Hot Dip Galvanizing 101

Hot Dip Galvanizing Design Considerations

Protection against corrosion begins on the drawing board. No matter what corrosion
protection system is used, it must be factored into the design of the product.
Once the decision has been made to use hot dip galvanizing to provide corrosion
protection for the steel, the design engineer should ensure that the pieces can be
suitably fabricated for high quality galvanizing.
Certain rules must be followed to design components for galvanizing. These rules are
readily applied and, in most cases, are simply those which good practice would dictate
to ensure maximum corrosion protection. Adopting the following design practices will
ensure the safety of galvanizing personnel, reduces your coating cost, and produce
optimum quality galvanizing
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Liason Between Design Engineer, Fabricator, and Galvanizer

The most important rule is that the designer, fabricator, and galvanizer should work
together before the product is manufactured. This three-way communication can
eliminate most galvanizing problems.The designer can better appreciate hot dip
galvanizing design requirements if the basic steps of the galvanizing process are
understood. Though the process may vary from galvanizer to galvanizer, the
fundamental steps in the galvanizing problems are:
1. Soil and grease removal: A hot alkaline cleaner is usually used to remove oil, grease, shop oil, and
soluble paints. This will not, however, remove such things as epoxies, vinyls, asphalt, or welding slag.
These soils must be removed by grit blasting, or other mechanical cleaning which is normally not the
responsibility of the galvanizer.
2. Pickling: An acid bath is used to remove surface rust and mill scale to provide a chemically clean
metallic surface. Many galvanizers prefer the use of hydrochloric acid since it is more environmentally
friendly and will not effect the surface of the steel which may be possible with the use of sulfuric acid.
3. Prefluxing: A steel article is immersed in a liquid flux predip (usually zinc ammonium chloride
solution) to remove oxides and to prevent oxidation prior to dipping into molten zinc. By utilizing the dry
kettle process, a galvanizer can eliminate the potential of flux inclusion or entrapment on the galvanized
steel product. The wet kettle process, where the steel goes through a flux blanket on top of the
galvanizing bath, can result in these particles adhering to the steel surface.
4. Galvanizing: The article is immersed to molten zinc at approximately 850F (455C). This results in a
formation of a zinc and zinc-iron alloy coating which is metallurgically bonded to the steel.
5. Finishing: After the article is withdrawn from the galvanizing bath, excess zinc is removed by
draining, by vibrating, or, for small items, by centrifuging. The galvanized item is then cooled in air or
quenched in water. The air quenching process, which takes a bit longer than the water quenching
method, will result in a better surface finish which is an important consideration in architecturally
exposed steel.
6. Inspection: Thickness and surface condition inspections are the final steps in the galvanizing process.
Information on inspection procedures and quality control criteria is available.
Iron and steel articles hot dip galvanized after fabrication may range in size from
small pieces of hardware such as bolts and washers to large welded steel assemblies or
castings weighing several tons. The ability to galvanize these articles can be improved
by following the design practices recommended in this manual and by consulting with
the galvanizer during the design stage of a project.
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Materials Suitable for Hot Dip Galvanizing

Most ferrous materials are suitable for hot dip galvanizing. Cast iron, malleable iron,
cast steels, hot rolled steels and cold rolled steels all can be protected by hot dip
galvanizing. Structural steel shapes, including those of high strength low alloy
materials, are hot dip galvanized after fabrication to obtain the long lasting protection
afforded by the zinc coating.
Though most ferrous materials can be hot dip galvanized, the characteristics of the
galvanized coating will be primarily a function of the chemical composition of the
material.
The galvanized coating has as its basis a reaction between steel and molten zinc
resulting in the formation of a series of zinc-iron alloy layers, which are normally
covered by a layer of solidified zinc. For most hot rolled steels the zinc-iron alloy
portion of the coating will represent 50 to 70 percent of the total coating thickness.
Steel compositions vary depending upon strength and service requirements. Major
elements in the steel, such as carbon silicon, affect the necessary galvanizing
techniques as well as the structure and appearance of the galvanized coating. For
example, certain elements, when present in the steel, may result in coating that is
all, or nearly all, zinc-iron alloy.
While a description of the mechanism that causes this type of coating is beyond the
scope of this manual, a description of the characteristics of an all or nearly all zinc-
iron alloy coating is listed below:
Visual - Visually, the zinc-iron alloy coating may have a matte gray appearance due to
the absence of the free zinc layer. It is the free zinc layer which imparts the typical
bright finish to a galvanized coating.
Adherence - The coating which is all or nearly all zinc-iron alloy may have a lower
adherence when compared to the typical galvanized coating. This type of coating
tends to be thicker than the typical galvanized coating. As the thickness of this type
increases, a reduction of adherence may be experienced.
Corrosion Resistance - In general, galvanized coatings are specified more for their
corrosion resistance than for their appearance. Thus, designers primary interest is the
relative corrosion resistance of the two coating types. Fabricators and consumers
should be aware that while a gray or matte appearance may occur, this matte
appearance does not reduce the long term atmospheric corrosion protection of the
steel. For all practical purposes the corrosion resistance, mil for mil, of these coatings
is equal.
It is difficult to provide precise guidance to the designer in the area of steel erection
without qualifying all of the grades of steel commercially available. The guidelines
discussed below, however, will usually result in the selection of steels having good
galvanizing characteristics:
Plain carbon structural grade steel will, under most circumstances, galvanize with the production of a
typical coating. However, it is known that levels of carbon less than 0.25%, phosphorous less than 0.05%
or manganese less than 1.35% are beneficial.
Silicon at levels less than 0.04% or between 0.15% and 0.25% is desirable.
Silicon may be present in many steels commonly galvanized even though it is not a
part of the controlled composition of the steels. This occurs primarily because silicon
is used in the de-oxidation process for the steel and is commonly found in continuous
cast steels. Steels containing the higher silicon levels may be exhibit bright, shiny
areas adjacent to gray matte areas, due to the silicon distribution. A recognized
method to combat the effects of high silicon steel is to add a trace amount of nickel,
usually between .05 - .09% to the zinc bath.
The galvanizer should always be advised of the grade of steel selected in order that he
might determine whether or not special galvanizing techniques will be required.
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Combining Different Materials and/or Surfaces

Optimum galvanizing quality is seldom obtained when different surface conditions,
different fabricating methods, or ferrous metals with different chemistries are
combined.
This is because different parameters for pickling (solution concentrations,
temperatures, immersion time) are required for:
excessive rusted surfaces
pitted surfaces
machined surfaces
cast iron (especially with sand inclusions)
cast steel
malleable iron
hot rolled steel
cold rolled steel
steels containing more than normal carbon, phosphorous, manganese and silicon.
The use of old and new steel or castings and rolled steel in the same assembly should be avoided,
when possible. Where assemblies of cast iron, cast steel, malleable iron and rolled steel are unavoidable,
the entire assembly should be thoroughly shot or sand blasted prior to pickling in order to produce a
galvanized coating of acceptable quality.
Excessively rusted, pitted or forged steels should not be used in combination with new
or machined surfaces because difference in required pickling time can cause over
pickling of the machined surfaces. Where this combination is unavoidable, through
abrasive blast cleaning of the assembly (normally before any machining is done) will
remove rolled-in mill scale, impurities, and non-metallics prior to pickling. Products
containing different ferrous materials will then pickle in a more uniform matter,
providing an optimum galvanized coating.
Omission on blast cleaning of mixed material assemblies will result in combined under-
and over-pickling of the different surfaces. This omission may adversely affect the
quality of the galvanized coating.
Whenever possible, the materials described should be galvanized separately and
assembled after galvanizing. Whenever steels of different chemical composition or
different surface finishes of steel are joined in an assembly, the galvanized finish is
generally not uniform in appearance. The corrosion protection provided by the
galvanized coating, however, is not affected by variations in color and texture of
coating.
When abrasive blast cleaning is used to prepare a surface for galvanizing, a coating
thicker than the normal galvanized coating will be produced. Abrasive cleaning rough-
ens the surface and increases its surface area. The result is an increased reactivity
with the molten zinc. Greater zinc-iron alloy growth occurs during galvanizing of a
blast-cleaned steel, producing thicker coating at the expense of a moderately rougher
surface. These thicker coatings will sometimes have a dark gray appearance because
the alloy layers may extend to the outer surface.
Combinations of steels of different compositions may result in different compositions
may result in different coating thicknesses and surface appearances. This is not
necessarily detrimental to certain applications, but the designer and fabricator must
consider this an, in the planning stage, should consult with a galvanizer.
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Welding Procedures and Flux Removal

When welded items are galvanized, both the cleanliness of the weld area after
welding and the metallic composition of the weld itself affect galvanizing quality and
appearance at the weld.
The specifics of welding techniques can best be obtained from the American Welding
Society or your welding equipment supplier, but several welding processes and
techniques have been found to be most satisfactory for items to be galvanized. These
are:
1. 1. In welding, an uncoated electrode should be used wherever possible to prevent flux deposits.
2. If a coated electrode is used, all welding flux residues must be removed by wire brushing, flame
cleaning, chipping, grinding, pneumatic needle gun, or abrasive blast cleaning. Welding flux residues are
chemically inert in the normal pickling solutions used by galvanizers; their existence will produce rough
and incomplete zinc coverage. Flux residue removal is normally the fabricators responsibility unless other
arrangements have been made.
3. A welding process such as metal-inert gas (MIG), tungsten-inert gas (TIG) or C02 shielded arc is
recommended when possible since they produce essentially no slag.
4. In the case of heavy weldments, a submerged arc method is recommended.
5. If none of these are available, select a coated rod specifically designed for selfslagging, as
recommended by welding equipment suppliers.
6. Choose a welding rod providing a deposited weld composition as close as possible to the parent
metal. This will help prevent differential acid attack between the weld area and the parent metal during
acid cleaning.
7. Welding rods high in silicon may cause excessively thick and/or darkened coatings to form in the
welded area.
Materials which have been galvanized may be welded easily and satisfactorily by all
common welding techniques. Additional information can be found in Welding Zinc-
Coated Steel.*
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Mechanical Properties of Galvanized Steels

The hot dip galvanizing process produces no significant changes in the mechanical
properties of the structural steel commonly galvanized throughout the world.
The mechanical properties of 19 structural steels from major industrial countries of
the world were analyzed before and after galvanizing in a major 4-year research
project of the BNF Metals Technology Center, UK, under the sponsorship of
International Lead Zinc Research Organization. Included were steels to ASTM Standard
Specifications A36 and A572 Grade 60 and Canadian Standards Association (CSA)
Specifications G40.8 and G40.12.
The BNF report, Galvanizing of Structural Steels and Their Weldments (ILZRO, 1975),
concludes that the galvanizing process has no effect on the tensile, bend or impact
properties of any of the structural steels investigated when these are galvanized in the
as manufactured condition.
Many structures and parts are fabricated using cold rolled steel or cold working
techniques. In some instances, severe cold working may cause the steel to become
strain-age embrittled. While cold working increases the incidence of strain-age
embrittlement, the embrittlement may not be evident until after the work has been
galvanized. This occurs because aging is relatively slow at ambient temperatures but is
more rapid at the elevated temperature of the galvanizing bath.
Any forms of cold working reduces the ductility of steel. Operations such as punching
holes, notching, producing filets of small radii, shearing and sharp bending may lead
to strain-age embrittlement of susceptible steels.
Cold worked steels less than 1/8 inch (3.18 mm) thick which are subsequently
galvanized are unlikely to experience strain-age ebrittlement.
Since cold working is the strongest factor contributing to the embrittlement of
galvanized steel, the following precautions are recommended to reduce the incidence
of strain-age embrittlement when cold working is necessary:
a. Select steel with a carbon content below 0.25%.
b. Choose steel with low transition temperatures since cold work raises the ductile-brittle transition
temperatures and galvanizing (heating) may raise it even further.
c. Susceptibly to stain-age embrittlement is usually less of a potential problem with aluminum-killed
steels.
d. For steels having a carbon content between 0.1%-0.25%, a bending radius at least three times the
section thickness (3t) should be maintained. If less that 3t bending is unavoidable, the material should be
stress relieved at 1100F (595C) for one hour per inch (25.4mm) of section thickness.
e. Notches should be avoided since they are stress raisers. Notches may be caused during shearing or
punching operations. Flame cutting or sawing is preferred, particularly for heavy sections.
f. Drill, rather than punch, holes in material thicker than 3/4 inch (19.05 mm). If holes are punched,
they should be punched undersize then reamed an additional 1/8 inch (3.18 mm) overall or drilled to size.
Shapes between 1/4 and 3/4 inch thick are not seriously affected by cold punching if the punching is done
under good shop practice.
Small shapes up to 1/4 inch (6.5 mm) in thickness which have been cold worked by punching do not need
stress relieving operations before galvanizing.
g. Edges of steel sections greater than 5/8 inch (15.88 mm) thick subject to tensile loads should be
machined or machine cut. Edges of section up to 5/8 inch (15.88 mm) thick may be cut by shearing.
h. In critical applications, the steel should be hot worked above 1200F (650C) in accordance with the
steel makers recommendations. Where cold working cannot be avoided, stress relieve as recommended
in item d above.
ASTM Recommended Practice Al 43, Safeguarding Against Embrittlement of Hot-Dip
Galvanized Structural Steel Products and Procedure for Detecting Embrittlement and
CSA Specification Gi 64, Galvanizing of Irregularly Shaped Articles, provide guidance
on cold working of susceptible steel is better avoided, if at all possible.
If there is concern with possible loss of ductility due to strain-age embrittlement, the
galvanizer should be alerted. A sample quantity of the cold-formed items should be
galvanized and tested before further commitment.
Hydrogen Embrittlement
Hydrogen embrittlement is a ductile-to-brittle change which occurs in certain high
strength steels. Hydrogen released during the pickling operation can cause this
embrittlement. This hydrogen can be absorbed into a steel during the acid pickling but
at galvanizing temperatures it is generally expelled from the steel.
Hydrogen embrittlement is not common, but precautions should be taken, particularly
if the steel involved has an ultimate tensile strength exceeding approximately 150,000
psi. If high strength steels are to be processed, grit blasting instead of acid pickling is
recommended to minimize the likelihood of hydrogen embrittlement.
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Size and Shape

With the increase in the size and capacities of galvanizing installations, facilities now
exist for galvanizing components covering a significant range of sizes and shapes.
Duncans galvanizing kettle measures 42 feet long by 7 feet deep by 5 feet 2 inches
wide. Almost any component can be galvanized by designing and fabricating in
modules suitable for available galvanizing facilities. However, it is wise to check
kettle size restrictions with your galvanizer at an early stage.
Large structures are galvanized by designing in modules or sub-units. These are then
assembled by shop welding or site bolting after galvanizing. Modular design techniques
often produce economies in manufacture and assembly because they simplify handling
and transport.
When an item is too large for total immersion in the molten zinc of the largest
galvanizing kettle available, but more than half of the item will fit into the kettle, one
end may be immersed and withdrawn, and then the other end may be galvanized. This
is referred to as the double dip process. ALWAYS CONSULT YOUR GALVANIZER BEFORE
PLANNING TO USE DOUBLE DIP GALVANIZING.
Large cylindrical objects may be galvanized by progressive dipping. This procedure can
be used when the width of the article exceeds that of the kettle. The item is
galvanized by using a series of dips or by rolling the article in the molten zinc of the
kettle.
The designer should consider the material handling techniques used in galvanizing
plants. The use of hoists and cranes is commonplace. Large assemblies are usually
supported by chain slings or by lifting fixtures, if provided. Special jigs and racks are
often used to galvanize large numbers of similar items simultaneously.
If aesthetics are important provide lifting fixtures for the galvanizer. Since all material
is immersed into the galvanizing kettle from overhead, chains, wire or other holding
devices will be used to support the material, unless special lifting fixtures are
provided. Chains and wire normally leave a mark on the galvanized article. This mark
is not necessarily detrimental to the coating but could affect the desired aesthetics.
Large pipe sections, open top tanks and similar structures may require the addition of
cross stays to maintain their shape during handling.
Although size normally brings large items to mind, the smaller items should also
receive attention. The galvanizing process can treat small items by racking. Pieces less
than about 15 inches (38.1cm) in length are frequently galvanized in perforated
baskets. The basket is then centrifuged to throw off excess zinc from the pieces and
provide smoother coatings. Fasteners, small brackets and clips typify work handled in
baskets.
The heavy weight of fabrications can be a factor in galvanizing-largely because of the
handling required to move items step to step. Thus, weight-handling capacity of your
galvanizer should be determined, if it appears this might be a factor in your design
considerations.
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Allowing for Proper Drainage

For effective galvanizing, cleaning solutions and molten zinc must flow into, over,
through and out of the fabricated article without undue resistance.
Failure to provide for this free, unimpeded flow is a frequent cause of problems for
both galvanizer and customer. Improper design for drainage results in galvanizing of
poor appearance and in excess buildups of zinc which are unnecessary and costly.
To ensure unimpeded flow of solutions, all stiffeners, gussets and bracing should be
cropped a minimum of 3/4 inch (19.05 mm).
Provide holes at least 1/2 inch (13 mm) in diameter in end plates on rolled steel
shapes, to allow access of molten zinc in the galvanizing bath and drainage during
withdrawal. Alternatively, holes at least 1/2 inch (13 mm) in diameter can be located
in the web within 1/4 inch (6 mm) of the end plate.
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Enclosed and Semi-enclosed Products

Tanks and enclosed vessels, should be designed to allow for acid cleaning solutions,
fluxes and molten zinc to enter and flow upwards through the enclosed space and out
through an opening at the highest point. This prevents air from being trapped as the
article is immersed. The design must also provide for complete drainage of both
interior and exterior details during withdrawal.
When both internal and external surfaces are to be galvanized, at least one filling and
draining hole and a vent hole must be provided. The filling hole should be as large as
the design will allow but at least 3 inches in diameter for each cubic yard (or 10 cm in
diameter for each 1.0 cubic meter) of volume with a minimum diameter of 2 inches
(50 mm). A vent hole of at least the same size should be provided diagonally opposite
the filling hole. This allows the air to escape and facilitates draining.
In tanks, internal baffles should be cropped on the bottom or provided with suitable
drainage holes to permit the free flow of molten zinc. Manholes, handholes, bosses
and openings should be finished flush inside to prevent trapping excess zinc.
Openings must be placed so that the flux on the vessel can float to the surface of the
bath. They will also prevent air pocket formations which would keep the acid bath
from completely cleaning the inside of the vessel.
The diameter of the opening should be at least 1 inch per foot (83.3 mm per meter) of
tank diameter. Minimum allowable diameter opening is 2 inches (50 mm). Tanks over
48 inches (1.22 meters) in diameter should have a manhole in one end and should have
all six holes.
Items such as vessels and air receivers which are to be galvanized on the outside only
must have snorkel tubes or extended vent pipes. These openings provide an air exit
from the vessel above the level of molten zinc in the galvanizing kettle. The
galvanizer should be consulted before using these temporary fittings.
It is always wise to have the galvanizer review the drawings of enclosed or partially-
enclosed vessels before they are fabricated. He can advise you of any changes that
would provide you a better product. If a change is needed to facilitate galvanizing, the
least expensive time to make the change is before fabrication.
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Tubular and Hollow Items

Tubular assemblies such as handrail, pipe columns, pipe girders, street light poles,
transmission poles, pipe trusses, and sign bridges are commonly galvanized.
Cleaning.
As with all steel to be galvanized, pipe and other hollow materials must be thoroughly
cleaned before the molten zinc will alloy with the steel to produce the galvanized
coating. Pipe commonly presents two special cleaning problems:
1. The mill coating (varnish, lacquer, and similar materials) applied by the manufacturer costs extra
to remove at the galvanizing plant. Further, some formulations, both foreign and domestic, are extremely
difficult to remove with common cleaning solutions; blasting may be required. Removing this mill coat at
the galvanizing plant can be avoided by ordering uncoated pipe from your supplier, for which there is
usually no extra charge.
2. Welding of mill-coated pipe burns and carbonizes the varnish in the surrounding heated areas. This
soot must be removed by blasting or other mechanical means. The burned coating could be removed
when blasting to remove weld flux, but if welding has been done with an uncoated rod, any blasting or
other hand cleaning is expensive and highly impractical.
Venting.
It is mandatory that tubular fabrications and hollow structurals be properly vented.
Any pickling acid or rinse waters that might be trapped in a blind or closed joint
connection will be converted to superheated steam and can develop a pressure of up
to 3800 psi when immersed in molten zinc at 850~F (455~C). This is a serious potential
hazard to galvanizing equipment and to personnel.
Since proper galvanizing demands that the inside, as well as the outside, be
completely cleaned and coated with zinc, air and frothy fluxes must be allowed to
flow upward and completely out; cleaning solutions and molten zinc must be allowed
to flow in and completely wet the surfaces.
Simply stated, the structure must be lowered into the solution without trapping any
air. It must be raised from the solution without trapping any solution. Consequently,
ample passageways which allow flow in and out must be designed into the assemblies.
Since items, to be galvanized are immersed and withdrawn at an angle, the vent holes
should be located at the highest point and drainage holes at the lowest point each
member.
All sections of fabricated pipework should be interconnected with full open tee or
with miter joints. Each enclosed section must be provided with a vent hole at each
end.
Most galvanizers prefer to visually identify the venting from outside when the
assembly is received. This is necessary to check the adequacy of the venting as well as
to determine that it has not been omitted by mistake. Some galvanizers may hesitate
to process complicated pipe assemblies (such as hand railing) unless all venting is
visible on the outside and readily accessible for inspection.
Base plates and end plates must be designed to facilitate venting and draining. Fully
cutting the plate provides minimum obstruction to a full, free flow into and out of the
pipe. Since this is not always possible, the use of vent holes in the plate often provides
a solution.
Vent holes can be closed with drive caps or plugs installed after galvanizing. To do
this, pear shaped-shaped lead weights are often used. These can easily be hammered
in and filed off flush with surrounding surfaces.
It is recommended that tubular structures be completely submerged in one dip in the
galvanizing kettle. This may be difficult to discover during inspection because of the
size and shape of the item.
Various methods of providing vent holes are acceptable but the subsequent plugging of
these holes should be kept in mind when necessary.
Internal gusset plates and end flanges should also be provided with vent and drainage
holes. In circular hollow shapes these should be located diametrically opposite to each
other at opposite ends of the member.
In rectangular hollow shapes, the four corners of the internal gusset plates should be
cropped. Internal gusset plates in all large hollow sections should be provided with an
additional opening at the center. Where there are flanges or end plates, it is more
economical to locate holes in the flanges or plates rather than in the section.
Handrail.
1. Vent holes must be as close to the weld as possible and not less than 3/8 in diameter.
2. Internal holes should be the full l.D. of the pipe for best galvanizing quality and lowest galvanizing
cost.
3. Vent holes in end sections on similar sections must be 1/2 diameter.
4. Any device used for erection in the field that prevents full openings on ends of horizontal rails and
vertical legs should be galvanized separately and attached after galvanizing.
Vent holes should be visible on the outside of any pipe assembly.
If full internal holes (the full I.D. of the pipe) are not incorporated in the design of the
handrail, the following should occur:
1. Each vent hole must be as close to the welds as possible and must be 25% of the l.D. of the pipe, but
not less than 3/8 diameter.
2. Vent holes in end sections or in similar sections must be 1/2 diameter.
3. Any device used for erection in the field that prevents full openings on ends of horizontal rails and
vertical legs should be galvanized separately and attached after galvanizing.
Vent holes should be visible on the outside of any pipe assembly.
Rectangular Tube Truss
Vertical Sections
Each vertical member should have two (2) holes at the top and bottom, l8Oj apart in
line with the horizontal members. The size of the holes preferably should be equal and
the combined area of the 2 holes at either end of the verticals should be at least 30%
of the cross sectional area.
End PLates Horizontal
1. Most desirable - completely open.
2. If H+W=24 or larger, area of holes. Clips should equal 25% of the area of the tube (H+W).
If H+W less than 24 to and including 16 - 30%.
If H+W less than 16 to and including 8 - use 40%.
If H+W under 8 - leave open.
Pipe Truss 3 & Larger
Vertical Sections
Each vertical member should have two (2) holes at the top and bottom, 180 apart in
line with the horizontal members. The size of the holes preferably should be equal and
the combined area of the 2 holes at either end of the verticals should be at least 30%
of the cross sectional area.
End PLates Horizontal
1. Most desirable - completely open same diameter.
2. Equal substitutes - openings should be at least 30% of the area of the inside diameter.
Box Sections
INTERNAL GUSSETS should be spaced a minimum of 36.
Box Sections - H+W-24 or larger - the area of hole plus clips should equal 25% of the
cross sectional area of the box (H+W).
Box Sections - H+W less than 24 but greater than or equal to 16 - use 30%.
Box Sections - H+W less than 16 but greater than or equal to 8 - use 40%.
Box Sections - H+W under 8 leave completely open; no end plate or internal gussets.
The following table is for square box sections only. For rectangular sections, calculate
required area and check with your galvanizer for positioning of openings.
Box Size
H + W
Holes
A-DIM
Clipped Corneres
B-DIM
48 8 6
36 6 5
32 6 4
28 6 3
24 5 3
20 4 3
16 4 2
12 3 2

Tapered - Signal Arm
A. Small end open completely.
Pole Plate End
1. Most desirable - completely open.
2. Acceptable alternates - half circles or slot and round hole must equal 30% of the area of the I.D. of
the pole end of the tapered arm for 3 and larger I.D. The opening must equal 45% of the area of the pole
end of the tapered arm if the I.D. is under 3.
Pipe Columns, Pipe Girders, Street Light Poles and Transmission Poles With Base Plates
and With or Without Cap Plates.
Location of Openings
1. Most desirable - completely open same diameter as section top and bottom.
Dimensions
Openings at each end must be at least 30% of I.D. area of pipe for pipe 3 and over
and 45% of the I.D. area for 3 pipe or smaller.
The following is an example of sizes for 6 diameter section. Allow 30% of the area of
the l.D. for hole sizes at each end.
#2 Half Circle A - 1-3/4 R.
#3 Slot B = 3/4 - Center Hole C = 3 Diameter.
#4 Half Circle D = 1-5/8 R.
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Minimizing Distortion

Some fabricated assemblies may distort at the galvanizing temperature as a result of
the stresses induced during manufacturing of the steel and in subsequent fabricating
operations.
To minimize distortion, design engineers should observe the following
recommendations:
1. Where possible, use symmetrical rolled sections in preference to angle or channel frames. I-beams
are preferred to angles or channels.
2. Use parts in an assembly that are of equal or near equal thickness, especially at joints.
3. Bend members to the largest acceptable radii to minimize local stress concentration.
4. Accurately perform members of an assembly so that it is not necessary to force, spring or bend them
into position during joining.
5. Continuously weld joints using balanced welding techniques to reduce uneven thermal stresses.
Staggered welding techniques to produce a continuous weld are acceptable. For staggered welding of 1/8
inch (3.18 mm) or lighter material weld centers should be closer than 4 inches (10.16 cm).
6. Avoid designs which require double dip galvanizing or progressive galvanizing. It is preferable to build
assemblies and sub-assemblies in suitable modules so that they can be immersed quickly and fully in a
single dip. In this way, the entire fabrication can expand and contract uniformly. Where double dip or
progressive galvanizing is required, consult with your galvanizer if you anticipate a wide variance of
section size.
7. Consult with your galvanizer regarding the use of temporary bracing and/or reinforcing to minimize or
prevent warpage and distortion during galvanizing.
Guidelines for minimizing distortion warpage are provided in ASTM Recommended
Practice A384, Safeguarding Against Warpage and Distortion During Hot-Dip
Galvanizing of Steel Assemblies and CSA Specification G164, Hot Dip Galvanizing of
Irregularly Shaped Articles.
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Overlapping and Contacting Surfaces

When designing articles to be galvanized after fabrication, it is best to avoid narrow
gaps between plates, overlapping surfaces, and back-to-back angles and channels.
When overlapping or contacting surfaces cannot be avoided, all edges should be
completely sealed by welding. This is because the viscosity of the zinc keeps it from
entering any space tighter than 3/32 inch (2.38 mm). Less viscous pickling acids will
enter, but zinc will not
Two further problems encountered with tightly overlapping surfaces are:
1. Pickling acids that may be trapped will flash to steam when the part is immersed in the galvanizing
bath. The blowing out of this steam can prevent zinc from adhering to the area adjacent to the lap
joint.
2. Pickling acid salts can be retained in these tight areas due to impossibility of adequate rinsing. The
galvanized coating may be of good quality in the adjacent area, but humidity encountered months, or
even weeks, later may wet these acid salts. This will cause an unsightly rust staining to run out on top of
the galvanized coating.
Cleaning solutions will not effectively remove oils and greases trapped between
surfaces in close contact. Any residual oil and grease will partially volatilize at the
galvanizing temperature. This will prevent a satisfactory zinc coating in the immediate
area of the lap joint. It is important to specify that contacting joint surfaces be
thoroughly cleaned before fabrication and then completely sealed by welding.
If the area of seal-welded overlap is large, there should be vent holes through one or
both sides into the lapped area. This is to prevent any moisture which gets in through
a pin hole in the weld from building up explosive pressure while in the galvanizing
bath. This venting becomes more important when the area is large or steel is thin.
Consult Recommended Details for Galvanized Structures for vent size and numbers.
Vent holes can be sealed after galvanizing. Seal welding is not mandatory, but does
not prevent trapping moisture, internal rustling and seepage, all of which are possible
in any unsealed connection regardless of the protective coating used.
Where two bars come together at an angle, a gap of at least 3/32 inch (2.38 mm) after
welding must be provided to ensure the area is wetted by the molten zinc. An
intermittent fillet weld may be used. This can be on one side of the bar only or, where
necessary, an intermittent staggered fillet weld may be employed on both sides so
that no pocket can be formed. This type of welding, however, is not suitable for load
bearing members.
ASTM Recommended Practice A385 Providing High Quality Zinc Coatings (HotDip)
provides guidance for galvanizing overlapping surfaces.
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Castings

Cleanliness is very important to achieve proper and complete galvanizing of castings.
Thorough abrasive cleaning is the most effective method of treatment for the removal
of foundry sand and impurities. Conventionally, this is accomplished by grit shot, or
sand blasting. Grit blasting or a combination of grit and shot is generally preferred.
Usually, castings are cleaned at the foundry since most galvanizers do not have
abrasive blasting facilities.
Conventional acid cleaning process employed by most galvanizers does not clean
castings well because sand and other surface inclusions are not removed by
hydrochloric or sulfuric acid. After castings have been abrasively cleaned, they may
then be flash pickled to prepare them for galvanizing.
Galvanizing sound, stress-free castings with good surface finish will produce high
quality galvanized coatings. The following design and preparation rules should be
applied for castings to be galvanized:
1. Avoid sharp corners and deep recesses.
2. Use large pattern numerals and generous radii to facilitate abrasive cleaning.
3. Specify uniform wall sections. Non-uniform wall thicknesses in certain casting designs may lead to
distortion and/or cracking. These results from stresses developed as the temperature of the casting is
increased during the galvanizing process. Uniform wall sections and a balanced design will reduce this.
4. Heat treat castings before galvanizing. Under certain conditions of composition or thermal history,
the impact resistance of malleable iron castings may be significantly reduced as a result of galvanizing.
This can be avoided if the castings are heat treated prior to galvanizing as follows:
a. Heat at a temperature of 1250F (677C) until all sections have reached that temperature
(no soak required).
b. Perform finish machining and/or heat treating after abrasive blasting.
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Threaded Parts

Galvanized fasteners are recommended for use with hot dip galvanized subassemblies
and assemblies. Galvanized nuts, bolts and screws in common sizes are readily
available from commercial suppliers.
Bolted assemblies should be sent to the galvanizer while in the disassembled
condition. Nuts and bolts or studs to be galvanized should also be supplied
disassembled.
When the item to be galvanized incorporates threaded assemblies, the pitch diameter
of the female threads must be increased to permit hand assembly after the addition of
zinc to the male threads of the mating part.
Bolts are thus completely galvanized, but internal threads of nuts must be tapped
oversize after galvanizing to accommodate the increased diameter of the bolts. While
tapping or retapping of the nuts after galvanizing results in an uncoated female
thread, the zinc coating on the engaged male thread will protect both components
from corrosion. For economy, nuts are usually galvanized as blanks and the threads
tapped oversize after galvanizing.
To remove excess zinc and produce smoother coatings, small parts including fasteners
are centrifuged in special equipment when they are removed from the galvanizing
bath.
Items too long or too large to be centrifuged, such as long threaded rods, may be wire
brushed while hot to remove any excess zinc from threads.
Studs welded to assemblies may have to be cleaned after the assembly has cooled.
This requires reheating with an acetylene torch and wire brushing to remove excess
zinc. Alternatives to welded studs should be considered when possible.
Masking to prevent galvanizing threads on pipe or fittings is very difficult. The
recommended practice is to clean or tap after galvanizing.
Anchoring devices (such as threaded rods and anchor bolts) are sometimes specified to
be galvanized in the threaded areas only or in the areas to be exposed above ground.
This can be more expensive than galvanizing the complete unit because of the
additional handling required. Complete galvanizing can be specified for items to be
anchored in concrete. Research has proved the high bond strength and performance of
galvanized steel in concrete.
Tapped-through holes must be retapped oversize after galvanizing if they are to
contain a galvanized bolt after assembly. Tapping of all holes after galvanizing is
recommended to eliminate double tapping costs and the possibility of cross threading.
The recommended over tapping for nuts and interior threads is as follows:
Bolt or Stud Size
Diameter, inches
Minimum Overtapping of Female
Threads, inches*
7/16 and smaller 0.016
Over 7/16 to 1 0.021
Over 1 0.031
* Applies to both pitch and minor diameters, minimum and
maximum limits.
On threads over 1 & 1/2 inches it is often more practical, if design strength allows, to
have the male thread cut 0.031 inches (0.79 mm) undersize before galvanizing so a
standard tap can be used on the nut. ASTM Specification A563 (A563M) Carbon and
Alloy Steel Nuts discuss the required minimum diametral amount of overtapping of
nuts used with hot dip galvanized bolts. (Note: overtapping allowances contained in
A563 as of this printing are undergoing review and revision.)
Manufacturers of threaded parts recognize that special procedures must be followed in
their plants where certain items are to be galvanized. Following are some examples:
1. Low carbon bars are recommended since high carbon or high silicon causes a heavier, rougher
galvanized coating on the threads.
2. Hot formed threading or bending requires cleaning at the manufacturing plant to remove scale before
threading. Otherwise, over-pickling of threads will result during scale removal.
3. Sharp manufacturing tools are mandatory. Ragged and torn threads open up in the pickling and
galvanizing processes. Worn tools also increase bolt diameters. Frequent checking is necessary on long
runs.
4. Standard sized threads are cut on the bolt while standard sized nuts are retapped oversize after
galvanizing.
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Moving Parts

When a galvanized assembly incorporates moving parts (such as drop-handles, shackles
and shafts), a radial clearance of not less than 1/16 inch (1.59 mm) must be allowed
to ensure full freedom of movement after the addition of zinc during galvanizing.
It is recommended that, whenever possible, work be designed so that hinges can be
bolted to frames, covers, bodies and the like after galvanizing.
Hinges should be galvanized separately and assembled after galvanizing. All hinges to
be galvanized should be of the loose pin type. Before galvanizing, any adjacent edges
should be ground to give at least 1/32 inch (0.8 mm) clearance. The pin holes can be
cleared of excess zinc at time of assembly. After hinges are galvanized, it is
recommended that an undersized pin be used to compensate for the zinc picked up
during the galvanizing process. If desired, the pin holes in the hinges may be reamed
1/32 inch (0.8 mm) after galvanizing to permit the use of regular size pins.
At times, it is necessary to reheat moving parts in order to make them work freely.
Heating may cause discoloration of the galvanized coating near the reheated area.
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Marking for Identification

Identification markings on fabricated items should be carefully prepared before
galvanizing, so they will be legible after galvanizing.
Do not use paint to apply addresses, shipping instructions, and job numbers on items
to be galvanized. Oil based paints and crayon marks are not removed by the pickling
acids. This results in extra work and extra charges by the galvanizer to properly
prepare the steel for galvanizing.
For temporary identification, detachable metal tags or a water soluble marker should
be specified.
Where permanent identification is needed, there are three suitable alternatives for
marking steel fabrications to be hot dip galvanized. Each will enable items to be
rapidly identified after galvanizing and at the assembly site. The three marking
alternatives are:
1. Deep stenciling a steel tag (minimum #12 gauge) and firmly affixing it to the fabrication with a
minimum #9 gauge steel wire. The tag should be wired loosely to the work so that the area beneath the
wire can be galvanized and the wire will not freeze to the work when the molten zinc solidifies. It is
also recommended that more than one tag be used on each piece of work requiring identification.
Handling in transportation can result in loss of an occasional tag. If desired, the tags may be seal-welded
directly to the materials.
2. Stamping the surface of the item using die cut deep stencils or series of center punch marks. These
marks should be placed in a standard position on each of the members. They should be a minimum of 1/2
inch (12.7 mm) high and 1/32 inch (0.08 mm) deep to ensure readability after galvanizing. This method
should not be used to mark fracture critical members.
3. Using a series of weld beads to mark letters or numbers directly on the fabrication. However, it is
essential that all weld flux be removed.
Do not use aluminum, plastic, paper, or paint to mark an item before galvanizing.
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Galvanized Surface Repair

Sometimes hot dip galvanized coatings are damaged by excessively rough handling
during shipping or erection. Damage may also be the result of welding or flame
cutting.
Where limited areas are damaged, the use of low melting point zinc alloy repair rods
or powders, the use of organic zinc rich paint or the use of sprayed zinc (metallizing)
is recommended to protect the area.
ASTM Recommended Practice A780 Repair of Damaged Hot Dip Galvanizing Coatings
covers acceptable methods of reconditioning the damaged areas.
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After-Galvanizing Considerations

Wet Storage Stain Prevention
When galvanizers know items will be stacked or stored in humid environments after
they have been galvanized, they will often suggest application of an after-galvanized
treatment which will inhibit wet storage stain (white rust).
Wet storage stain is an attack on the galvanized coating producing a white corrosion
product. It is caused by retention of condensation or runoff water between contacting
surfaces when air circulation is poor. While the attack is frequently superficial,
despite the relative bulkiness of the corrosion product, its appearance may be
objectionable. Your galvanizer can discuss simple treatments which can be applied at
the galvanizers facility.
See AGA publication Wet Storage Stain for more details.
Painting
In general, galvanized coatings used alone provide the most economic corrosion
protection for steel. When galvanized coatings are painted it is usually for aesthetic
reasons, for identification or warning, for camouflage, or added corrosion resistance
under severe service or exposure conditions.
In many applications duplex systems of galvanizing-plus-paint are an ideal
combination. The galvanized coating provides a stable base which greatly increases
paint life, while the paint film protects the zinc coating to give a synergistic effect in
which the combination lasts considerably longer than the total of each coating alone.
Where steel is exposed to highly corrosive environments or where access is difficult
and the longest possible systems of hot dip galvanized coating-plus-paint provide the
best available protection for steel. Very long service life is achieved even under
adverse exposure conditions, resulting in outstanding economics compared to other
coating systems.
The longer life of correctly chosen and applied paint coatings on zinc coated steel
surfaces results from the stable zinc substrate which prevents initiation of rust at
pores and scratches, and resulting creep corrosion beneath the paint film.
Test results show that suitable paint coatings on galvanized steel achieve a synergistic
effect in which the duplex coating lasts up to three times as long before maintenance
as equivalent paint coatings on black steel.
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Pertinent Specifications

American Society for Testing and Material (ASTM)
A90 Test Methods for Weight of Coatings on Zinc Coated (Galvanized) Iron or Steel
Articles
A123 Zinc (Hot Dip Galvanized) Coatings on Iron and Steel Products
Al 43 Recommended Practice for Safeguarding Against Embrittlement of Hot Dip
Galvanized Structural Steel Products and Procedure for Detecting Embrittlement
Al 53 Zinc Coating (Hot Dip) on Iron and Steel Hardware
A325 High-Strength Bolts for Structural Steel joints, including Suitable Nuts and Plain
Hardened Washers
A384 Recommended Practice for Safeguarding Against Warpage and Distortion During
Hot Dip Galvanizing of Steel Assemblies
A385 Recommended Practice for Providing High Quality Zinc Coatings (Hot Dip) on
Assembled Products
A394 Galvanized Steel Transmission Tower Bolts and Nuts
A780 Practice for Repair of Damaged Hot-Dip Galvanized Coatings
B6 Zinc Metals (Slab Zinc)
E376 Recommended Practice for Measuring Coating Thickness by Magnetic-Field or
Eddy-Current (Electromagnetic) Test Methods
Canadian Standards Association
C164-M Hot Dip Galvanizing of Irregularly Shaped Articles
Duncan Galvanizing Specifications
Section 05030-Galvanizing and Metal Coatings-available on disk in Mac or PC format or
CD-ROM.
FAQ
The following is a list of frequently asked questions about hot-dip galvanizing.

1. How does galvanizing protect steel from
corrosion?

Zinc metal used in the galvanizing process provides an impervious barrier between
the steel substrate and corrosive elements in the atmosphere. It does not allow
moisture and corrosive chlorides and sulfides to attack the steel. Zinc is more
importantly anodic to steel meaning it will corrode before the steel, until the zinc is
entirely consumed.
2. What are the steps in the galvanizing process?
There are four steps:
Pre-inspection where the fabricated structural steel is viewed to ensure it has, if
necessary, the proper venting and draining holes, bracing, and overall design characteristics
necessary to yield a quality galvanized coating
Cleaning steel is immersed in a caustic solution to remove organic material such as
grease and dirt, followed by dipping in an acid bath (hydrochloric or sulfuric) to remove mill
scale and rust, and finally lowered into a bath of flux that promotes zinc & steel reaction and
retards further oxidation of the steel (steel will not react with zinc unless it is perfectly
clean)
Galvanizing the clean steel is lowered into a kettle containing 850 F molten zinc
where the steel and zinc metallurgically react to form three zinc-iron intermetallic layers and
one pure zinc layer
Final inspection the newly galvanized steel is sight-inspected (if it looks good, it is),
followed up by measurement of coating thickness with a magnetic thickness gauge
View animation
3. How does the cost of hot-dip galvanizing
compare to other corrosion protection systems,
such as paints?
When compared with paint systems, hot-dip galvanizing after fabrication has
comparable initial application costs and, almost always, lower life-cycle costs . In
fact, the lower life-cycle costs of a hot-dip galvanized project make galvanizing the
smart choice for today and tomorrow.
4. How long can I expect my galvanized steel
project to last in service?
Hot-dip galvanized steel resists corrosion in numerous environments extremely well.
It is not uncommon for galvanized steel to last more than 70 years under certain
conditions. To get a good idea of how long your project will last, see the service-life
chart.
5. Does the galvanized steel coating of zinc resist
abrasion?
The three intermetallic layers that form during the galvanizing process are all harder
than the substrate steel and have excellent abrasion resistance.
6. What causes wet storage stain and how can it
be prevented?
Zinc on newly galvanized steel is very reactive and wants to form zinc oxide and zinc
hydroxide corrosion products that eventually become the stable zinc carbonate.
When galvanized steel is tightly stacked or stored in wet boxes that dont allow for
free flowing air, the zinc forms excessive layers of zinc hydroxide, otherwise known
as wet storage stain. Most wet storage stain can be easily removed with a cleaner or
nylon brush. To prevent wet storage stain, store galvanized steel indoors or block it
so that there is ample free flowing air between each galvanized article.
7. Why do galvanized steel appearances differ
from project to project and galvanizer to galvanizer
and is there any difference in the corrosion
protection offered by the different appearing
coatings?
The steel chemistry is the primary determinant of galvanized coating thickness and
appearance. Continuously cast steel produced by the steel companies has a wide
variety of chemistries, thus the different coating appearances. There are several
different additives galvanizers may put in their zinc kettle to enhance the coating
appearance by making it shiny, spangled or matte gray. The appearance of the
coating (matte gray, shiny, spangled) does nothing to change the corrosion
protection of the zinc coating.
8. Can galvanized steel in service withstand high
temperatures for long periods of time?
Constant exposure to temperatures below 390 F (200 C) is a perfectly acceptable
environment for hot-dip galvanized steel. Good performance can also be obtained
when hot-dip galvanized steel is exposed to temperatures above 390 F (200 C) on
an intermittent basis.
9. Why would you want to paint over galvanized
steel?
Called duplex coatings, zinc and paint in combination (synergistic effect) produce a
corrosion protection approximately 2X the sum of the corrosion protection that each
alone would provide. Additionally, duplex coatings make for easy repainting,
excellent safety marking systems, and good color-coding. Painting over galvanized
steel that has been in service for many years also extends the life of the zinc coating.
10. What are the specifications governing hot-dip
galvanized steel?
Structural steel (plate, wide-flange beams, angles, channels, pipe, tubing) are
galvanized to ASTM A 123/A 123M. Fasteners and small parts that fit into a
centrifuging basket are galvanized to ASTM A 153/A 153M. Reinforcing steel is
galvanized to ASTM A 767/A 767M.
11. Isnt galvanizing more expensive than paint?
Depending on the product mix, square feet per ton, and condition of the steel
surface, galvanizing is often less expensive on an initial cost basis . However, as
with any purchase, the lifetime costs should be considered when making a project
decision on the corrosion prevention system to utilize. And, with galvanizing, the life-
cycle cost, i.e. the cost per year to maintain, is almost always less than a paint
system. Paint systems require maintenance, partial repainting and full repainting
several times over a 30-year project life. The costs can be staggering, making the
decision to paint a costly one in the long run.
12. What if the article to be galvanized is larger
than the dimensions of the galvanizers kettle?
Can it still be galvanized?
Galvanizers can progressively dip such a fabrication or article of steel. They dip one
half in the molten zinc bath, remove it, turn it around or over and immerse the other
half in the zinc. This method is often erroneously referred to as double dipping.
13. What is the difference between hot-dip
galvanized fasteners and zinc-plated fasteners?
Hot-dip fasteners generally have about 10 times as much zinc on the surface and
are suitable for use in all exterior and interior applications. Zinc-plated fasteners will
provide a disappointing performance if used outside, especially when used to
connect hot-dip galvanized structural steel members.
14. How long will hot-dip galvanizing protect my
steel from corrosion?
The corrosion rate of zinc and how long it will provide protection is a function of the
coating thickness and the amount of corrosive elements in the atmosphere. For
example, in rural settings where there is less automotive/truck exhaust and plant
emissions, galvanized steel can easily last for 100 150 years without maintenance.
Industrial and marine locations contain significantly more aggressive corrosion
elements such as chlorides and sulfides and galvanized steel may last for 50 100
years in those cases. The relationship between coating thickness and atmospheric
conditions is contained in a popular graph developed by the AGA. Please see the
publication Hot-Dip Galvanizing for Corrosion Protection: A Specifiers Guide.
15. Are there any special design and fabrication
considerations required to make steel ready for
hot-dip galvanizing?
Yes. Specifically, fabricated steel must allow for easy flow of the cleaning chemicals
and molten zinc metal over and through it. This means that gussets must be
cropped, holes put in the proper location for draining and venting of zinc from tubular
configurations, weld flux removed, overlapping surfaces must be seal-welded, and
light gauge material temporarily braced. The details of design and fabrication are
contained in the AGA publication The Design of Products to be Hot-dip Galvanized
After Fabrication.
16. Where are galvanized steel products used?
First of all, the variety of things galvanized is broad. Structural steel (angles,
channels, wide-flange beams, I-beams, H-beams), grating, expanded metal,
corrugated sheets, wire, cables, plate, castings, tubing, pipe, bolts & nuts. The
industries that utilized hot-dip galvanized steel range from bridge &
highway (reinforcing steel for decks and column concrete, girders, stringers, light and
signposts, guardrail, fencing), water & wastewater treatment plants (walkway
grating/expanded metal, handrails) architectural (facades, exposed structural steel,
lentils), parking garages (reinforcing steel for concrete decks, exposed structural
steel columns and barriers), pulp & paper plants (structural steel, walkways,
handrail), OEMs (motor housings, electrical cabinets, frames, heat exchanger
coils), electrical utilities (transmission towers, distribution poles, substations, wind
turbine poles), communication (cell towers), rail transportation (poles, switchgear,
miscellaneous hardware), chemical/petro-chemical (pipeline hardware,
manufacturing buildings, storage tanks, walkways), recreation (boat trailers,
stadiums, arenas, racetracks), and many more.
17. What are the size limitations of steel that is to
be galvanized?
The hot-dip galvanizing process can accommodate various different shapes and
sizes of steel. Kettle sizes vary in dimensions from one galvanizer to the next. You
can view the online listing of all the galvanizers in North America and their kettle
sizes.
18. What types of products can be galvanized?
Numerous different fabrications for a variety of applications are galvanized each
year. To view a list of the different types of products that have been hot-dip
galvanized click here.
19. Sometimes, the galvanized coating is shinier in
some places than others. Why is that?
The galvanized coating appearance may either be bright and shiny resulting from the
presence of an outer layer of pure zinc, or duller, matte gray as the result of the
coatings intermetallic layers being exposed. Performance is not affected. Coating
appearance depends on the amount of zinc in the coating.
View animation
20. Is the zinc coatings thickness consistent over
the entire piece?
Coating thickness depends on the thickness, roughness, chemistry, and design of
the steel being galvanized. Any or all of these factors could produce galvanized
coatings of non-uniform thickness. Members of the American Galvanizers
Association galvanize to ASTM standards, which define minimum average coating
thickness grades for various material categories.
View animation
21. What can I do to minimize possible warping &
distortion? Is it possible to determine prior to
galvanizing which pieces might be prone to this
occurrence?
Minimizing potential warpage and distortion is easily done in the projects design
stages by selecting steel of equal thicknesses for use in every separate
subassembly that is to be hot-dip galvanized, using symmetrical designs whenever
possible, and by avoiding the use of light-gage steel (<1/16 / 1.6 mm). Some
structures may benefit from the use of temporary bracing to help maintain their
shape and/or alignment.
View animation 1
View animation 2
22. Can I paint right over the galvanized coating?
If so, what procedure should be followed?
Galvanized coatings can be easily and effectively painted, not only for aesthetics but
also to extend the structures service life. The age and extent of weathering of the
galvanized coating dictate the extent of surface preparation required to produce a
quality paint system over galvanized steel. ASTM D 6386, Practice for Preparation of
Zinc (Hot-Dip Galvanized) Coated Iron and Steel Product and Hardware Surfaces for
Painting, should be consulted for suggested surface preparation methods for
galvanized coatings of varying ages.
23. How much weight will my material gain from
galvanizing?
As an average, the weight of the article will increase by about 3.5% due to zinc
picked up in the galvanizing process. However, that figure can vary greatly based on
numerous factors. The fabrications shape, size, and steel chemistry all play a major
role, and other factors like the black weight, the different types of steel that get
welded together, and the galvanizing bath chemistry can also have an effect.
24. Are slip-critical connections a concern when
the steel is to be galvanized?
When galvanized parts are used for slip-critical connections, they must either be
brushed, abrasive blasted, or painted with zinc-silicate paint to increase the surface
roughness and, thus, the slip factor.
View animation
25. Im interested in specifying hot-dip galvanizing
for reinforcing steel. Are there any concerns with
fabricating rebar after galvanizing?
Rebar is commonly fabricated after galvanizing. In order to minimize the possibility
for coating damage, avoid bending the rebar at a radius of more than 8 times its
radius. ASTM A 767, Specification for Zinc-Coated (Galvanized) Steel Bars for
Concrete Reinforcement, has a table that provides maximum bend diameters for
various-sized rebar.
View animation
26. Can I specify how much zinc to put on the
steel?
No, the steel chemistry and surface condition are the primary determinants of zinc
coating thickness. Leaving the steel in the molten zinc a little longer than optimal
may have one of two effects: 1) it may increase the coating thickness, but only
marginally; 2) it may significantly increase the coating thickness and cause a brittle
coating.
27. What does it mean to double-dip steel?
Double-dipping is the progressive dipping of steel that is too large to fit into the
kettle in a single dip. Double-dipping cannot be used to produce a thicker hot-dip
galvanized coating.
View animation
28. What is the reason for incorporating venting &
drainage holes into a projects design?
The primary reason for vent holes is to allow otherwise trapped air and gases to
escape; the primary reason for drain holes is to allow cleaning solutions and molten
zinc metal to flow entirely into, over, and throughout the part, and then back into the
tank or kettle.
View animation
29. If I stitch-weld, will there be uncoated areas
after galvanizing?
When stitch-welding is used, there is a possibility of gas release between gaps,
which will prevent the galvanized coating from forming in these areas. By leaving at
least a 3/32 (2.4 mm) gap between the contacting surfaces, gases are allowed to
escape and cleaning solutions and molten zinc are allowed to flow in between the
surfaces for a complete and uniform coating.
View animation
30. What is white rust and how can it be
avoided?
White rust is the term mistakenly applied to wet storage stain, which actually is a
milder corrosion product than white rust. Wet storage stain can be avoided by
properly stacking freshly galvanized articles, avoiding unprotected exposure to wet
or humid climates, or by using a surface passivation treatment after galvanizing. Wet
storage stain typically weathers away once the part is in service. (True white rust is
most commonly associated with galvanized cooling towers.)
View animation
31. Is there a way to provide for intentionally
ungalvanized areas?
Yes, but because masking or stop-off materials may not be 100% effective, contact
your galvanizer for suggestions.
View animation
32. Is there any environmental impact when the
zinc coating sacrificially corrodes? Is zinc a safe
metal?
There are no known studies to suggest zinc corrosion products cause any harm to
the environment. Zinc is a naturally occurring element (25th most abundant element
in the earth), and necessary for all organisms to live. It is a recommended part of our
diet (RDA 15 mg) and necessary for reproduction. It is used in baby ointments,
vitamins, surgical instruments, sunscreens and cold lozenges.
33. Should I be concerned when galvanized steel
comes in contact with other metals?
Zinc is a noble metal and will sacrifice itself (i.e. corrode, give up its electrons and
create a bi-metallic couple) to protect most metals. So, it is recommended to insulate
galvanized steel so that it doesnt come in direct contact with dissimilar metals.
Rubber or plastic, both non-conductive, are often used to provide this insulation.
34. What is the difference between hot-dip
galvanizing after fabrication and continuous hot-
dip galvanized sheet?
The process steps are similar but the production equipment is very different. After
fabrication galvanizing is a more manual process where structural steel (fabricated
plate, wide-flange beams, angles, channels, tube, pipe, fasteners) is suspended by
wire, chain or hook from crane hoists and immersed in the cleaning solutions and
zinc. Continuous sheet galvanizing involves uncoiling sheet, passing it through the
cleaning steps and molten zinc bath at speeds up to 500 feet per minute, drying and
recoiling. The uses of after-fabrication galvanized steel are usually exterior in nature
because the zinc coating is relatively thick (3.0 6 mils, 75 150 microns, 1.7 to 3.6
oz/sq. ft.) and will protect steel from corrosion in most atmospheric conditions for 50
to 100 years. Galvanized sheet is suitable for interior applications because of the
relatively thin coating (0.45 oz on each side), unless it is painted after galvanizing.
35. What is a G90 or A60 coating?
G90 is a grade of galvanized sheet produced to ASTM A653. It has 0.90 oz/sq. ft. of
zinc overall or 0.45 oz/sq. ft. per side. A60 is also a grade, has 0.30 oz/sq. ft. per
side, and has been annealed after galvanizing to produce a surface that promotes
good adhesion of paint.
36. Is a salt spray test in a laboratory appropriate
to estimate the corrosion rate of zinc coated steel?
In order for zinc to develop its protective patina of zinc carbonate that is very stable
and non-reactive, it requires a wetting and drying cycle like that produced by nature.
Salt spray tests keep the zinc wet and essentially wash the zinc corrosion products
off as they develop, inflating the corrosion rate of zinc. This lab test is not reflective
of real-world performance of zinc coatings.
37. Can galvanized steel in service withstand high
temperatures for long periods of time?
Constant exposure to temperatures below 390 F (200 C) is a perfectly acceptable
environment for hot-dip galvanized steel. Good performance can also be obtained
when hot-dip galvanized steel is exposed to temperatures above 390 F (200 C) on
an intermittent basis.
38. Can I specify how much zinc to put on the
steel?
No, the steel chemistry and surface condition are the primary determinants of zinc
coating thickness. Leaving the steel in the molten zinc a little longer than optimal
may have one of two effects: 1) it may increase the coating thickness, but only
marginally; 2) it may significantly increase the coating thickness and cause a brittle
coating.
39. What is cold galvanizing?
There is no such thing as cold galvanizing. The term is often used in reference to
painting with zinc-rich paint. Galvanizing by definition means a metallurgical reaction
between zinc and iron to create a bond between the zinc and the steel of
approximately 3600 psi. There is no such reaction when zinc-rich paints are applied
and the bond strength is only several hundred psi.