Corrosion costs the United States $297 billion annually, but utilizing adequate corrosion protection systems can drastically reduce these costs. Galvanized steel provides effective corrosion protection through a process of dipping steel parts in a molten zinc bath to form a zinc coating. The manufacturing process for galvanized steel towers involves planning, acquiring raw steel materials, fabrication through cutting and bending, hot dip galvanization by passing the steel through molten zinc, and quality testing to check coating thickness and uniformity.

1. Introduction of Galvanized Steel
Corrosion and repair of corrosion damage are
multi-billion dollar problems. Estimates show
metallic corrosion costs the United States
approximately $297 billion annually, or about 3% of
the national GDP. Although corrosion is a natural
phenomenon, and can never be completely
eliminated, utilizing adequate corrosion protection
systems in harsh environments can drastically
reduce the costs.

2. Manufacturing Process
• Planning and Design
• Raw Material
• Fabrication
• Hot Dip Galvanization
• Quality and Testing
• Bundling and Loading

3. Planning and Design
Planning of project was started when basic task of the
project was received. For setting up about the main idea
of project, several meetings were arranged among the
team members.
The Company has in-house design centres with a
strong team of over 100 design experts in India and
Americas who continuously develop innovative,
construction friendly and cost- effective designs. It is
equipped with the latest software like PLS Tower, PLS
Pole, PLS CADD, AUTOCAD, MICROSTATION, BOCAD and
Google Earth.

4. Raw Material
The raw material used for manufacturing of
self-supported power transmission towers are steel
angle bars. It can be in different sizes and different
profile types i.e. L,
V, T-shape and flat
angle bars iron net
and other sheet
metal.

5. Fabrication
The raw material is issued from the storage the next
and first operation of manufacturing are
straightening and cutting of angle bars that are
done with the presses. Before cutting the angle
bars it needed to measure and have to do some
marking according to required sizes. There are
three presses in the factory which are used to cut
different angle bars in different shapes and sizes
and then material is sent to machine shop.

6. Flow Chart of Fabrication Process
Marking &
Measurement
Straightening
Cutting Punching
Bending
Stamping Notching
• Marking and Measurement
• Straightening
• Cutting
• Punching
• Bending
• Stamping
• Notching
Raw Material
To galvanization
process

7. CNC Punching Machine Hot Treatment
Bending and Notching Machine Cutting Machine

8. Galvanization Process
The process of applying a protective zinc coating on
iron or steel by passing the metal through a molten
bath of zinc to prevent it from rusting. The steel is
dipped into the molten zinc bath and held there until
the temperature of the steel equilibrates with that of
the bath.
Temperature of molten bath is around 860°F(460°C).
Zn+O₂=ZnO
ZnO+CO₂=ZnCO₃

9. Hot Dip Galvanization Process
• Degreasing- The product is dipped into hot alkali
solution to remove contaminants such as dirt,
grease, paint markings and oil.
• Rinsing- Alkali is removed by washing lightly with
water.
• Pickling- The product is dipped into a dilute solution
of HCL to remove rust.
• Rinsing- HCL is removed by washing with water.
• Fluxing- Zinc ammonium chloride is applied to
remove oxides and further formation of oxides on
the surface of steel and promotes bonding of zinc to
steel.

10. • Zink Bath-In this tank steel frames are diping in
the hot melt Zink tank around 3-4 minutes
according to the frame thickness.
• Rising Tank- This tank consist water. The material
is dipped into it for cooking, cleaning after Zn
coating.

11. Rising Tank
Zink Bathing

12. Quality & Testing
The inspection of hot-dip
galvanized steel is simple
and fast. The two
properties of the coating
closely scrutinized are
coating appearance and
coating thickness. A variety
of simple physical and
laboratory tests may be
performed to determine
thickness, uniformity,
adherence, and
appearance.

13. Tower Erection
The last operation after
manufacturing is erection of
simply supported towers.
When the towers are
transported to site, the
foundation of tower is ready
before the tower structure is
unloaded. The foundation of
the part is constructed by
company's civil engineers who
make the foundation ready
two weeks before the erection
of tower.

14. Thank You