Double G Coatings Company, L.P., a steel processing company, is a valued customer for Hydradyne. Double G Coatings, which operates a hot dip galvanizing and Galvalume facility, is located in Jackson, Mississippi and processes steel supplied by U.S. Steel and ArcelorMittal, the company’s joint owners. Double G Coatings primarily serves the prepainted construction market and has an annual production capability of approximately 315,000 tons.
Read Hydradyne’s previous story with Double G Coatings Company to learn more about the galvanizing process and how Hydradyne goes above and beyond to help its customers. Galvanizing Steel | Heater Core Repair – Blog Post
One of the many critical steps in setting up the galvanizing process is loading the Zinc ingots, or Galvalume blocks, into the open furnace pot. An “ingot” is a piece of relatively pure material, in this case Zinc, which is cast into a shape suitable for further processing. The pot, where the cold Zinc ingots are loaded into, is extremely deep and hot (approximately 420 degrees Celsius or 788 degrees Fahrenheit) in order to melt down the zinc to a liquid form so that Double G can coat the raw steel sheet. Double G must be able to safely lower the solid ingots into this open furnace.
Hydradyne provides the lifting bars in order to lower the Zinc, or Galvalume blocks, into the pot.
Hydradyne uses round solid stainless steel bars to create the lifting bars. A section of the bar is heated to cherry-red with a torch in order to make it pliable; the bar is then bent a little beyond 90 degrees by a hydraulic cylinder in a fixture. This bend is made in two places to make a “horse-shoe”. After the bar cools, it is placed in a different fixture, set up with a come-along, and cold bent back to a perfect 90 degrees. Hydradyne uses this process because as the bar cools the metal will move out of place and a cold bend is easier to control.
The arms are then cut to the proper length and staged for the next process.
Lifting eyes are then cut out from stainless plates, using a CNC cutting table, and welded onto the ends of the “horse-shoe” creating the lifting bars.
Two lifting arms, provided by Hydradyne, are used to load the zinc ingots into the open furnace pot. The arms must stay in the furnace until the zinc becomes completely molten and therefore have a fairly short lifespan. A set of two bars may last 3 to 4 weeks.