Unparalleled Combinations
For almost all galvanizers the principal cost problems are
Those can cost you your bottom line if not managed
At Gongda Galvanizing we have the tools to assist you to manage
those critical problems
The tools are:
Laboratory procedures to give you accurate results using simple and
reliable wet chemistry techniques
Software to assist you to interpret the meaning of those results
Q’s & A’s to take you through diagnosis of problems
Internet assistance to solve problems
Access to advanced analytical tools such as metals analysis
Training tutorials on a subject by subject basis in ordinary
everyday language
These tools compliment our range of equipment which include:
Prep line management procedures and software to optimize your
process to reduce all costs
Advanced Immersion Heated, Ceramic Kettle to reduce dross and
energy consumption
Flash pre-fluxorpre-flux iron reduction to reduce dross and
increase fluidity as a means of achieving accurate coatings
Counter flow rinse systems to eliminate the need to discharge waste
rinse water and to recover process chemicals
Computer controlled cranes to aid in controlling and optimising the
preparation and galvanizing process
Efficient nickel addition to economically give even surfaced,
compact, bright coatings even when working with reactive steels.
Alloy viscosity is reduced to give thinner coatings
Post galvanizing chemicals to protect the fresh zinc surface
against oxidation
The practical results are:
Accurate coating best practice is to within 3 microns
Minimal dross production zero to 25% of normal
Greatly reduced ash make 25% to 80% of normal
Improved surface appearance particularly when using nickel
Greater assurance of product quality
More production
Reduced liquid and gas discharges
Little solid waste to discharge
The financial results are dramatic:
8% to 30% reduction in zinc consumption
Reduced energy consumption up to 30%
Increased revenue from reduced downtime for dross removal up to 5%
additional production
Increased revenue from enhanced quality one jobbing galvanizer
increased production by 150% as a consequence of much improved
surface appearance
Increased revenue and reduced costs from reduced reworking
Prep line management procedures and software
A rigorous set of control procedures are applied to ensure:
Each stage of the process is carried out under the same conditions
each day. The process is moved from an art form to one of
scientific control
Complex analysis of changing conditions is handled by easy to use
software to ensure that the operators know how much of what has to
be added when
Process control information is captured and presented for
interpretation
Ceramic kettle
A thermally efficient, one piece ceramic kettle with a 20 year life
ensures accurate control of the galvanizing temperature while
ensuring no iron enters the molten zinc from the material of the
kettle. Energy sources are electricity, gas or oil
Flash” pre-flux
This Gongda developed and patented procedure applies a zinc-rich
seal to the work before the hot dipping process precisely preparing
the work for the hot dipping process and thus ensuring that:
Little iron enters the molten zinc from the work:
Reducing dross
Maintaining good fluidity of the melt & good run-off
Reducing misses
improving adhesion
Improving malleability of the coating
Improving surface appearance
25% of normal ash production
Pre-flux ferrous iron reduction
Where it is not practical to apply the flash” pre-flux process
Gongda has developed a semi-automated ferrous iron removal process
and management plan which maintains the concentration of ferrous
iron in the pre-flux below 0.6 g/l and generally about 0.1 g/l to:
Reduce dross make
Ensure excellent fluidity of the melt & good run-off
Efficient nickel addition
Past methods of nickel
