IDOD SYSTEMS
Creators of GAL-5 and GAL-7 Sprinkler Pipe
IDOD Systems, LLC PO BOX 1635 Homewood,
Illinois 60430
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IDOD Process Potential
The Goals:
Fully Galvanized Inside and Outside Pipe produced in-line on the
Pipe Mill.
DONE!!
The
results Thin or heavy wall galvanized Pipe, Cut to length galvanized pipe,
Superior Adhesion galvanized pipe, Consistent coating thickness galvanized
pipe, Variable coating thickness galvanized pipe.
DONE!!
Develop Alternative Metallic
Alloy Coatings for Pipe or tube in addition to zinc galvanized
DONE!!
The results
Zinc-Aluminium, Zinc-Aluminium-Magnesium, More to come!!
DONE!!
History of In-Line Coating
Superiority
One at a time Production vs.
Continuous Production
In the Mid 1800s, Hot dip galvanizing is Invented All Steel pieces are independently dipped one at a time
In the early 1931, Thadeous Sendzimir Installed the first Continuous In-Line galvanized Strip coating line in Poland.
Individual pieces of steel strip are no longer hot dipped
one at a time.
In the 1850s, Electroplating with zinc was adapted - All OD Zinc coated Steel pieces are independently dipped one at a time.
In 1960, Theodore Krengel installed the first Continuous In-Line OD tube Galvanizing line in Blue Island, IL.
Individual pieces of
steel light wall conduit are rarely electroplated one at a time.
In 1999, Theodore Krengel installed the first Continuous In-Line fully galvanized inside and out tube and pipe line in Grant Park, IL.
It is the belief of IDOD Systems and others that eventually,
the hot dipping of pipe - independently dipped one at a time will be
replaced.
In the early 1970s, additional exotic zinc alloys are being developed in the strip coating industry. Galvalume, ZAM, Galfan, SuperDyma Primary combinations of zinc Aluminium Magnesium with 20 to 30 times the salt spray protection than zinc only. Strip coated products in the building and structural industries are replacing zinc only coatings to take advantage of the superior properties. The IDOD Process has produced alternative alloy coatings for steel pipe.
Quality
IDOD In-Line Process Pipe Standard Hot Dip Pipe
With Roll Groove with Roll Groove
Microstructure IDOD Process Microstructure Standard Hot Dip Process
The Standard hot dip pipe process chips and flakes when fabricated. The alloy layer is thick and brittle, when flexed to a certain point, it will fail. The IDOD process like the strip coating process has a small amount of Aluminium that retards the alloy layer buildup and leaves a thin Ternary Alloy layer that is flexible. Consider all of the products using galvanized continuous strip coated products that goes through sever fabrication Automotive, Appliances, HVAC, etc. None have chipping or flaking issues.
The Standard hot dip pipe process has inconsistent coating thickness. Consider the type of coating controls you can have by dipping a long piece of pipe into a bath of molten zinc and then removing it at an angle. From top to both both radially and tangentially the liquid zinc wants to run down. In the best cases, with Super-Heated steam, the coating thickness can at least look relatively consistent (it isnt). In the worst cases, the zinc has drips freezing in place. Internal flux burns and pieces of dross are left inside the pipe. The IDOD process is continuous so the coating is consistent top to bottom length to length. Not only can thick coatings be applied (A53 1.8 Ounces per Square foot per side / 560 Grams per Meter per side), but thinner coatings as well.
The Standard hot dip process is limited
on wall thickness. If the wall
thickness is to light, the pipe will bow or warp from the heat and the weight
of the zinc. In the United States, the
lightest wall pipe sold as a commodity is schedule 10, some schedule 7s can be
dipped on a case to case basis, but generally is not done. The IDOD process
has FM Approval to fully galvanize a schedule 7 pipe, but schedule 5 as
well. Thinner wall steel can also be
coated if needed.
The Standard hot dip process, as a
secondary process, has length limitations.
The length of the pot will dictate the maximum length allowed, and the
shorter the pipe; the less efficient the process is because it is a piece count
process. It takes about as long to dip
a 10 foot pipe as it does a 20 foot pipe.
If you can dip 600 pieces in an hour, that would be an equivalent 200
feet per minute using 20 footers. Using
10 footers, that would equate to 100 feet per minute. The IDOD process limitations are tied to
the tube mill limitations. The speed,
length, and number of cuts allowed by the cutoff, the speed of the tube mill
itself, etc. Using the previous
example, if the mill runs at 200 feet per minute, you would still get the 600
pieces per hour. At 10 foot lengths, assuming
the mill, cutoff and material handling are not affected, the number of pieces
per hour doubles to 1200 pieces.
Standard hot dip pipe is a second step
process, is limited on length and wall thickness, is inconsistent on coating
thickness, and has terrible fabricating properties causing the zinc to chip or
flake. The
IDOD process is a continuous in-line process, has no process limitations
relative to length and wall thickness, has superior coating thickness controls
far exceeding the range of hot dipped products, and has unparalleled coating
adhesion.
Available Coating Options
For the past 150+ years, the only optional steel pipe with complete metallic coating available has been zinc.
In the early 1970s, companies like Bethlehem Steel, Inland Steel,
etc. started to develop alternative coatings for the continuous in-line strip
coating industry. Products like Galvalume (BIEC International) 55% Aluminium
/ 45% Zinc, Galfan (Galfan
Technology Center Inc.) 95% Zinc / 5% Aluminium, ZAM (Nisshin Steel)
Primarily zinc w/ Aluminium and Magnesium Alloys, SuperDyma (Nippon Steel) -
Primarily zinc w/ Aluminium and Magnesium Alloys, have been adding to the
competitive superior coating technologies.
These coatings have superior salt spray protection 20 to 30+ times the
life. They are harder to protect
against erosion. They have better
protection even when scratched. The
same product markets that zinc only coated products had held for years are
being replaced by these superior coating alloys. Automotive, Appliances, HVAC, Building Construction, etc. Are all
replacing the zinc only coated products.
In
the tube and pipe industry there is
..
Zinc.
The IDOD Process is the marriage of the strip coating industry technology with tube and pipe making technologies. Whatever superior metallic coatings can be coated on a continuous strip coating line can be coated on an IDOD line.
The IDOD Process has taken 2 leaps of technology that the strip industry has taken almost 80 years to make. In-line continuous and variable coating alloys. The future of steel metallic coated tube and pipe has never been better.
For more information, contact us at: IDOD Systems, LLC, P.O. Box 1635, Homewood, IL; 60430
Phone 708-647-0330 / Fax 708-647-0330
E-Mail c.brown@idodsystems.com