Toe Crack Inspections Through Zinc. Can They Happen?

What are Toe Cracks?

When a technician discusses toe cracks, they are referring to imperfections that can occur after welding is complete.

Toe cracks are cracks that typically appear after welding in the “toe” of a pole shaft: the area where the pole shaft and the base plate or flange plate meet. These post-galvanizing cracks occur directly after the hot dip procedure.

The cracks can occur in two different locations: at the “toe” of the reinforcing weld on the shaft side, or at the “corners” of multi-sided formed shafts.

These are often a sign of residual stress on a particular joint of the pole.

What to Know About Toe Cracks

What are Toe Crack Inspections?

Ultimately, the best approach is to be proactive rather than reactive. Make sure that you and your technicians are using the best practices to prevent toe cracks before they arise.

That being said, even highly skilled technicians with great intentions may make mistakes at times. In this case, a reactive approach of inspecting for and managing toe cracks is necessary.

One of the best ways to inspect for toe cracks is through the commonly used nondestructive testing method known as ultrasonic testing or UT.

According to the NDT Resource Center, ultrasonic testing is a form of NDT that uses high frequency sound waves to inspect and measure particular assets. When this procedure is conducted, the receiver can detect interruptions in the wave signals being sent through the component and display that interruption, signifying the presence of a crack in the component.

Can this work through Zinc?

Many technicians believe that toe crack inspections cannot be performed through zinc, and there are some justifiable reasons for this.

During the essential hot-dip process of galvanizing, a layer of zinc or zinc alloy is deposited on the surface of the component. While this is a wonderful protective layer, it can also create problems.

Typically, toe cracks are only found on poles that have already been galvanized and welded together.

A common misconception is that, after this process, the layer of zinc would need to be removed to properly inspect for toe cracks.

In actuality, a toe crack inspection can absolutely be performed through zinc, it just requires the right kind of equipment and procedures coupled with specific expertise– expertise like the kind held by the professionals at Exo Inc.

When it comes to testing for toe cracks, thoroughly vetting your assets could be the difference between components with a full lifecycle and assets that become a heavy financial burden.

Don’t let toe cracks progress; trust the experienced professionals at Exo Inc. Exo Inc.’s programs such as Ex Tend lifecycle management help to ensure that your assets are protected from construction to replacement.

A company of integrity, Exo Inc. will work to ensure that you are receiving the highest quality services without breaking the bank. Our trusted technicians are happy to help you protect the long-term value of your assets and save you money holistically without sacrificing quality.

Call us today at (281) 259-7000 or contact us online for a free consultation to see how Exo Inc. can protect your assets.

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Our team would love to talk to you, so we can learn about your lighting company’s goals and primary areas of concern. Contact us today, and we’ll help you take the first step in creating a comprehensive lighting asset management program. Give us a call at 281-259-7000.
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