Zinco UK have just completed the first ever non invasive kettle tests for leading wire manufacturer, Betafence who are based in Sheffield, England.

Betafence are one of the leading European wire manufacturers with other sites in France and Italy.

The wire galvanizing lines in Sheffield are 9.0m long x 1.5m deep and 2.0m wide and hold approximately 185 tonnes of zinc. Each kettle coats thirty separate wires on a continuous basis (generally operating 24/7), this equates to a steel production in excess of 4000T per month, per kettle.

The conventional method of measuring the steel kettles would have been to remove the zinc and a “cold” UT measurement being taken. This would have given a production downtime of approximately 10 to 14 days. 

Zinco’s specialised ultrasonic kettle inspection device (known as the KID) can be used at 450°C - the temperature of the molten zinc.  This probe is mounted on a special framework that sits on the top of the kettle, with or without fume enclosures while the furnace is in operation.

The KID framework that holds the probe in place can be manipulated through 4 axes in order to provide total flexibility to the customer.

Once contact is made the ultrasonic probe transducer produces a signal that is sent through the steel and returns to the probe. 

This signal is then collected and analysed by our specialist ultrasonic software and a record of the echo is taken.  From this signal the thickness of the kettle wall can be interpreted to an accuracy of +/- 1.0mm. 

Zinco’s Managing Director, David Watkins commented that, “We were pleased that Betafence understood the benefits of using our technology and the dramatic saving in time for them. The data we have provided allows our customer to make informed decisions regarding maintenance and future use of the kettle before changing.”

Mike Southworth, Process Engineer for Betafence also commented, “We are really pleased with the professional attitude and work that Zinco have undertaken for us. With the inspections undertaken in one day there has been no impact on production.” He added, “We certainly see Zinco UK becoming a strategic long term partner in terms of kettle corrosion measurement”.

Zinco UK were proud sponsors of the UK’s Galvanizers Association Galvanizing Awards.  These awards are an opportunity for the galvanizing community to celebrate the innovative and exceptional uses of galvanizing in a large variety of different situations, showing what a versatile process it is.  This year the categories were “Galvanizing in Architecture” which was won by  Kraus Schönberg Architects for an excellent integration between galvanized steel and brickwork in an extension to a Victorian warehouse in Bradford.

.  The next award was for “Galvanizing in Industry” and was won by RIM Fabrications.  The project was at Roseisle Distillery and is a modern interpretation of a traditional still house. 

The third award was for “Galvanizing in Detail” and was won by P. Johnson & Company for their work on the south porch gates at St Michaels Church in Linlithgow, Scotland.  The intricate designs on the gates were handcrafted using traditional blacksmithing techniques, with the work then being galvanized top provide protection.  To provide a final lustre the gates were painted with a graphite paint and then burnished to give texture and sheen

 The final award was the “Duplex Award”.  This award focuses on the use of galvanized steel in conjunction with any other organic material such as paint or powder coating and was won by Denis Byrne Architects for their work at Tolka Rovers AFC in Dublin. 

The awards were held at the Royal Aeronautical Society in London where galvanizers and award nominees came together to appreciate the different uses of galvanized steel in a large variety of projects.  Zinco UK have sponsored the awards for the past three years and each year the entrants push the bar higher with their uses of the material.  For more information please visit the Galvanizers Association web page to view the entrants in more detail.  

The Zinco Global Network had the honour of sponsoring part this year’s European Galvanizers Galvanizing Association assembly.  Held in the stunning city of Vienna it brought together galvanizers from across Europe to discuss various innovations in the galvanizing industry with numerous presentations on key topics that affect galvanizers. The Zinco Global Network also had a presence in the exhibition area where existing and  potential customers were introduced to the various services that we can offer and questions could be asked of our team.  The event also encompassed visits to impressive local galvanizing plants, and a gala dinner at the Vienna Museum of Fine Art.