This content details the industrial process of galvanizing steel, highlighting the multi-step procedure and the skilled labor involved in protecting metal from corrosion. It emphasizes that seemingly simple tasks require precision and expertise, especially when dealing with hazardous materials and high temperatures.
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now that i'm suited up it's time to head
to the factory floor and get busy
galvanizing i hear the sounds of work
and i'm drawn to it like a moth to a
flame i know we're gonna get you to work
real quick awful lot of the steel you
see outside has been galvanized whether it's
it's
shelving or sort of fencing for home use
or these full-on electrical poles
it's a process and it works yeah first
step attach some steel wire to the
components being galvanized
how hard can that be you're going to put
them in that hole right there
two of them yeah two of them
all right then you're going to twist
them three times uh-huh
you'll make a mistake on the wire
you have to separate it like this oh
doing it the wrong way again oh geez
just one yeah one at a time
like most seemingly simple tasks this
one is critical to the job at hand
and harder than it looks
that's okay [Music]
[Music]
no it's not quick
much harder actually
uh you do it wrong i did it wrong yes
sir what am i looking to do what's the
goal oh wrap it more maybe oh right
there right in the burner right there
i can't decide do these guys make it
look easy or do i just make it look hard
now you're making the run again i make
it wrong yeah let me cut it oh i got i
got oh crap i did the whole thing wrong
well the importance is because we're
gonna lift it with the crane and that's
gonna weigh around 300 pounds
and if we don't do it like this it's
gonna fall into the acids not to
overstate things but if one of these
three-ton bundles should happen to drop
into the acid the resulting splash would
be very bad uh you did it wrong again no
come on that's going to be great nope huh
twisting wire round and round and round
and round
now [Music]
[Music] yeah
yeah
it's now oh it's good ah not my sport
you got it
well it only took me three and a half tons
tons
in an hour
are you starting am i sweating i know it's
it's
let's have a look oh man yes i'm
sweating me nothing you're nothing for
you no that's cause you don't have any
moisture in your body lupe
these hooks are what hold the components
together during the galvanizing process
and like everything else here they're
[Music]
if you're just tuning in no i do not
know what i'm doing
you're going to put this bar between
those hooks
to hold the angles okay
okay
hector and lupe are wondering how many
times it's going to take me to get this right
right
[Music] [Applause]
[Applause] [Music]
[Music]
okay you're done god
so all that
just so the crane can pick it up yes
thank you guys all right i feel like i
learned a lot i feel like i got the last
one right kinda
kinda
i feel like you've got a lot of job
security you don't have to worry about me
me
all right that's asking no business
salty sodium calcium
sodium hydroxide solution and is that is
this where it goes first uh sometimes
when we see oil in the parts this is
where we put it
this chemical is going to dissolve all
the dirt uh grease paint
and other impurities and the seal so you
want this thing as clean as it can be
yes sir it goes into the next one this
is nelson hey nelson how are you
uh so that's the control
it's all yours man all right
that's the one thing what he needs to do
actor i think it's basically pressing
this button yes sir
is it lined up alright yes sir
it's complicated because there's not a
lot of
there's no arrows or anything and i
think they're all configured a little
differently so there's a
certain amount of trial and error
all right so this is probably going to
which one this guy or this guy
this is exactly what happens every time
i try to program my dvr that one [Music]
[Music]
you sure
you're going back
and move it that way a little bit
okay it's the thing the terminator crawl
out of right yep [Music]
[Music]
the ph of this bath is around 4.5 you
got it meaning somewhere between the
acidity of wine and coffee just let it
sit for 20 minutes 20 to 35 minutes but
the acid in question is both toxic and
sulfuric so i won't be tasting it
anytime soon the steel angles acid bath
is finished and we are ready for the
truly dangerous part of the process good
thing my apron is trapped on tight i'll
pick them up next step
dunk the parts in a 160 degree pre-flux
bath the preflux will prevent oxidation
from leaving bare spots on the finished product
product
you grab that one i grab this one
zinc melts at 787 degrees but the zinc
bath in this plant is even hotter than
that which makes it one of the most
hazardous spots in a plant
full of hazardous spots and this is the
sink melted
time now to clean the surface of the
molten sink how does one clean ash out
of an 850 degree
swimming pool we're gonna show you in a minute
minute [Music]
[Music]
he's gonna come to the site
pick him up
i'll let him drain a little bit
so what's happening here
it's a shovel
like a sieve and you're scooping into
the zinc and the the zinc is dripping
out at 850 degrees
and the ash stays in sort of and you
dump the ash that's
that's the
i said that's good enough now we're just
gonna dip your angles good enough
that's what we're shooting for my angles
are ready for their zinc bath this is
where metal meets metal it'll get coated
with a layer of zinc 35 to 200 microns
thick roughly the thickness of a human
hair that thin coating will add between
four and eight percent to the standard
weight of the item being galvanized and
decades of additional life all right
we're good to go how long does it stay
in about five minutes or less
you use your hook right here yep
and the purpose of this is what just to
get as much zinc on every square
millimeter now you are taking all the
dirt out of it you see all this dirt oh
yeah it's coming out of the angles so
the more you shake the cleaner they're
gonna come out the last thing i want are
dirty angles once the items are coated
with zinc they're protected from the
effects of corrosion and we're going to
clean them have them ready for the
customer and ship them right now we have
to cut them got to cut the
wires i'm going to enjoy that
the wires have done their job admirably
now it's time to get rid of them
this is gonna cool for two three hours
and then what's gonna happen somebody's
gonna pick it up stack it
ship it yes
i think it goes without saying that when
you dip something into molten zinc it's
not going to come out perfect that's
where the cleaning comes in everything
that comes out of that
zinc pond
is going to have these little icicles on
it like this yep so every single piece
has to be laid out here
and hand grinded by these guys yes sir
this is kind of like at the end of a
haircut when the barber sweeps your neck
or buzzes off the now noticeable hair
growing out of your ears
this this is the object of my attack
right now all this stuff it's just
covered with these little
what do you got little zinc boogers
right they're everywhere
hundreds of thousands of them and they
say they've just got to go
they've all got to go [Music]
[Music]
[Music]
next time you walk into a building
you can't see them but
just remember what you saw here today these
these
supports they're everywhere they're
galvanized they've been dipped in zinc
probably by hector here and then a team
of guys with tools like this smooth them
all off buildings
buildings
electrical poles everywhere you look
well the work might never stop my friend
but i do
thank you for your hospitality thanks guys
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