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Dr. Galv KnowledgeBase


TechForum Presentations

Jim Saylor & Bob Messler

V&S Galvanizing

Kettle Changeouts/Avoiding Near Misses at the Kettle - Lessons Learned from Operations Perspective

Jim will share his experience on this topic across multiple facilities to address safety concerns, efficient operations, spares, change-outs, considerations when choosing to pump zinc in-house, and other lessons learned.

David Watkins

Zinco International Limited

Thermo Dynamics of Kettle Wall Thickness: Knowledge and Experience of Galvanizing Kettle Corrosion Profiling

All operations use data to measure performance / outputs and an essential piece of equipment for any galvanizing plant is fully functioning kettle full of molten zinc. The life expectancy of any kettle can depend on multiple factors such dip weights, product mix, production hours and heat sources.

The presentation explores the experience of corrosion profiling zinc kettles used in general hot dip galvanizing plants. It explains the technology used in large and smaller kettles, examines the differing heat sources that result in variable corrosion rates / wear patterns and the data captured which allows the plant to make informed choices.

Jared Kaufman

CIC Pittsburgh

Digitalization Application for the Hot Dip Galvanizing Furnace

A new, significant trend throughout industry has been the application of digitalization strategies, known as Industry 4.0. Industry 4.0 refers to the application of increasing interconnectivity and smart automation. Much emphasis has been on the application of sensors and data gathering to gain new insight into the operation and maintenance of plant equipment. However, applications to Galvanizing Furnaces have been extremely minimal in nature despite being a centerpiece of the production facility. This presentation discusses development and real-world implementation of a system that provides continuous monitoring of the firing conditions of each of the burners on a furnace. This is of particular importance for Pulse-Fired systems and provides benefits in the form of kettle protection and energy efficiency.

Noam Sugarman & Charl Pohlmann


Norgalv Virtual Plant Tour

Norgalv, located in North Bay, Ontario is a semi-automated, single-line, hot-dip galvanizing plant in operation since 2020. The new 32,500-square-foot facility was designed by leading industry specialists and uses some of the most advanced technology supplied by expert manufacturers from Austria, Germany and the UK. Additionally, the facility features many sustainability efforts such as chromium-free passivation and 100% emissions-free and fully enclosed pre-treatment process which is remotely-operated.

Alana Fossa

American Galvanizers Association

Galvanize the Troops: Expanding AGA's Influence in Specification Development

The American Galvanizers Association (AGA) has worked hard to establish the association as THE voice of the hot-dip galvanizing industry in North America. As we have expanded the interest in our industry throughout various markets, the number of specifiers and specification committees talking about galvanizing is higher than ever before. Although this is a "good" problem to have, the AGA needs your support to stay on top of these groups and remain the source for accurate, modern, and practical information. The risk lies in groups who lack AGA's presence or are unaware of our expertise which can lead to galvanizing being excluded and/or passing impractical or costly requirements. This presentation will cover the importance of these groups and pathways to get involved.

Mike Williams

Duncan Galvanizing Corp.

HDG Process and Knowledgesharing

The AGA Technical Services HDG Processing subcommittee recently organized a group messaging service (GroupMe) to help galvanizers exchange ideas about the HDG process with other galvanizers including topics related to maintenance, inspection, quality, part design concerns, customer complaints, and more. Learn more about the benefits of information exchange and how it is used by AGA members.

Kettle/Furnace – Small Group Discussion

Proper operation of the kettle is critical for a safe operation and to achieve a good return on investment. Attendees will break into small groups led by TechForum planning committee members to discuss and exchange ideas on kettle maintenance, kettle change outs, and lessons learned. This is a great opportunity to meet and learn from other operations personnel in the industry.

Firoz Rohile

Valmont Coatings - Pure Metal Galvanizing Mississauga

In-person Plant Tour Preview

Come learn about what to expect on Wednesday afternoon’s galvanizing plant tour of Valmont Coatings - Pure Metal Galvanizing Mississauga. Established in 1937, the facility is equipped to handle difficult projects with multiple galvanizing kettles, the ability to progressively dip oversized material, and a spinning line that can galvanizing rods and rebar up to 9' long. Plus, real-time digital order tracking keeps our customers in the loop through every step of the galvanizing process.

Duane Bickers

AZZ Galvanizing - Galvcast

In-person Plant Tour Preview

Come learn about what to expect on Wednesday afternoon’s galvanizing plant tour of AZZ's facility in Acton, Ontario. Acquired in 2012 by AZZ, Galvcast has a rich heritage of commitment and service since its founding in 1981 by the Christopher family. The facility has three kettles (46 ft. 32 ft. and 16 ft. long) for a variety of material.

Dr. Caroline Bennett

Civil, Environmental & Architectural Engineering, University of Kansas

Mitigation of Weldment Cracking in Steel Highway Structures

Under NCHRP Project 10-94, “Mitigation of Weldment Cracking of Highway Steel Structures due to the Galvanizing Process,” the University of Kansas was charged with proposing improved design, materials, and construction specifications of galvanized steel highway structures—specifically structural supports for signs, luminaires, traffic signals, and bridge superstructures—to mitigate weldment cracking or liquid metal assisted cracking (LMAC) associated with the hot-dip galvanizing process. This presentation from Principal Investigator Dr. Caroline Bennett will review the experimental investigation and a computational study performed to evaluate the effect of contributing factors and their interactions on weldment cracking.

Fernando Correia


Research on Mechanical Characterization and Zinc Consumption of Steel Wire Used for Hanging Steel Products During Hot Dip Galvanizing

This presentation will cover new research findings on the on mechanical characterization and zinc consumption of steel wire used for hanging steel products during hot dip galvanizing, focusing on three important topics: Rating of zinc adherence on wires according to the type of steel used, an analysis of the mechanical strength as a function of the number of wires used for tying and of their diameter (use of multiple strands in one knot), and rating of stability of the ties performed by operators in function of the applied load. These topics are of utmost importance for the safety and health of operators, material efficiency, and zinc economy.

Angela Curtis

Hasco-Thermic Ltd

Digital Twin Technology: a Reduction in Energy Consumption, Maintenance Cost and Increase Kettle Life

The galvanizing furnace, which maintains hundreds of tonnes of liquid zinc at precise temperatures, is arguably the most critical asset in a galvanizing plant. Key indicators of a furnace's performance and technological aptitude include energy consumption and kettle lifespan, both of which significantly influence the operational costs of a galvanizing plant. Despite their importance, there has been minimal innovation in furnace control systems over the past decades aimed at reducing gas usage and prolonging kettle life. This presentation will cover technology and case studies to diminish the operational expenses of galvanizing plants through intelligent control of furnace operations, thereby conserving gas and extending kettle longevity.

Panel Discussion: Kettle Maintenance & Handling

Come hear different perspectives from industry experts Columbiana Boiler Company and W. Pilling on kettle maintenance and handling. This panel will be Q&A format with some guidance questions to aid the discussion. Bring your questions!

Liuba Shaplyko

Sirio Impianti Industriali

Dual Power Furnaces

Martin Gagne

International Zinc Association

Technical Details on Hot-Dip Galvanizing with Thermal Spray Zinc (Metallizing)

This presentation will discuss technical concerns regarding the specification of metallizing for oversized components together with HDG of ancillary components as well as practical concerns at the galvanizing facility (3rd party or DOT inspectors, finish on faying surfaces, and more) to keep in mind when taking on projects where HDG is specified alongside metallizing.

David Watkins

Zinco International Limited

Kettle Changeouts – a European View

Periodically a galvanizing plant needs to replace its kettle. The presentation explores the experience of kettles changeouts from a European perspective including the pumping of zinc into moulds and the use of portable furnaces to speed up the changeout time. Considerations to a smooth kettle change include careful planning and trusted supply chain such as furnace engineer & lifting solutions. The presentation also provides some guidance as to best practice to avoid economical / environmental incidents of kettle failures.

Andrew Marchioni

V&S Galvanizing

Language Barriers and the Future of Safety

Andrew will share his experience on language barriers among operations personnel at the galvanizing facility and ways the galvanizer can overcome them to ensure a safe workplace.

Sally Buck

Valmont Coatings

Building an Effective Emergency Response Plan

Emergencies can create a variety of hazards for workers in the impacted area. Preparing before an emergency incident plays a vital role in ensuring galvanizers have the necessary equipment, know where to go, and know how to keep themselves safe when an emergency occurs. But equally as important, it also ensures you have everything in place to efficiently and effectively discuss with regulators and emergency response teams. This presentation will discuss examples and information on how to prepare and train for emergencies and the hazards to be aware of when an emergency occurs such as kettle failure, fire, chemical release, and more.

Muriel Golabkan

Zinco Technologies

Predicting Kettle Aging: Effectiveness of Kettle Ultrasonic Inspection on Wall Thickness Readings at Corners and in Small to Mid-sized Kettles

The leaking of molten zinc, or the kettle failure, is a significant concern for galvanization plants. Once such issue occurs, it's usually too late as it is always an exceptional situation. What’s normal are the kettle replacements instead which are part of any plant’s life cycle, whether due to equipment breakdown or not. Thus, a shift in perspective is necessary. Preventing kettle breakage is essential, and it's equally vital to assist galvanizers in managing capital expenditures related to equipment replacement. This involves choosing the right time for investment based on production load and cash flow. Monitoring the kettle's aging and predicting its remaining useful life are key aspects of this strategy. Although some doubt the effectiveness of kettle inspections for corners or smaller kettles, advancements in inspection systems have made them highly reliable even in challenging scenarios. One notable example helping in these cases, it’s the K.I.D.TM system.