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The galvanizing process explained?

 

I am currently writing a play that involves the discussion of the galvanizing process for nails.

How many people are going to want to watch a play about nails, you ask? Well, for a short time in the late 70's I worked as a galvanizer at the Independent Nail Corporation in Bridgewater, MA. I am using the process as a second story line in my play and I am interested in getting information about the actual step by step process of the procedure.

While I remember having to slowly(!) dip the nails into a big cauldron of bubbling zinc and then wash them off after they came out, I am unsure of the process before they arrived at my station. I DO remember that they had a terrible acid-like smell. Any help that you could give me in this search would be greatly appreciated. Thank you for your time.

Sincerely,
Jack

Jack G [last name deleted for privacy by Editor]
- Sacramento, California

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Hi, Jack. The nails would be cleaned in a caustic cleaner, pickled in hydrochloric acid (which is the acid-like smell you speak of), dipped in a flux sort of like what is used for soldering, and then go to your work station for dipping in the molten zinc. After that, on to rinsing, probably with a dilute chromic acid.

Break a leg, and let us know when it gets to Broadway!

Regards,

Ted Mooney, P.E.
Striving to live Aloha
finishing.com - Pine Beach, New Jersey
June 2, 2009