CGL Maintenance

Continuous Galvanizing Line Maintenance

The Bronx Continuous Galvanizing Line Maintenance Program is a service provided by our Customer Relations Department for Bronx International's galvanizing line customers. The focus and objective of the program is to assist our customers with an affordable program to maximise their galvanizing equipment with a view to achieve enhanced product quality and productivity.

Some benefits of the Bronx Continuous Galvanizing Line Maintenance Program include:

  • More efficient production with reduced costs
  • Reduced line downtime (maintenance can be programmed in and around scheduled line shutdowns)
  • Higher production yields
  • An opportunity to introduce a quality management system where previous operational practices have led to the premature failure of critical pot equipment
  • An opportunity to provide training to staff to increase operational knowledge and troubleshooting capabilities

Some features of the Bronx Continuous Galvanizing Line Maintenance Program:

  • Provision of a Bronx Technologist to carry out an EXTENSIVE LINE AUDIT one month prior to the Pot Change to identify and plan for programmed maintenance
  • Provision of a Thermal Engineer to undertake and supervise a 42 point maintenance schedule and Galvanizing Pot Service that also includes the supervision of the remelt and recommissioning of the pot
  • Option for the return of the Bronx Technologist to ensure the line returns to full operating specifications. Improvement practices are put in place and commissioning of a Product Operational Quality System

The Bronx Continuous Galvanizing Line Maintenance Program  offers a regular service that coincides with natural and regular opportunities that occur in the life of a galvanizing line.  For instance, galvanizing pot changes are a regular occurrence and coincide with periods where planned maintenance has been allocated and access to the furnace and personnel is ensured.

What does the Line audit Include?

One month prior to the Pot change, a Bronx Technologist will visit the plant and carry out an extensive Line Audit. The full physical line audit is undertaken with your choice of company personnel, identifying current problems, product quality and line performance.

The Line Audit includes at least the following:

  • Coil cars
  • Stitchers / Welder
  • Entry tower tracking and tension control
  • Alkali tanks, rinse tanks
  • Brush scrubbber, acid etch, preheater
  • Pot, including temperature control, flux, metal additions, blowers & after pot cooling & temperature profile
  • Quench and passivation tank and passivation dryer
  • Exit accumulator
  • Edge guide and stagger wind
  • Belt wrapper and recoiler operation and condition
  • Squeegee rolls

  • Testing and start up / shut down procedures

What does the Galvanizing Pot Service Include?

The Galvanizing Pot Service includes at least the following:

  • Inspect and repair refractories
  • Check burner blocks
  • Check flue path, damper
  • Check thermocouples
  • Supervise re-installation of new pot
  • Check bearings on recirculation fans and combustion blower and apply new grease
  • Check belts on recirculation fans, drive and fan side motor current and repair and record
  • Check operation of UV cells and cells and lenses and replace if required, and check that the cooling air is operational
  • Clean and adjust pilot burners
  • Check and record opso regulator
  • Record air pressure at sense line of ratio regulator
  • Clean or replace main gas filter element
  • Check flame length at high fire for fan impingement
  • Install thermocouples for stress relieving operation
  • Stress relieve pot and record
  • Check and repair gas train leakages
  • Check percentage of oxygen in the flue gas which is measured at fan discharge
  • Record gas pressure at outlet of ratio regulator and double block solenoid valve
  • Measure and record distance from limiting orifice screw to surface
  • Check modulation control valve linkages
  • Adjust flue dampers to balance the system
  • Record recirculation fan current at fan discharge temperature and fan bearing temperatures
  • Check operation of recirculation speed switches, combustion blower pressure switch and purge timer setting
  • Check operation of zinc temperature controller
  • Check operation of drive and operator side recirculation air temperature controller
  • Supervise loading lead
  • Check operation of zinc and lead metal thermocouple
  • Carry out additional training
  • Check spares and make a list of existing and required spares

 For more detailed information together with costings, please contact our Customer Relations Manager at This e-mail address is being protected from spambots. You need JavaScript enabled to view it This e-mail address is being protected from spambots. You need JavaScript enabled to view it