Technology Committees

Galvanizing Technology Committee Activities

The GTC toured the Nissan Smyrna Vehicle Assembly Plant on 8 September 2017.

The GTC met 7–8 September 2017, Nashville, Tenn., USA. Discussion revolved around session building for AISTech 2018 in Philadelphia, Pa., USA. The role of session chair was reviewed and volunteers solicited. Those interested in serving as session chair should contact Anna Voss.
The next few galvanizing-related meetings across the industry were discussed, including Galvatech 2017 in Tokyo, Japan.
The past few years’ meeting topics were reviewed to identify any areas that have not been reviewed in a while.
The meeting included four presentations in the afternoon. The first two presentations were operations based, covering coating weight thickness control and fundamentals of annealing, whereas the latter two were focused on the zinc refining process as well as a zinc market review. 
The next day, Nissan Smyrna Vehicle Assembly Plant hosted the group for a tour of the facility.

Nathan Wenning (left) presented William Lucas (right) with the GTC service plaque.

The GTC met 9 May 2017, Nashville, Tenn., USA.

The following officers were elected:

  • Chair: Nathan Wenning, Steel Dynamics Inc. – Jeffersonville Plant

  • Vice chair: Jonathan Minucci, Atlas Machine and Supply Inc.

  • Papers co-chairs: Frank Goodwin, International Zinc Association, and Joseph McDermid, McMaster University

  • Education co-chairs: Gary Dallin, International Zinc Association, and Stavros Fountoulakis, ArcelorMittal Global R&D – East Chicago

Jeff Roach, galvanizing manager at Steel Dynamics Inc. – Flat Roll Group Columbus was presented with a plaque of appreciation for hosting the SHTC and GTC (left to right): Nathan Wenning, GTC vice chair; Bill Lucas, GTC chair; Roach; and Malcom Dunbar, SHTC vice chair.

The SHTC and GTC met 1–2 March 2017, Columbus, Miss., USA. The committees reviewed the 2016 Steel Industry Fatalities report, followed by a safety roundtable discussion.
Each committee finalized its AISTech 2017 technical sessions. The roles of session chair and papers chair were reviewed.
Committee officers for 2017–2018 were discussed and elections will take place at each committee’s meeting during AISTech 2017.
The committees discussed their fall meetings. The GTC’s meeting will possibly be held in Memphis, Tenn., USA, with Big River Steel or Nucor Steel–Arkansas serving as host plant. The SHTC’s fall meeting will be held on 19–20 September 2017 in Charleston, S.C., USA, with Nucor Steel–Berkeley serving as host plant.

The following technical presentations were given:

  • “Ceramic Bearings — Four Case Studies,” by Mark Hall, McDanel Advanced Ceramic Technologies.

  • “From Start to End Where Coatings Offer Advantages on Rolls,” by Charles Kay, ASB Industries Inc.

  • “Pot Solutions,” by Michael Brennan, Praxair Surface Technologies.

  • “Pot Rig Maintenance Practices and Equipment Repairs,” by Chad Donovan, SMS Technical Services in cooperation with Duma BandZinc and FOEN.

  • “Pot Equipment Refurbishment,” by Jonathan Minucci, Atlas Machine & Supply.

  • “Recommended Practices to Improve Inductor Life,” by Bert Armstrong, Inductotherm Corp.

  • “Exposure Monitoring at Galvanizing Lines,” by Barry Momyer, AM Health and Safety Inc.

  • “Overhead Crane Safety Lighting Innovations,” by Susan Snapp, Steel Dynamics Inc. – Flat Roll Group Columbus.

  • “SDI Columbus Plant Overview and Safety Requirements,” Jeff Roach, Steel Dynamics Inc. – Flat Roll Group Columbus.

The SHTC and GTC enjoyed a tour of the Steel Dynamics In. – Flat Roll Group Columbus galvanizing department during their joint meeting on 1–2 March 2017. 

The GTC met 13–14 September 2016, Pittsburgh, Pa., USA.  The GTC reviewed the 2016 Steel Industry Fatalities report, followed by a roundtable safety discussion.
The GTC organized a seven-paper session for MS&T16, which was held 23–27 October 2016, Salt Lake City, Utah, USA. The session was titled “Advances in Zinc-Coated Sheet Steel Processing and Properties.”
For AISTech 2017, the GTC selected four papers for the Tuesday morning session.
Galvatech 2017 will be held on 12–17 November at Itoo Research Center in Tokyo, Japan.
The following presentations were given:

  • “End User Observations: Steel Service Center,” by Chris Menke, Pacesetter Steel Service Center. 

  • “Theory, Temper Mill Control,” by Brian Braho, Braho Machinery.

  • “Temper Rolling Process Objectives and Equipment Requirements,” by Michael Peretic, SMS USA LLC.

  • “The Ultimate Temper Mill,” by Lionel Goiset, Fives DMS.

  • “Tension Leveling and Roll Alignment,” by Dave Withrow, Allor Manufacturing Inc.

  • “Paintable Passivants,” by Dave Kelly, TecCoat.

  • “Advancement in RoHS Compliant Surface Treatments,” by Chad Johnson, Quaker Chemical Corp.

  • “On-Line Surface Roughness Measurement,” by Patric Jobst, EMG USA Inc.

  • “Passivation Film Measurement,” by Christopher Burnett, ThermoFisher Scientific.

  • “Post-Treatment Roll Coaters,” by Ned Kohler, Danieli Fata Hunter.

The group toured Wheeling-Nisshin’s facility in Follansbee, W.Va., USA.

Bill Lucas (left), GTC chair, presented Patrick Pendleton (right) with a plaque of appreciation for hosting the GTC’s tour of Wheeling-Nisshin during its 13–14 September 2016 meeting.
The GTC service plaque was presented to Mark Marietti
(left to right): Joe McDermid, Marietti, Frank Goodwin and
Bill Lucas.

The GTC met 17 May 2016, Pittsburgh, PA, USA.

The following officers were elected:

  • Chair: Bill Lucas, Ebner Furnaces

  • Vice chair: Nathan Wenning, Steel Dynamics Inc.

  • Papers co-chairs: Frank Goodwin, International Zinc Association, and Joe McDermid, McMaster University

The GTC met on 8–9 March 2016 and toured ArcelorMittal Burns Harbor’s hot-dip coating line.

The GTC met 8–9 March 2016, Merrillville, Ind., USA. The GTC reviewed its four technical sessions at AISTech 2016 and discussed the responsibilities of session chair.
Presentations were given on the following topics:

  • Furnace safety related to personal protective equipment and safety practices while operating or during maintenance.

  • Burner operating practices for energy efficiency and longer tube life.

  • Wrought tubes, including bubble tubes vs. cast tubes.

  • Furnace rolls, alignment and roll coating technologies.

  • Considerations and developments in furnace design and materials used in construction of radiant tube furnaces as well as direct-fired furnaces dedicated to advanced high-strength steel and for selective oxidation.

  • Furnace improvements and upgrades.

The GTC was given a tour of ArcelorMittal Burns Harbor’s hot-dip coating line.

The GTC and Sensor Systems Subcommittee (SSSC) met 24–25 September 2015, Evansville, Ind., USA. The GTC’s AISTech 2016 technical session development was discussed.
The GTC finalized its AISTech 2017 Call for Papers topic and discussed items to be reviewed at the AIST Leadership Conference.
A subcommittee including Stavros Fountoulakis, Mark Marietti, Jim Evans, Matt McCosby and Bill Lucas was established to determine what additional fields should be added to the existing Galvanizing Lines Roundup.
Technical presentations were given on the following topics:

  • The EMG IMPOC® system and its benefits.

  • Technologies involved to measure strip coating weight.

  • Tecnar’s zinc pot aluminum chemistry testing system.

  • ArcelorMittal Dofasco’s edge buildup detection sensor.

  • Keyence’s VK-X250 laser scanning microscope.

  • Advancements in surface inspection.

AK Steel Corp. – Rockport Works hosted a tour of its hot-dip galvanizing line.

Mark Marietti (right) presented a plaque of appreciation to Dan Tipton (left) for hosting a tour of AK Steel Corp. – Rockport Works during the GTC’s meeting on 24 September.
Frank Goodwin (left) presented the GTC service plaque to Dan Lamprecht (right).

The GTC met 5 May 2015, Cleveland, Ohio, USA.
The following officers were elected:

  • Chair — Mark Marietti, AK Steel Corp. – Dearborn Works

  • Vice chair — Nick Lagios, Drever International USA

  • Papers co-chairs — Frank Goodwin, International Zinc Association, and Joe McDermid, McMaster University

  • Program planning chair — Harve Anderson, Rotadyne Roll Group

Meeting Highlights:
Frank Goodwin provided an overview of his team’s effort to maintain the data for the Galvanizing Lines Roundup. Gary Dallin is leading this effort at
Members participating in the AIST Process Benchmarker® (APB®) were encouraged to enter data. Ken Landau of AIST reviewed the status of producing companies who subscribe to the APB.

The CSRTC and GTC met on 10–11 March 2015, Louisville, Ky., USA. 

The CSRTC and GTC reviewed their respective technical sessions for AISTech 2015.

The following presentations were given:

  • “Strip Shape,” by Primetals Technologies.

  • “Strip Sensor Applications,” by EMG.

  • Cold Mill Shape — Mill Survey Review,” with four mills offering feedback of mill equipment and controls, limits and typical hold criteria.

  •  “Coating Line Steering — Mill Survey Review,” with nine mills offering feedback on systems, capabilities, incoming limits and issues.

  •  “Cold Mill Marks,” by ArcelorMittal Dofasco Inc.

  •  “Issues Versus Improvements in Roll Cover Design,” by Vail Rubber.

  •  “Cold Mill Strip Cleanliness,” by Quaker Chemical Corp.

  •  “Continuous Galvanizing Line Cleaning,” by Quaker Chemical Corp.

  •  “Cold Mill Surface Cleanliness — Mill Survey Review,” on tests, performance and limits.

  •  “Coating Line Cleaners — Mill Survey Review,” on systems, tests, performance and related issues.

Producer and supplier members were given an opportunity to discuss safety-related items.

A representative from Ternium Mexico discussed the company’s process of identifying new employees by issuing them specially colored helmets. As training progresses, stickers are awarded for performance, which are displayed on the helmet, until the employee is capable of working on his/her own. The employee’s helmet is then replaced with that of a permanent status employee.

Tours of AK Steel Corp. – Rockport Works’ continuous cold mill and Steel Dynamics Inc. – Flat Roll Group Jeffersonville’s galvanizing line were held.

Both committees met on Tuesday, 5 May 2015 at AISTech 2015 in Cleveland, Ohio, USA.

The GTC met in Youngstown, OH., on 9 September 2014. The one-day meeting was attended by 69 people, including 31 galvanizers, and began with two plant tours. Matt Keller hosted a tour of Taylor-Winfield Technologies’ world headquarters, which also houses its engineering and some manufacturing. Scott Bishop hosted a tour of NLMK – Sharon Coating’s galvanizing line.
A welders’ roundtable was moderated by Mark Mariette of AK Steel Corp. – Dearborn Works. Mariette summarized the welder survey responses received and encouraged discussion among the attendees. Welder-related presentations were given by Mike Prokop of Taylor-Winfield Technologies, Eric Thokar of Siemens Industry Inc. and Ralf Wallmeyer of IDEAL-Werk.

The GTC met in Southbend, IN., on 25–26 March 2014. 
I/N Tek & I/N Kote hosted the GTC on a tour of its continuous descale cold mill, roll shop and hot-dip galvanizing line.
Frank Goodwin, International Zinc Association and GTC papers chair, reviewed the GTC session for AISTech. He then reviewed the sessions that are being planned for MS&T’14, which will be held in Pittsburgh, Pa., USA, in October. Goodwin reported on the GalvInfo training, which is scheduled for November 2014 in Pittsburgh. He also announced that Galvatech 2015 will be in Toronto, Ont., Canada, on 31 May–5 June 2015 and will be co-located with the Hot Press Forming Conference (CHS2). Abstracts for CHS2 are due 1 August 2014.
Jim Evans, AK Steel, moderated a health and safety roundtable discussion with seven producer representatives who shared their facilities’ safety initiatives and experiences:
Erwin Lakia of Worthington Steel, Ilias Garidis of AM/NS Calvert, John Wray of California Steel Industries Inc.,
Jason Schulz of ArcelorMittal Dofasco Inc. and GTC chair, Chris Shuff of Spartan Steel and Phil Shawk of Gregory Industries, in addition to Evans.Dan Lamprecht, CMI Industry and GTC vice chair, moderated the presentations about side trimmers, which included the following:

Aaron Langness of I/N Kote, “In-Line Side Trimmer Project,” which provided an overview of I/N Kote’s project and experiences improving the CGL’s side trimmer and scrap baller.
Todd Bailey of ArcelorMittal Dofasco Inc., “Unslit Reworks Quality Improvement Project,” which gave an overview of an investigation of issues related to edge trimming.
Kurt Hilderbrand of Siemens Industry Inc., “SIROLL Side Trimmers,” which discussed the range of side trimmer technologies, configurations and controls offered by Siemens.
Frank Beddings of Primetals Technologies U.S.A. Holdings, Inc., “Side Trimmers,” which discussed the range of side trimmer technologies, configurations and controls offered by Primetals Technologies U.S.A. Holdings, Inc.

Harve Anderson of Rotadyne presented “Downstream, Value-Added Rubber Roll Technology,” which provided an overview of unique roller applications for printing, embossing and decorating metal surfaces for aesthetic markets.
Jason Schulz moderated a roundtable discussion regarding non-capital to small/medium capital improvements. Jim Evans presented “AK Steel’s No. 3 ZincGrip Temper Mill Wringer Roll Improvements.” Mike Koraido of Gregory Galvanizing explained a change in practice which Gregory Galvanizing made to the acid section of its galvanizing line’s cleaning section that has saved significant waste acid disposal costs due to the elimination of elemental zinc in the acid bath. Tom Minor of Spartan Steel presented details about how Spartan Steel eliminated heat buckle defect by adjusting tensions in the furnace per grade of steel. John Wray presented an update on California Steel Industries Inc.’s unique and successful furnace steering section sensor supplied by EMG called Vivialdi®.

The GTC met in Charleston, S.C., on 19–20 March 2013. Jason Schulz of ArcelorMittal Dofasco Inc. chaired the meeting. There were 73 attendees. Barry O’Hara of ArcelorMittal Dofasco Inc. led the safety session with a presentation entitled, “Accident-Free Workplace Team.” Chris Calvin of Nucor Steel followed with a presentation entitled, “Safety Improvements,” and the session closed with each producer company representative discussing a health and safety initiative/improvement being implemented at his/her facility. The theme of the meeting was increasing the throughput of galvanizing lines, with a number of producers and suppliers explaining various tactics to accomplish that goal. To conclude the meeting, Nucor Steel–Berkeley hosted a tour of its hot-dip galvanizing line.

The Galvanizing Technology Committee (GTC) met on 5–6 September 2012 in Columbus, Ohio, with 66 attendees. Jason Schulz of ArcelorMittal Dofasco Inc. opened the producer-only portion of the meeting. The 2012 North American Steel Mill Fatalities Report was reviewed, which prompted a safety incident discussion by the attendees, who shared summaries of safety incidents to enhance hazard identification and injury mitigation. Joanne Zaraliakos of U. S. Steel Canada – Hamilton Works gave a presentation on hand safety, which provided detailed information on hand injuries, including statistics, case studies, proven policies, personal protective equipment review and hazard identification. Zaraliakos’ presentation opened a roundtable safety discussion in which all attendees participated. Jack Abbruzzese of DJ Galvanizing facilitated a discussion on a previous maintenance survey, in which producers shared details of line capabilities and characteristics of them.
The meeting was then opened to the entire committee, and  the attendees introduced themselves. Eric Almquist of Star Tool & Die volunteered to take the meeting minutes. The meeting topic focused on maintenance for galvanizing lines, with an emphasis on furnace roll alignment. Presentations were given by Wayne Bontempo of ArcelorMittal Columbus, Wynn Kearn of CMI, Peter Lewis of ArcelorMittal Dofasco Inc., Jeff Duhart of DJ Galvanizing, Jim Lynch of Nucor Steel–Decatur, Mike Ciocys of Prüftecknik Service Inc., Ted Todd of Drever International, and Mr. Abbruzzese. The GTC wishes to thank Brian Stack and ArcelorMittal Columbus for hosting a tour of its hot-dip galvanizing line facility.

The Galvanizing Technology Committee (GTC) met during AISTech 2012 on 7 May in Atlanta, Ga. Dan Cerrone of Siemens VAI opened the meeting and welcomed everyone, including the Brazilian students who were in attendance. Frank Goodwin of International Zinc Association explained the GTC-related sessions at MS&T’12, which will be held in Pittsburgh, Pa., on 7–11 October 2012. The GTC officers for 2012–2013 are Jason Schulz of ArcelorMittal Dofasco Inc., chair; Dan Lamprecht of CMI Industry, vice chair; and Goodwin and Joe McDermid of McMaster University, papers chairs. Stavros Fountoulakis of ArcelorMittal introduced himself as the new AIST Division V board of directors representative for the next two years. The next GTC meeting will be in Columbus, Ohio, on 5–6 September 2012 and will include a tour of the ArcelorMittal Columbus galvanizing line. The meeting will focus on annual shutdown maintenance on a galvanizing line.

The Galvanizing Technology Committee (GTC) met 27–28 March 2012 at ThyssenKrupp’s Erich Heine Training Center in Calvert, Ala., for their 2012 Spring Meeting and 6th Workshop. The attendance was diverse, with approximately 50 producers and 40 suppliers. The workshop topic was “Benchmarking Operating and Maintenance Practices.” After a brief welcome by Stavros Fountoulakis of ArcelorMittal, introductions and a review of the AIST Antitrust Guidelines, the meeting began with a Producer-Only subcommittee segment on safety. Jason Faragher of ArcelorMittal Dofasco Inc. presented, “World-Class Hazard Recognition and Hands-On Safety Training.” A representative from each mill was asked to discuss safety statistics and major incidents or accidents in his/her facility. Don Earley of ThyssenKrupp facilitated a roundtable  discussion on operating and maintenance of the coating section equipment, coating section-induced defects and countermeasures, in which a representative from each mill was asked to give an example of a success and an area in need of improvement in his/her mill. All of the attendees joined in after the first break for the AIST business portion of the meeting.
Dan Cerrone of Siemens VAI opened the general meeting by welcoming everyone and explaining the history of leadership of the GTC. The AIST Antitrust Guidelines were again reviewed and everyone agreed to abide by them. Earley explained the safety protocols of the building, and Cerrone presented a plaque to show the committee’s appreciation to Earley and ThyssenKrupp Steel USA for hosting the meeting and tour. Eric Almquist of Star Tool and Die volunteered to take the meeting minutes. Dr. Fountoulakis reviewed the minutes from the GTC’s 8 September 2011 meeting in Toledo, Ohio, which were approved as written. Frank Goodwin of the International Zinc Association reviewed the GTC sessions for AISTech 2012 in Atlanta. Dr. Goodwin announced the AIST Forum on Galvanized Sheet Technologies, which will take place 18–22 March 2013 in Detroit, Mich. This conference will be devoted to the current topics in galvanized sheet. The three-day event will open with a “customer day,” on which the focus will be the most recent developments in galvanized sheet product capabilities. The remainder of the conference will focus on recent advances in selected production and processing technologies. Dr. Goodwin reviewed the upcoming MS&T’12 conference, which will be held in Pittsburgh, Pa., on 7–10 October 2012. Six timely metallurgical papers specifically associated with HDGL and one paper related to electrogalvanizing will be presented. The galvanizing benchmarking effort was discussed, and the parameters have been defined.
The balance of the meeting followed a workshop format. A main topic was discussed through a number of presentations, followed immediately by town hall discussions that allowed the attendees to ask questions. The first topic was pot equipment, which was covered with two presentations. Parag Bedekar of Hitachi Metals of America presented, “Ceramic Bearings, Stabilizer and Sink Rolls,” and Mark Bright of Pyrotek presented, ”Snout Pump Technology, Maintenance and Operating Practices.” The next topic was coating wiping. Steffen Dombrowski of EMG presented, “Experience With Strip Stabilizing Systems”; Ned Kohler of Danieli Kohler presented, “Case Studies From Implementation of New Knife Design Improvements and Peripheral Components”; and Michel Dubois of CMI presented, “Review Coating Wiping Fundamental, a Key Process Limiting Line Productivity.” The next topic was entry equipment/strip production with a presentation by Brian Braho of SEMAC titled, “Entry Mechanical Equipment for Strip Preparation Into the Welder.” Chemical cleaning/brushing was the next topic. Bryan Gorr of Osborn International presented, “Advances in Brushes and Electro-Cleaning Systems,” and Frank Kestler of Mark One Corp. presented, “GreenCleen Technology.” Annealing furnaces was the final topic, which was covered with four presentations. Daniel Plaetzer of Band-Zink presented, “Hearth Roll Pickup-Resistant Coating for Processing AHSS”; Richard Gagg of AMETEK Land presented, “Challenges, Solutions in Temperature Measurement”; Thomas Larrick of Williamson presented, “Solutions for Challenging Temperature Measurement”; and Sudodh Chaudhari of West Virginia University – Industrial Assessment Center and Senthil Kumar of Hudson Technologies presented, “Coating Line Cost Minimization Model: Case Studies From CGL Energy Analyses.” Mr. Earley concluded the presentation portion of the workshop with, “TKS Alabama Facility and Coating Lines.” The GTC toured ThyssenKrupp’s four brand-new galvanizing lines and were given a separate tour of SMS Millcraft, featuring the Band-Zink coating process. The committee met at AISTech 2012, and its next meeting will be 5–6 September 2012 at a location yet to be determined.