beautiful facility and looks forward to seeing McKinney families enjoy it for years to come.

To learn more about AZZ and its products, visit AZZ.com today!

Minneapolis Plant Increases Efficiency, Safety, and Capacity with New Galvanizing Kettle

Minneapolis Plant Increases Efficiency, Safety, and Capacity with New Galvanizing Kettle

Galvanizing

With the installation of a new, more efficient, and safer kettle, the plant is now able to galvanize material that is 30 feet long, a significant increase from our previous capacity. In the past, our customers in the area often had to drive long distances to galvanize large materials. Now, even their largest projects can be serviced in Minneapolis, saving significant time and money.

With our previous kettle, after dipping about 20,000 pounds the kettle would lower 20 degrees. This meant time and energy was spent reheating the kettle in order to dip more material. This new kettle can dip 40,000 pounds with a change of only 5 degrees. With this upgrade we will be able to increase production by roughly 50 percent. 

The new system is also more energy efficient. The old kettle has been a part of our plant since 1988, and furnace technology has come a long way since then. We are able to use half the burners we used to, while heating in a more even and efficient manner. This new setup also has a castable concrete floor and built-in airspace to retain heat once we reach the desired temperature. While the kettle itself will have to be changed every eight years, the furnace system is designed to last us another thirty.

We also took the opportunity to upgrade our safety measures, changing the traditional 3 ½ foot safety rim to a complete enclosure around the entire system. The full enclosure has side opening doors, which allows our galvanizing specialists to work in the kettle while remaining safe from splashing and keeping our plant clean. 

As a key supporter for the power generation, transmission, distribution and industrial markets, AZZ Inc. is proud to announce our latest galvanizing plant upgrade. By increasing our capacity and abilities, we are easing the burden on all of our partners and ensuring we will be able to protect your steel from corrosion far into the future.

To learn more about our services, or to see how AZZ Inc. can help your business, visit us at AZZ.com today! 

AZZ Employee Wins Barrow Way Award

AZZ Employee Wins Barrow Way Award

Galvanizing

Elias Jimenez is an exceptional man.  He joined the ranks at AZZ a decade ago, starting as a maintenance service employee. His supervisors, however, quickly noticed that Elias was a force to be reckoned with.  Today, the entire galvanizing industry recognizes Elias’ dedication to service, by awarding him the Barrow Way Award for “Outstanding Operations Personnel”.

As Tim Pendley, Senior Vice President of AZZ Metal Coatings, explains, “Commemorating the manner in which the Barrow family managed the Columbiana Boiler Company (CBC) for over 100 years, the AGA annually recognizes one operations employee from our member companies who exemplifies the core values which everyone looks for in their employees. The core values include: outstanding skill, pride and work ethic, integrity, understanding of their role within their organization, customer commitment, and community service.  I congratulate Elias as this years’ recipient of the Barrow Way Award”.

Elias joined AZZ in 2006 as a service as a maintenance employee. Quickly and consistently he demonstrated his mechanical aptitude and ingenuity. Elias has built an impressive knowledge base of furnace and kettle maintenance, and he has become a valuable resource—actively assisting nearly half of all AZZ facilities, each with their own unique maintenance challenges. He now holds the position of maintenance supervisor, and is tasked with improving facility performance by leading the maintenance team at the Plymouth site.

“People can’t stop talking about Elias”, says Bill Bowden, Regional Manager at AZZ Galvanizing. “In the past three years, he has been a key contributor to over six kettle changes. He is inventive, coming up with fixes for distorted stay bucks and equipment that would otherwise be considered obsolete.”

In addition to his commitment to AZZ, Elias is an involved, active member of his community supporting numerous community services with his wife, Anna, and their family.

The AZZ Galvanizing facility in Plymouth boasts one of the lowest down times in the industry. As maintenance supervisor, Elias no doubt contributes to this success with his exceptional skills, strong leadership, and customer commitment. Customers know they can rely on the Plymouth plant with confidence. AZZ’s 60 years of experience has contributed to critical enhancements for companies, industries, and the world’s infrastructure: dedicated employees, including those such as Elias Jimenez, are credited with making great things happen here. To learn more about our operations, services and team, visit us online at www.AZZ.com.