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TechForum Presentations

Tuesday, September 28

Robert J. Wills

American Iron and Steel Institute (AISI)

Transportation/Infrastructure Public Policy and Steel Industry Update

This keynote presentation will review the current proposed government infrastructure plans, with information on the latest U.S. transportation bill’s potential impact on the steel and hot-dip galvanizing industries from the perspective of the American Iron and Steel Institute.

Andrew Bennison

TIB Chemicals AG

Turning Down the Heat on Cleaning

Energy costs and the protection of the environment is a constantly growing factor that no one can ignore. Over the years various approaches have been attempted to decrease the energy demands of the cleaning process, while still effectively and efficiently cleaning metal surfaces. This presentation looks at the different approaches and the costs and benefits involved of metal cleaning and the development of an alternative low temperature Alkaline cleaner that meet the demands of the HDG industry, whilst saving energy and resources. This presentation will look at how the product was developed and tested, cost/use benefits, and a look at the implementation of the product in real plants. 

Alana Fossa

American Galvanizers Association (AGA)

Research on Abrasive Blasting Before Hot-Dip Galvanizing

It is well known that abrasive blast cleaning steel before hot-dip galvanizing can either stunt coating growth for reactive steels or increase coating thickness for steels of low silicon content. The amount of reduction or increase has not yet been quantified in the industry, and customers/specifiers are hesitant to pay for blasting at additional cost without technical justification. The AGA developed a test program to quantify these benefits for steels grades known to exhibit either low coating thickness (Aluminum-killed plates/shapes) or flaking (recycled steels, A992 and A709 shapes/beams). In this presentation, AGA’s Alana Fossa will provide a sneak peak at the study’s results and identify strategic uses for this optional surface preparation step.

Dan Charpie, Steve Zink and Chris Borgen

Marsh & McLennan Agency

Current Safety and Environmental Trends for the Galvanizing Industry

Safety culture at the galvanizing plant and opportunities for risk management.

Jim Dvoratchek and Ted Stanaszek

Hard Rock Concrete Cutters

Abrasive Non-Ferrous Metal Cutting for Reclamation and Demolition

Soft metals like zinc, copper and aluminum are easily deformed during the cutting process making them extremely challenging to move or repurpose in a manufacturing environment. Cutting zinc spills or damaged furnaces into pieces that can be moved by hand or with a skid steer or crane is no easy task. However, there are tools and techniques available to help plant owners get their lines and furnaces up and running after catastrophic events or during scheduled maintenance. This presentation will review case studies of specialized demolition services where cutting metal slabs or scrap into manageable pieces have allowed manufacturers to reintroduce zinc and other materials back into the production process or sell the material to turn their waste into profits.

David Harrison

Galvanizers Association of Australia (GAA)

Effect of Micro-Environments on Corrosion Rates – Practical Considerations for Residential Construction

The atmospheric corrosion rate of zinc in various macro-environments world-wide has been well researched through the work of the ISOCORRAG program, and others, and is documented in various standards including ISO 9223 and ISO 9224 and in Australian Standards AS/NZS 2312.2 and AS 4312. A micro-environment can be created at a local level through any site-specific feature that modifies macro-environment variables such as the time of wetness, degree of rain washing or exposure to salt aerosols and contaminants.

The effect of micro-environments created by poor construction practices can have a significant impact on durability and is not well understood. In 2019, a study aimed to investigate the effects of real time exposure at a severe marine site for a range of different steel sections, with various corrosion protection coating systems, using common construction practices for residential housing systems. A range of frequently used configurations, with different corrosion protection options, were installed at the site over time. This presentation provides a progress report after 18-30 months exposure and discusses the impact of construction practices and design on localized corrosion.

Wednesday, September 29

Jeff Suda and John Roy

Steel Utility Pole Coalition
Connecticut Galvanizing

HDG Industry Updates – Steel Utility Pole Coalition (SUPC) and Rebar Focus Group (RFG)

Come hear about the latest efforts of the Steel Utility Poles Coalition (SUPC) to increase specification of steel poles for use in sub-transmission and distribution and hear about ongoing activities from the Rebar Focus Group (RFG) to increase the specification of hot-dip galvanized reinforcing bars for use in concrete.

Reddy Vantari

Nucor Skyline

Basics of Steel Metallurgy

This presentation will dive into the basics of steel metallurgy, the reasons for aluminum-killing vs. silicon killing, and how elements like silicon and phosphorus end up in the steel and affect steel reactivity for hot-dip galvanizing. Reddy Vantari of Nucor Skyline was previously the chief metallurgist for Nucor-Jewitt and has vast experience with steel making and chemical properties as it relates to the beam and galvanizing world.

Christine Kleen

American Galvanizers Association (AGA)

AGA Personal Protective Clothing Study

What protective clothing is suitable to wear around the galvanizing kettle? Previous Tech Forum presentations addressed this question and provided information on fabrics that prevented adhesion of molten zinc. The AGA Personal Protective Clothing study evaluated protective clothing currently worn at galvanizing facilities, as well as new fabrics often used in the foundry industry. Besides testing adhesion of molten zinc, heat transfer was measured and followed the testing protocol of ASTM F955, Standard Test Method for Evaluating Heat Transfer through Materials for Protective Clothing upon Contact with Molten Substances. This presentation will provide some background into the development of the protective clothing study and summarize the results of the testing.  

Sally Buck

Valmont Coatings

Environmental, Social, and Governance (ESG) Performance and Waste Minimization

This presentation will review the sustainability of hot-dip galvanizing and best practices. Key topics include improving the quality of the bath chemistry while reducing chemical waste along with the use of frequent preventative maintenance to reduce down time, waste generation, and the toxicity of generated waste. The impact of flux chemistry on air emissions and drossing will also be reviewed.

Jared S. Kaufman, P.E.

CIC Pittsburgh

10 Things to Know About Combustion

The combustion system used to heat the kettle is central to a hot-dip galvanizing operation, yet many operations and maintenance personnel have limited knowledge of how it works.  This presentation will provide a basic understanding of what is most important to support the furnace operation:  an introduction into the basics of combustion, a summary of the components that comprise the combustion system, and an explanation of the purpose and use of the various devices. 

Bernardo Duran

International Zinc Association (IZA)

Transformative Studies in the Batch Galvanizing Industry – Part II

At virtual TechForum 2020, Bernardo Duran reviewed the history and contents of select studies on cope cracking, material properties, and reactive steels that had far-ranging impacts on the specification and processing of batch hot-dip galvanizing. Part II of this presentation will review another selection of research studies which contain technical information galvanizers can use to improve their customers’ experience with specifying hot-dip galvanizing. 

Thursday, September 30

Philipp Roth

Scheffer Krantechnik GmbH

Rope & Chain: Hoists in the Galvanizing Industry

Mainly there are two different types of hoists used in hot dip galvanizing plants: ROPE-hoists and CHAIN-hoists. This presentation will review the different technical aspects of each system, different properties, and many possibilities of each application.

Ryan Monnig

Monnig Industries, Inc.

Big Bend Galvanizing (Monnig Industries): Virtual Plant Tour

Big Bend Galvanizing, located in Trenton, TN is part of the Monnig Industries family. This plant operates three kettles with the largest size being 33 ft x 5.4 ft x 8 ft and one kettle is also used as a dedicated spin line. Ryan Monnig will present a short video-tour of the plant followed by a Q&A session.

André Gómez

W. Pilling

Typical Kettle and Failures and How to Prevent Them

This is an overview of how kettles are fabricated and should be maintained. As well most frequent kettle failures and prevention will be discussed, making an emphasis on adding Bismuth to the kettle, which can be critical to kettle life.

Michael W. Patterson

Western Technologies, Inc.

Systems to Control Emissions in Galvanizing Plants

Over the years, there have been many improvements in technology when it comes to controlling the emissions from a hot-dip galvanizing plant. This presentation will provide an overview of the emissions in a typical hot-dip galvanizing plant and the best available methods to control them.

Thomas J Langill, Ph.D.

American Galvanizers Association (AGA)

Hot-Dip Galvanizing Industry Research Updates

Learn about the AGA’s involvement in ongoing research programs and their potential impact on the galvanizing industry:

  1. Transportation Research Board, NCHRP Study No. 10-94, Mitigation of Weldment Cracking of Highway Steel Structures due to the Galvanizing Process
  2. Research Council on Structural Connections (RCSC) Slip of Metallic Coatings Study
  3. AGA study (performed at U. Kansas) to develop a Kleingarn Curve for sulfuric acid and study the impact of zinc content on pickling rates