The Design of

Products to be
Hot-Dip
Galvanized
After Fabrication
The Design of Products to be Hot-Dip Galvanized
After Fabrication

TABLE OF CONTENTS

Design Considerations ..............................................................................................................................1

Liaison Between Design Engineer, Fabricator and Galvanizer................................................................1
Materials Suitable for Galvanizing...........................................................................................................2
Combining Different Materials and Surfaces...........................................................................................3
Welding Procedures and Welding Flux Removal.....................................................................................4
Mechanical Properties of Galvanized Steel..............................................................................................5
Strain-Age Embrittlement...................................................................................................................5
Hydrogen Embrittlement ....................................................................................................................6
Size and Shape....................................................................................................................................6
Allowing for Proper Drainage ..................................................................................................................8
Tubular Fabrications and Hollow Structurals...........................................................................................8
Cleaning ..............................................................................................................................................8
Venting ................................................................................................................................................9
Handrail Examples............................................................................................................................10
Handrail Examples............................................................................................................................11
Rectangular Tube Truss Examples ...................................................................................................11
Pipe Truss Examples.........................................................................................................................12
Pipe Columns and Girders, Street Light and Transmission Poles Examples...................................12
Box Section Examples......................................................................................................................13
Tapered Signal Arm Example...........................................................................................................13
Designing for Proper Venting and Draining of Enclosed and Semi-Enclosed Products .................14
Minimizing Distortion ............................................................................................................................15
Precautions for Overlapping and Contacting Surfaces...........................................................................16
Castings...................................................................................................................................................17
Threaded Parts ........................................................................................................................................17
Moving Parts...........................................................................................................................................19
Marking for Identification ......................................................................................................................20
Repair of Damaged Galvanized Surfaces...............................................................................................20
After Galvanizing Considerations ..........................................................................................................21
Wet Storage Stain Prevention ...........................................................................................................21
Painting .............................................................................................................................................21
Related Specifications.............................................................................................................................22

 2000 American Galvanizers Association, Inc. The material in this publication has been developed to provide accurate and authoritative information about the design of products
to be hot-dip galvanized after fabrication. This material provides general information only and is not intended as a substitute for competent professional examination and verification
as to suitability and applicability. The publication of the material herein is not intended as a representation or warranty on the part of the American Galvanizers Association, Inc.
Anyone using this information assumes all liability arising from such use.
DESIGN CONSIDERATIONS Hot-Dip
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 Galvanizing
product.
Once the decision has been made to hot-dip galvanize steel for corrosion
Process
protection, the design engineer should ensure that the pieces can be suitably
fabricated for high-quality galvanizing.
Certain rules must be followed in order to design components for galva-
nizing. These rules are readily applied and in most cases are simply those that
good practice would dictate to ensure maximum corrosion protection.
Adopting the following design practices, along with those listed in
ASTM A 385, Practice for Providing High Quality Zinc Coatings (Hot-Dip), will
produce optimum quality galvanizing, reduce coating costs, assist with the time-
ly processing of the product, and ensure the safety of the galvanizing personnel. Caustic cleaning

COMMUNICATION AMONG DESIGN ENGINEER, FABRICATOR,

AND GALVANIZER
The most important rule of designing for galvanizing is that the designer,
fabricator, and galvanizer should work together before the product is manufac-
tured. Three-way communication can eliminate most issues that could delay or
prevent superior galvanizing quality.
The design engineer can better appreciate the design considerations for
hot-dip galvanizing if the basic steps of the galvanizing process are under-
stood. Though the process may vary slightly from company to company, the Rust removal (Pickling)
fundamental steps in the galvanizing process are:
Soil and grease removal − A hot alkaline solution is used to remove dirt, oil,
grease, shop oil, and soluble markings. This process is known as caustic clean-
ing. However, caustic cleaning will not remove some surface contaminants such
as epoxies, vinyls, asphalts, or welding slag. These contaminants must be
removed by grit blasting, sandblasting, or other mechanical cleaning methods.
The fabricator is best equipped to remove these tough surface contaminants.
Pickling − An acid bath is used to remove surface rust and mill scale to
provide a chemically-clean metallic surface. Pickling acids are either dilute
solutions of hydrochloric acid or sulfuric acid. Fluxing
Fluxing − A steel article may be immersed in liquid flux (usually a zinc
ammonium chloride solution) to remove oxides and to prevent oxidation prior
to dipping into the molten zinc bath. In the dry galvanizing process, the item
is separately dipped in a liquid flux bath, removed, allowed to dry, and then
galvanized. In the wet galvanizing process, the flux floats on top of the molten
zinc so the item passes through the flux immediately prior to galvanizing.
Galvanizing − The article is immersed in a bath of molten zinc at approxi-
mately 850 F (455 C). During galvanizing, the zinc metallurgically bonds to the
steel, creating a series of zinc-iron alloy layers topped by a layer of pure zinc.
Finishing − After the article is withdrawn from the galvanizing bath, Galvanizing
excess zinc is removed by draining, vibrating, or, for small items, centrifug-
ing. The galvanized item is then air-cooled or water-quenched.

1
 Inspection − Coating thickness and surface condition inspections are the
final steps in the process. Information on inspection procedures and quality
control criteria is available in the American Galvanizers Association (AGA)
publication Inspection of Products Hot-Dip Galvanized After Fabrication
which may be obtained from your galvanizer or the AGA.
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, 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 project’s design.
Inspection
MATERIALS SUITABLE FOR GALVANIZING
Most ferrous materials are suitable for hot-dip galvanizing. Hot rolled
Figure 1
steel, cold rolled steels, cast steels, ductile iron, and cast iron all can be pro-
tected from corrosion by hot-dip galvanizing. Structural
Eta steel shapes, including those of high-strength (under 150
(100% Zn) ksi), and low-alloy materials, are hot-dip galvanized after
Zeta fabrication to obtain long-lasting protection.
(94% Zn, 6% Fe)
Though most ferrous materials can be hot-dip gal-
Delta vanized, the chemical composition of the material
(90% Zn, 10% Fe) affects the characteristics of the galvanized coating.
Gamma
(75% Zn, 25% Fe) During galvanizing, the ferrous material reacts with
Steel the zinc to form a series of zinc-iron alloy layers, which
normally are covered by a layer of free zinc. For most
hot rolled steels, the zinc-iron alloy portion of the coating will represent 50 to
70% of the total coating thickness. Figure 1 shows a cross-section of a typi-
cal hot-dip galvanized coating.
Steel compositions vary, depending on strength and service require-
Figure 2 ments. Trace elements in the steel, such as silicon and phosphorus, affect
the galvanizing process as well as the structure and appear-
Free Zinc Layer ance of the galvanized coating. For example, certain ele-
ments present in the steel may result in a coating composed
Zinc-Iron
entirely, or almost entirely, of zinc-iron alloy layers. Figure
Alloy Layers 2 shows a cross-section of a galvanized coating made up
almost entirely of zinc-iron alloy layers. Note the thickness
of the free zinc outer layer.
The characteristics of a coating composed primarily
Steel of a zinc-iron alloy layer differ from those of a typical
galvanized coating:
Visual − The zinc-iron alloy coating may have a matte gray appearance due
to the absence of the free zinc layer. The free zinc layer imparts the typical
bright finish to a galvanized coating.
Adherence − The zinc-iron alloy coating tends to be thicker than a typical
galvanized coating. As the thickness of this type of coating increases, the
coating can experience adhesion problems under external stress such as
thermal gradients or sharp impacts.
Corrosion Resistance – In general, galvanized coatings are specified for
their corrosion resistance. While a gray or matte appearance may occur, this

2
 different appearance does not reduce the long-term corrosion protection of
the steel. The corrosion resistance of these coatings, mil for mil, is equal to
the more typical bright, shiny galvanized coating.
It is difficult to provide precise guidance in the area of steel selection
without qualifying all of the grades of steel commercially available. The
guidelines discussed below usually result in the selection of steels that pro-
vide good galvanized coatings.
• Levels of carbon less than 0.25%, phosphorus less than 0.04%, or man-
ganese less than 1.35% are beneficial.
• Silicon levels less than 0.03% or between 0.15 and 0.25% are desirable.
Silicon may be present in many steels commonly galvanized even though
it is not a part of the controlled composition of the steel. This occurs primar- Matte coating
ily because silicon is used in the deoxidization process for the steel and is
found in continuously cast steel.
The phosphorus content should never be greater than 0.04% for steel that
is intended for galvanizing. Phosphorus acts as a catalyst during galvanizing,
resulting in rapid growth of the zinc-iron alloy layers. This growth is virtually
uncontrollable during the galvanizing process.
When possible, the galvanizer should be advised of the grade of steel select-
ed in order to determine whether to utilize custom galvanizing techniques.

COMBINING DIFFERENT MATERIALS AND SURFACES

Bright, shiny coating
Varying surface conditions, different fabrication methods, or ferrous metals
with special chemistries, when combined, make it difficult to produce coatings Different steel chemistries
with uniform appearance. This is because different parameters for pickling will affect the appearance of
(such as immersion time, solution concentrations, and temperatures) and galva- the galvanized coating, but
nizing (such as bath temperatures and immersion time) are required for: do not negatively affect the
corrosion resistance; the
• excessively rusted surfaces matte coating above will last
• machined surfaces just as long, or longer than
• cast steel the bright, shiny coating
• malleable iron
• hot rolled steel
• cold rolled steel
• cast iron, especially with sand inclusions
• pitted surfaces
• steel containing excess carbon, phosphorus, manganese, or silicon
The use of old along with new steel or castings with rolled steel in the
same assembly should be avoided (see Figure 3). Where assemblies of cast
iron, cast steel, malleable iron, or rolled steel are unavoidable, the entire
assembly should be thoroughly abrasive blasted with shot or sand prior to
pickling to give the best chance for producing a galvanized coating of accept-
able quality. Varying steel chemistries cre-
Excessively rusted, pitted, or forged steels should not be used in combi- ate visually different coatings,
nation with new or machined surfaces because the difference in required pick- as illustrated by this pipe
assembly
ling time for sulfuric acid pickling baths can cause over-pickling of the new
or machined surfaces. Where this combination is unavoidable, a thorough
abrasive blast cleaning of the assembly (normally before any machining is
done) provides a more uniform galvanized coating.

3
 Omission of blast cleaning of mixed material assemblies results in a com-
Avoid bination of under- and over-pickling of the different surfaces in a sulfuric acid
pickling bath, adversely affecting the quality of the finished galvanized coating.
Combinations Whenever possible, the materials described should be galvanized sepa-
of Different rately and assembled after galvanizing. When steels of special chemical
composition or varying surface finishes are joined in an assembly, the galva-
Materials and nized finish generally is not uniform in appearance. The corrosion protection
Finishes provided by the galvanized coating, however, is not affected by variation in
the color and texture of the coating. After aging in the environment, the
Figure 3 entire coating usually ages to a uniform matte gray appearance.
If abrasive blast cleaning is used to prepare a surface for galvanizing, a
coating thicker than normal will be produced for low silicon steel. Abrasive
cleaning roughens the steel surface and increases its surface area, resulting in
increased reactivity with the molten zinc. Greater zinc-iron alloy layer
growth occurs during galvanizing of a blast-cleaned steel, producing thicker
coatings at the expense of a moderately rougher surface. These thicker coat-
Ductile iron pipe with
machined flange
ings sometimes will have a matte gray appearance because the alloy layers
extend to the outer surface.

WELDING PROCEDURES AND WELDING FLUX REMOVAL

When welded items are galvanized, both the cleanliness of the weld area
and the metallic composition of the weld itself affect the galvanized coat-
Forged bolt with machined ing’s quality and appearance.
threads
The specifics of welding techniques can best be obtained from the
American Welding Society (800-443-9353) or your welding equipment sup-
plier. Several welding processes and techniques have been found to be suc-
cessful for items to be galvanized:
• In welding, an uncoated electrode should be used when possible to prevent
flux deposits on the steel or product.
• Welding flux residues are chemically inert in the normal pickling solutions
used by galvanizers; therefore, their existence will produce rough surfaces
Castings with regular mild and coating voids. If a coated electrode is used, all welding flux residues
carbon steel must be removed by wire brushing, chipping, grinding, pneumatic needle
gun, or abrasive blast cleaning (see Figure 4).
ted • Welding processes such as metal inert gas (MIG), tungsten inert gas (TIG),
pit
d& or carbon dioxide (CO2) shielded are recommended since they essentially
Ol
New produce no slag. However, there can still be small flux-like residues that
&c need to be chipped off.
lean

• In the case of heavy weldments, a submerged arc method is recommended.

• If none of these welding methods is available, select a coated rod specifi-
Steels with different surface cally designed for “self-slagging,” as recommended by welding equipment
conditions suppliers.
• 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. The com-
position and compatibility will yield a more uniform zinc surface appear-
ance.
Machined surfaces on pitted
steel

4
 Welding rods high in silicon may cause excessively thick and/or dark-
ened galvanized coatings to form over the weld. In smooth products
welded together with high silicon weld rods, the coating over the weld
material will be thicker than the surrounding coating, causing a
bump in an otherwise smooth product. So, a very low or no silicon
content rod should be used.
Galvanized materials may be easily and satisfactorily welded by all com-
mon welding techniques. Additional information about welding galvanized
steel may be obtained from the AGA.

MECHANICAL PROPERTIES OF GALVANIZED STEEL Proper welding techniques

The hot-dip galvanizing process produces no significant changes in the should be followed when
mechanical properties of the structural steels commonly galvanized through- welded steel will be galva-
out the world. The mechanical properties of 19 structural steels from major nized
industrial countries around the world were investigated before and after galva-
nizing in a four-year research project of the BNF Metals Technology Centre,
UK, under the sponsorship of the International Lead Zinc Research Figure 4
Organization (ILZRO). Steels conforming to ASTM Standard
Specifications A 36 and A 572 Grade 60 and Canadian Standards
Association (CSA) Specifications G 40.8 and G 40.12 were included in
this study.
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’ condi-
tion.”
Strain-Age Embrittlement
Many structures and parts are fabricated using cold rolled steel or
cold working techniques. In some instances severe cold working may
lead to the steel’s becoming strain-age embrittled. While cold working Welding flux residues must
be removed by wire brushing,
increases the possibility of strain-age embrittlement, it may not happen until
chipping, grinding, pneumatic
after galvanizing. This occurs because aging is relatively slow at ambient needle gun or abrasive blast
temperatures but more rapid at the elevated temperature of the galvanizing cleaning
bath.
Any form of cold working reduces the ductility of steel. Operations such as
punching holes, notching, producing fillets of small radii, shearing, or sharp
bending may lead to strain-age embrittlement of susceptible steels.
Cold worked steels less than 1/8 inch (3 mm) thick that are subsequently
galvanized are unlikely to experience strain-age embrittlement. Since cold
working is the strongest contributing factor to the embrittlement of galva-
nized steel, the following precautions are recommended to reduce the inci-
dence of strain-age embrittlement:
• Select steels with carbon contents below 0.25%.
• Choose steels with low transition temperatures since cold work raises the duc-
tile-brittle transition temperature and galvanizing (heating) may raise it further.
• Specify aluminum-killed steels because they show less susceptibility to
strain-age embrittlement. Failure to remove weld
residues will result in incom-
• For steels with a carbon content between 0.1 and 0.25%, maintain a bend- plete galvanized coatings,
ing radius of at least three times the section thickness (3t). If bending is such as on this joint

5
 Avoid Severe required to be less than 3t, the material should be stress relieved at 1100 F
(595 C) for one hour per inch (25.4 mm) of section thickness.
Cold Working • Avoid notches because they increase stress. Notches may be caused during
shearing or punching operations. Flame cutting or sawing is preferred, par-
ticularly for heavy sections.
• Drill, rather than punch, holes in material thicker than 3/4 inch (19 mm). If
holes are punched, they should be punched undersize and then reamed an
additional 1/8 inch (3 mm) overall or drilled to size. Material between 1/4 and
3/ inch (6.5 - 19 mm) thick is not seriously affected by cold punching if the
4
punching is done under good shop practice. Material up to 1/4 inch (6.5
mm) thick that has been cold worked by punching does not need stress
relieving operations before galvanizing.
• For steel sections with edges greater than 5/8 inch (16 mm) thick that are
subject to tensile loads, cut using normal shop procedures. Edges of sec-
tions up to 5/8 inch (16 mm) thick may be cut by shearing.
• In critical applications, the steel should be hot worked above 1200 F (650
C) in accordance with the steel manufacturer’s recommendations. Where
Preferred Design
cold working cannot be avoided, stress-relieve the part.
ASTM A 143, Safeguarding Against Embrittlement of Hot-Dip
Galvanized Structural Steel Products and Procedure for Detecting
Embrittlement, and CSA Specification G 164, Galvanizing of Irregularly
Shaped Articles, provide guidance on cold working and stress relieving pro-
cedures. However, it is best to avoid severe cold working of susceptible steels.
If there is concern with possible loss of ductility due to strain-age embrit-
tlement, alert the galvanizer. 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 that occurs in cer-
tain high strength steels. Hydrogen embrittlement can occur when the hydro-
gen released during the pickling process is absorbed by the steel. However, at
galvanizing temperatures
hydrogen is expelled from the
steel unless it becomes trapped
in the grain boundaries.
Although hydrogen em-
brittlement is uncommon,
precautions should be taken
to avoid it, particularly if the
steel involved has an ultimate
tensile strength exceeding
150,000 psi. If high-strength
steels are to be processed, grit
blasting instead of acid pick-
ling is recommended in order
to minimize the introduction
of gaseous hydrogen during
the pickling process.
Galvanizers often rack products in order to effectively galvanize more than
one product at a time, such as with these guardrail posts, which are being Size and Shape
removed from the zinc bath With the increase in the
sizes and capacities of galva-

6
nizing kettles, facilities can accommodate fabri-
cations in a significant range of sizes and shapes.
Galvanizing kettles up to 42 feet (13 m) in length
are available in most industrial areas, and there
are several kettles between 50, 60, and 80 feet
(15, 19, and 25 m) in length.
Almost any component can be galvanized by
designing and fabricating in modules suitable for
the available galvanizing facilities. However, it is
wise to verify kettle constraints with the galva-
nizer at an early stage. [Kettle dimensions and
phone numbers of member galvanizers are avail-
able through the AGA.]
Large structures are galvanized by designing
in modules or sub-units that are assembled by
field welding or bolting after galvanizing.
Modular design techniques often produce
economies in manufacturing and assembly
because they simplify handling and transportation.
When an item is too large for total immersion
in the kettle of molten zinc, but more than half of
the item will fit into the kettle, the piece may be
double dipped. During double dipping, each end of
the article is dipped sequentially in order to coat
the entire item (see photos at right). Always con-
sult the galvanizer before planning to double dip.
Steel designers 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. Special jigs and racks Double dipping: Galvanizing oversized pieces
can be used to simultaneously galvanize large
numbers of similar items.
Where possible, lifting points should be provided for the
galvanizer. All articles are immersed into the galvanizing ket-
tles from overhead, so chains, wires, or other holding devices
are used to support the material unless special lifting points
can be provided. Chain and wire can leave a touch-mark on
the galvanized item. Although this touch-mark is usually fully
galvanized, it can be touched up if required for aesthetic rea-
sons.
Large pipe sections, open-top tanks, and similar structures
may require the addition of bracing to maintain their shape
during handling.
Small items also receive special attention during galva-
nizing. Pieces less than 30 inches (76 cm) in length are fre-
quently galvanized in perforated baskets. The basket is then
centrifuged to throw off excess zinc from the pieces, deliver-
ing smoother coatings. Fasteners, small brackets, and clips
typify work handled in baskets.
A perforated basket filled with bolts is placed
in a centrifuge to spin off excess zinc

7
 The weight of fabrications also should be considered in the design of
products for hot-dip galvanizing because of the handling processes required
Good Venting to move items from step to step in the galvanizing facility. Contact the galva-
and Cropping nizer to determine his weight-handling capacity if it appears that weight will
be a factor in the design considerations.

Figure 5 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 frequently the cause of
problems for the galvanizer and the customer. Improper drainage design
results in poor appearance, bare spots, and excessive build-up of zinc. All of
these are unnecessary and costly.
Where gusset plates are used, generously cropped corners provide for free
drainage. When cropping gusset plates is not possible, holes at least 1/2 inch
(13 mm) in diameter must be placed in the plates as close to the corners as pos-
sible (see Figure 5). Figure 7
To ensure unimpeded flow of solutions, all
Cropped corners stiffeners, gussets, and bracing should be
(preferred) cropped a minimum of 3/4 inch (19 mm) (see
Figure 6).
Provide holes at least 1/2 inch (13 mm) in diam-
eter in end plates on rolled steel shapes to allow
molten zinc access during immersion in the galva-
nizing bath and drainage during withdrawal.
Alternatively, holes at least 1/2 inch (13 mm)
Holes close to
in diameter can be placed in the web within 1/4
corners (alter- inch (6 mm) of the end plate. To facilitate
natively) drainage, end plates should have holes placed as
close to interior corners as possible (see Figure 7).

TUBULAR FABRICATIONS AND HOLLOW STRUCTURALS

Tubular assemblies such as handrails, pipe columns, pipe girders, street
light poles, transmission poles, pipe trusses, and sign bridges are commonly
galvanized because corrosion protection is afforded to the interior and exteri-
or of the product. To provide an optimal galvanized coating, hollow products
require proper cleaning and draining.
Cleaning
As with all steel, pipe and other hollow materials must be thoroughly
Figure 6
cleaned before the molten zinc will metallurgically bond with the steel. Pipe
can present two special cleaning difficulties.
First, the mill coating (varnish, lacquer, and similar materials) applied by
the pipe manufacturer requires extra time and effort to remove at the galva-
nizing plant. Some galvanizers do not have the capability to remove this coat-
ing. Some organic mill coating formulations, both foreign and domestic, are
extremely difficult to remove with common cleaning solutions, so blasting
may be required. Ordering uncoated pipe avoids costly removal of these mill

8
coatings. In some cases, it may be more cost effective to substitute tube for
pipe.
Various
Second, welding around mill coatings burns and carbonizes the varnish in
Methods of
the surrounding areas and cannot be removed by the normal cleaning process Venting Tubular
at a galvanizer. This soot must be removed by blasting or other mechanical
cleaning methods.
Fabrications
Venting Figure 9
The primary reason for vent and drain holes is to allow air to be evacuat-
ed allowing the object to be completely immersed in the molten zinc. Proper
sizing and location make it safer to galvanize and provide the optimal finish. Drilled
The secondary reason is to prevent explosions and destruction of the parts. hole
Any pickling acid or rinse waters that might be trapped in a blind or closed
joining connection will be converted to superheated steam or gas and can
develop a pressure of up to 3800 psi when immersed in molten zinc at 850 F
(455 C). This presents a serious explosion hazard to galvanizing person-
nel and equipment.
Proper galvanizing results in the inside and outside of a product that is
completely cleaned and coated with zinc. Air and frothy fluxes must be V
allowed to flow upward and completely out. Cleaning solutions and molten Notch
zinc must be allowed to flow in and completely wet the surfaces.
The structure must be lowered into the solution without trapping any air,
then raised from the bath without trapping any solution. Consequently, ample
passageways allowing unimpeded flow into and out of the part must be
designed into the assemblies.
Corner
Items to be galvanized are immersed and withdrawn at an angle, so the cut
vent holes should be located at the highest point and drain holes at the lowest
point in each member.
All sections of fabricated pipe-work should be interconnected with full
open tee or miter joints. Each enclosed section must be provided with a vent
hole at each end. Drilled
hole in
Most galvanizers prefer to visually identify the venting from the outside flange
when the assembly is received. This is necessary to verify the adequacy
of the venting as well as to determine that it has not been omitted
by mistake. Some galvanizers may hesitate to process com-

Figure 8

Internal venting

External venting Vent holes on the outside of pipe assembly

9
 plicated pipe assemblies (such as handrail) unless all venting is visible on the
outside and readily accessible for inspection (see Figure 8 – previous page).
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 the solution.
Vent holes are frequently left open but can be closed with drive caps or
plugs after galvanizing.
Various methods of venting are acceptable (see Figure 9 – previous page),
but the subsequent plugging of these holes should be kept in mind where nec-
essary.
It is recommended that tubular structures be completely submerged in one
dip in the galvanizing kettle. This minimizes potential internal coating prob-
lems which, because of the size and shape of the item, may be difficult to dis-
cover during inspection.
Internal gusset plates and end flanges should also be provided with vent
and drainage holes. In circular hollow shapes, the holes should be located dia-
metrically opposite 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.
The following drawings illustrate recommended designs for tubular fabri-
cations and hollow structurals. The vent dimensions are the minimum
required.

Figure 10 Handrail:
Figure 10 illustrates the most desirable
design for fabrications of handrail for galva-
nizing. It shows internal venting as well as
3 the minimum amount of external vent holes.
3 1. External vent holes must be as close to
2 the weld as possible and not less than 3/8
1 inch (9.5 mm) in diameter.
2
1 2. Internal holes should be the full I.D. of
2
2 the pipe for the best galvanizing quality and
1 4
1 lowest galvanizing cost.
2
3. Vent holes in end sections or in similar
2 sections must be 1/2 inch (13 mm) in diame-
5 1 ter.
4
4. & 5. Ends should be left completely
open. Any device used for erection in the
5 field that prevents full openings on ends of
horizontal rails and vertical legs should be
Vent holes should be visible on the outside of any pipe assembly
galvanized separately and attached after
to provide internal vent verification
galvanizing.
10
Handrail:
Figure 11
Figure 11 illustrates an acceptable alternative
if full internal holes (the full I.D. of the pipe)
are not incorporated into the design of the
handrail.
1. Each external vent hole must be as 2
close to the welds as possible and 2
must be 25% of the I.D. of the pipe, 1
but not less than 3/8 inch (10 mm) in
diameter. The two holes at each end 1
and at each intersection must be 180 1 1 3
degrees apart and in the proper loca-
tion as shown. 1
2. Vent holes in end sections or in similar 1
4 3
sections must be 1/2 inch (13 mm) in
diameter.
3. & 4. Ends should be left completely 4
open. Any device used for erection in
the field that prevents full openings on
ends of horizontal rails and vertical
legs should be galvanized separately External vent holes should be visible on the outside of any pipe
and attached after galvanizing. assembly

Rectangular Tube Truss: Figure 12

Vertical Sections
Hole locations for the vertical members
should be as shown on Figure 12.
Each vertical member should have two
holes at each end, 180 degrees apart in line 1
with the horizontal members. The size of the
holes preferably should be equal, and the
combined area of the two holes at either end
of the verticals should be at least 30% of the 2
cross-sectional area.
End Plates - Horizontal
1. The most desirable fabrication is complete-
ly open.
2. From Figure 17, if H + W = 24 inches or
larger, the area of the hole, plus clips,
should equal 25% of the area of the tube (H
x W).
If H + W = less than 24 inches but more
than 16 inches, the area of the hole, plus
clips, should equal 30% of the area of the tube.
If H + W = less than 16 inches but more than 8 inches, the area of the hole,
plus clips, should equal 40% of the area of the tube.
If H + W = less than 8 inches, leave it open.

11
Figure 13 Pipe Truss 3" & Larger:
Vertical Sections
E
Hole locations for the vertical members
1 should be as shown in Examples A and B and by
the arrows on Figure 13.
F Each vertical member should have two holes
at each end and 180 degrees apart in line with the
2 horizontal members as indicated by the arrows.
The size of the holes preferably should be equal
D C D C D and the combined area of the two holes at either
3 end of the verticals (Areas C and D or Areas E
and F) should be at least 30% of the cross-sec-
tional area.
A B 4 End Plates - Horizontal
1. The most desirable fabrication is completely
open with the same hole diameter as the tube
inner diameter.
2. & 3. & 4. Equal substitutes would have open-
ings as shown above and would be at least 30%
of the area of the inside diameter.
Figure 14 Pipe Columns, Pipe Girders, Street Light
Poles, and Transmission Poles:
(With base plates and with or without cap
1 2 3 4 5 plates, Figure 14.)
Location of Openings
1. The most desirable fabrication is to have
the end completely open, with the same
diameter as the section top and bottom.
D 2. & 3. & 4. This is an equal substitute if the
full opening is not allowed.
5. This must be used when no holes are
allowed in the cap or baseplate: two half cir-
cles 180 degrees apart and at opposite ends
of the pole.
C Dimensions
Openings at each end must be at least
B A 30% of the I.D. area of the pipe for pipe
three inches and greater and 45% of the I.D.
area for pipe smaller than three inches.
Allow 30% of the area of the I.D. for hole sizes at each end.
Illustration 1, end completely open.
Illustration 2, Slot B = 3/4 inch (19 mm), Center hole C = 3 inches (76 mm)
in diameter
The following is an example of sizes for a 6 inch diameter section.
Illustration 3, Half circle A = 13/4 inch (45 mm) radius
Illustration 4, oval opening = 13/4 inch (45 mm) radius
Illustration 5, Half circle D = 15/8 inch (19 mm) radius

12
Box Sections: Figure 15
Figure 15 shows the location of
holes and clipped corners, which must
be flush. Using the following formulas,
Table 1 shows typical sizes of holes. W
Internal Gussets − space at a minimum
of 36 inches. H
Box Sections − H + W = 24 inches or
larger, the area of the hole, plus clips,
should equal 25% of the cross-section-
al area of the box (H x W).
Box Sections − H + W = less than 24
inches but greater than 16 inches, the
area of the hole, plus clips, should
equal 30% of the cross-sectional area A
of the box.
Box Sections − H + W = less than 16
inches but greater than or equal to 8
inches, the area of the hole, plus clips,
should equal 40% of the cross-section-
Table 1
al area of the box.
Box Sections − H + W = under 8 inch- Box Size Holes A-Dim
es, leave completely open, no end plate (H + W)
or internal gusset. 48" 8"
Table 1 is for square box sections 36" 6"
only. For rectangular sections, calculate 32" 6"
the required area and check with the 28" 6"
galvanizer for positioning of openings. 24" 5"
20" 4"
16" 4"
12" 3"

Figure 16
Tapered − Signal Arm:
(Figure 16)
A. The small end should be com-
pletely open. A
Pole Plate End
1. The most desirable fabrication is
to have the end completely open.
2. & 3. & 4. For acceptable alterna-
tives, the half circles, slots, and
round holes must equal 30% of the 1 2 3 4
area of the I.D. of the pole end of the
tapered arm for 3 inches and larger
I.D.s. The opening must equal 45%
of the area of the pole end of the
tapered arm if the I.D. is less than 3
inches.

13
 Venting of Tanks Designing for Proper Venting and Draining of Enclosed and Semi-
Enclosed Products
and Vessels Tanks and enclosed vessels should be designed to allow acid cleaning
solutions, fluxes, and molten zinc to enter at the bottom and trapped air to
Figure 18 flow upward through the enclosed space and out through an opening at the
highest point. This prevents air from being trapped as the article is immersed
(see Figure 17). The design must also provide for complete drainage of both
interior and exterior details during withdrawal. The Figure 17
location and size of fill and drain holes are impor-
Vent diagonally
tant. As a general rule, the bigger the hole the opposite fill
Good better the air and zinc flow. hole
design When both internal and external sur-
faces are to be galvanized, at least one
Flush interiors fill/drain hole and one vent hole must
provide good be provided. The fill/drain hole
drainage should be as large as the design
will allow, but at least 3 inches
in diameter for each cubic yard
(10 cm in diameter for each 1.0
Cropped inter-
cubic meter) of volume. The nal baffle (top
minimum diameter is 2 inches and bottom)
(50 mm). Provide vent holes of
the same size diagonally opposite
Figure 19 the fill/drain hole. This allows the
air to escape.
In tanks, internal baffles should be cropped on the top and bottoms or pro-
vided with suitable drainage holes to permit the free flow of molten zinc.
Manholes, handholes, and openings should be finished flush inside to prevent
Poor trapping excess zinc (see Figures 18-20).
design Openings must be placed so that the flux on the vessel can float to the sur-
face of the bath. These openings also prevent air pocket formations that may
keep the acid bath from completely cleaning the inside of the vessel.
Items such as vessels or heat exchangers that are galvanized on the out-
Trapped zinc
side 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 gal-
vanizing kettle (see Figure 21). The galvanizer should be consulted before
using these temporary fittings because special equipment is needed.
The galvanizer should always review the drawings of enclosed or partially-
enclosed vessels before fabrication. Galvanizers may recommend changes that
Trapped moisture, air, acid, would provide a better galvanized Figure 21
and flux during submersion
product. If a change is needed to Vent pipes con- Flanges
Figure 20 facilitate galvanizing, the least nect interior to should be
expensive time to make the the atmosphere finished
Internal baffles
Vent hole change is before fabrication. flush inside
cropped top
and bottom

Fill/drain hole

14
MINIMIZING DISTORTION
Some fabricated assemblies may distort at the galvanizing
temperature as a result of relieving stresses induced during
manufacturing of the steel and in subsequent fabricating opera-
tions. A channel frame with a plate should be galvanized sepa-
rately and bolted later rather than welded together before gal-
vanizing, or it can be welded after galvanizing. Guidelines for
minimizing distortion and warpage are provided in ASTM A
384, Safeguarding Against Warpage and Distortion During
Hot-Dip Galvanizing of Steel Assemblies, and CSA
Specification G 164, Hot Dip Galvanizing of Irregularly
Shaped Articles.
To minimize distortion, design engineers should observe
the following recommendations: Some fabricated assemblies may distort at
the galvanizing temperature as a result of
Where possible, use symmetrically rolled sections in pref- relieving stresses induced during manufac-
erence to angle or channel frames. I-beams are preferred to turing of the steel and in subsequent fabri-
angles or channels. cating operations
Use parts in an assembly that are of equal or near equal Figure 23
thickness, especially at joints (see Figure 22).
Temporary Bracing
Bend members to the largest acceptable radii to minimize local stress
concentration.
Accurately pre-form members of an
Figure 22 assembly so that it is not necessary to
force, spring, or bend them into position
during joining.
Continuously weld joints using balanced
welding techniques to reduce uneven Channel frame typically
thermal stresses. Pinholes from welding fabricated toe-out
are very dangerous in items to be
galvanized and must be avoided.
Staggered welding techniques to produce
a continuous weld are acceptable. For
staggered welding of 1/8 inch (4 mm) or
lighter material, weld centers should be
closer than 4 inches (10 cm).
Avoid designs that require double dip
galvanizing or progressive galvanizing. Trough
It is preferable to build assemblies and
subassemblies in suitable modules so that they can be immersed quickly
and galvanized in a single dip. In this way, the entire fabrication can
expand and contract uniformly. Where double dip or progressive galva-
nizing is required, consult the galvanizer.
Consult with the galvanizer regarding the use of temporary bracing or
reinforcing to minimize warpage and distortion during galvanizing (see
Figure 23).

Cylinder

15
 PRECAUTIONS FOR OVERLAPPING AND CONTACTING SURFACES
When designing articles to be galvanized after fabrication, it is best to
avoid narrow gaps between plates, overlapping surfaces, back-to-back
angles, and channels (see Figure 24), whenever possible.
When overlapping of contacting surfaces cannot be avoided and is 3/32
inch (2.5 mm) or less, all edges should be completely sealed by welding. The
viscosity of the zinc keeps it from entering any space tighter than 3/32 inch (2.5
mm). If there is an opening, less viscous pickling acids will enter, but zinc
will not. The pickling acid may cause iron oxide weeping out of the joint later
on.
Further difficulties encountered with tightly overlapping surfaces include:
1. Pickling acids that may be trapped will flash to steam when the part is
immersed in the galvanizing bath. This steam can wash the flux off of the part
near the gap, causing bare areas adjacent to the lap joint.

Failure to seal weld small

2. Pickling acid salts can be retained in these tight areas due to the impossi-
spaces may result in iron bility of adequate rinsing. The galvanized coating may be of good quality in
oxide weeping and staining the adjacent area, but humidity encountered weeks or even months later may
caused by moisture wicked wet these acid salts. This will cause an unsightly rust staining to seep out onto
into the gap the galvanized coating.
3. 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 result in an unsatisfactory
zinc coating in the immediate area of the lap joint.
It is important to contact the galvanizer before constructing any piece that
will include overlapping surfaces. The trade-off between a completely sealed
weld joint that may undergo expansion and cracking when subjected to gal-
vanizing temperatures and a skip-welded joint that may experience weepage
and staining later becomes a very difficult choice. The galvanizer’s experi-
ence may greatly assist in making this decision.
When a weld joint is completely sealed there must be no weld imperfection
or pinholes. The penetration of moisture into the sealed cavity could cause
significant safety hazards during the hot-dip
Figure 24 galvanizing process as the sealed air will
greatly expand when the part reaches
the galvanizing temperature. This
Weld on gas expansion can cause the
Weld on top bottom molten zinc to splash out of the
bath and endanger galvanizing
workers.
If the area of a seal-weld
overlap is large, there should be
vent holes through one or both
Weld on Weld on top sides into the lapped area. This is
bottom to prevent any moisture that gets
in through a pinhole in the weld
from building up explosive pressure
while in the galvanizing bath. This vent-
ing becomes more important the greater the
area. Consult the galvanizer or the AGA publi-
cation Recommended Details for Galvanized

16
Structures for vent size and quantity. Vent holes can be sealed after galvaniz-
ing. Seal welding is not mandatory but prevents trapping moisture, which can
Figure 25
result in internal rusting and weepage.
Where two bars come together at an angle, a gap of at least 3/32 inch
(2.5mm) after welding must be provided to ensure the area is wetted by the
molten zinc (see Figure 25). An intermittent fillet weld may be used. This
can be on one side of the bar only or, where necessary, an intermittent stag-
gered fillet weld may be employed on both sides so that a pocket is not
formed. This type of welding, however, is not suitable for load-bearing
members.
3/32 inch gap after welding
CASTINGS
High quality castings and forged parts can be galvanized successfully. The
quality of the galvanizing is strongly influenced by the
quality of the casting. Cleanliness is very important to
achieve proper and complete galvanizing of castings.
Thorough abrasive cleaning is the most effective
method for removing foundry sand and impurities. This
is conventionally accomplished by grit, shot, or sand
blasting. Grit blasting or a combination of grit and shot
generally is preferred. Castings are usually cleaned at
the foundry since most galvanizers do not have abra-
sive blasting facilities.
Conventional acid cleaning processes employed by
most galvanizers do 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 pickled in prepa-
ration for galvanizing. Castings must be abrasively
cleaned in order to achieve a
Galvanizing sound, stress-free castings with good surface finishes will fully galvanized coating
produce high quality galvanized coatings. The following design and prepara-
tion rules should be applied for castings to be galvanized:
• Avoid sharp corners and deep recesses.
• Use large pattern numerals and generous radii to facilitate abrasive clean-
ing.
• Specify uniform wall sections. Non-uniform wall thickness in certain
casting designs may lead to distortion and/or cracking. Cracking results
from stress developed as the temperature of the casting is increased dur-
ing the galvanizing process. Uniform wall sections and a balanced design
will prevent cracking.

THREADED PARTS
Hot-dip galvanized fasteners are recommended for use with hot-dip gal-
vanized 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 in a disassembled con-
dition. Nuts, bolts, or studs to be galvanized also should be supplied disas-
sembled.
Galvanized bolts

17
 When the item to be galvanized incorporates threaded assemblies, the
pitch diameter of the female threads must be increased to permit hand assem-
Overtapping bly after the addition of zinc to the male threads of the mating part.
Guidelines for Bolts are completely galvanized, but internal threads on nuts must be tapped
oversize after galvanizing to accommodate the increased diameter of the bolts.
Nuts and While chasing or retapping the nuts after galvanizing results in an uncoated
Interior Threads 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
(see Figure 26).
Table 2* Figure 26
To remove excess zinc and produce smoother
Nominal Nut Diametrical coatings, small parts, including fasteners, are cen-
Size (inches) Allowance trifuged in special equipment when they are
and Pitch (inches) removed from the galvanizing bath.
Items too long or too large to centrifuge, such
0.250-20 0.016 as long threaded rods, may be brushed while hot
0.312-18 0.017 to remove any excess zinc from the threads.
0.375-16 0.017 Studs welded to assemblies may have to be
0.437-14 0.018 cleaned after the assembly has cooled. This
requires reheating with an acetylene torch and Increase
0.500-13 0.018
brushing to remove excess zinc. Alternatives tolerance
0.562-12 0.020
to welded studs should be considered when
0.625-11 0.020
possible.
0.750-10 0.020
0.875-9 0.022
Masking to prevent galvanizing
threads on pipe or fittings is very diffi-
1.000-8 0.024
cult. The recommended practice is to clean and
1.125-8 0.024 tap after galvanizing.
1.125-7 0.024
Anchoring devices (such as threaded rods and anchor bolts) some-
1.250-8 0.024
times are specified to be galvanized in the threaded areas only or in the areas
1.250-7 0.024 to be exposed above-ground. This can be more expensive than galvanizing the
1.375-8 0.027 complete unit because of the additional handling required. Complete galvaniz-
1.375-6 0.027 ing can be specified for items to be anchored in concrete. Research has proven
1.500-8 0.027 the high bond strength and performance of galvanized steel in concrete.
1.500-6 0.027 Tapped-through holes must be retapped oversize after galvanizing if they
1.750-5 0.050 are to contain a galvanized bolt after assembly. Tapping of all holes after gal-
2.000-4.5 0.050 vanizing is recommended to eliminate double tapping costs and the possibil-
2.250-4.5 0.050 ity of cross-threading.
2.500-4.5 0.050 Table 2 shows the recommended overtapping for nuts and interior threads
2.750-4 0.050 as detailed in ASTM A 563, Specification for Carbon and Alloy Steel Nuts.
3.000-4 0.050 On threads over 11/2 inches (38 mm) it is often more practical, if design
3.250-4 0.050 strength allows, to have the male thread cut 0.031 inches (0.8 mm) undersize
3.500-4 0.050 before galvanizing so a standard tap can be used on the nut.
3.750-4 0.050 Manufacturers of threaded parts recognize that special procedures must be
3.750-4 0.050 followed in their plants when certain items are to be galvanized. Following
4.000-4 0.050 are some examples:
• Low carbon bars are recommended since high carbon or high silicon cause
* For metric overtapping a heavier, rougher galvanized coating on the threads.
allowances, see
ASTM A 563M, section 7.

18
• Hot formed heading or bending requires cleaning at the manufacturing
plant to remove scale before threading. Otherwise, over-pickling of
threads will result during scale removal.
• 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.
• Standard sized threads are cut on the bolt, while standard sized nuts are
retapped oversize after galvanizing.

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 Figure 27
inch (1.5 mm) must be allowed to ensure full freedom of move-
ment after the addition of zinc during galvanizing (see
Figure 27).
Whenever possible, work should be designed
so that hinges can be bolted to frames, covers,
bodies, and other items after galvanizing.
Hinges should be galvanized separately and
assembled after galvanizing. All hinges to be gal-
vanized should be of the loose pin type. Before Provide 1/16 inch mini-
galvanizing, any adjacent edges should be ground mum radial clearance
to give at least 1/32 inch (0.8 mm) clearance (see
Figure 28). The pin holes can be cleared of excess
zinc during assembly. After hinges are galva-
nized, it is recommended that an undersized pin be used to compensate for the
zinc picked up during galvanizing. If desired, the pin holes in the hinges may
Figure 28
be reamed 1/32 inch (0.8 mm) after galvanizing to permit the use of regular size
pins.
On hinges, all adjacent surfaces must be ground 1/32 inch on both pieces to
allow for thickness increases. Grinding both pieces is necessary.
At times, moving parts must be reheated in order for them to work freely.
Heating may cause discoloration of the galvanized coating near the reheated
area. This discoloration does not affect the corrosion protection of the galva-
nized surface.

1/
32

19
Figure 29
MARKING FOR IDENTIFICATION
Identification markings on fabricated items
should be carefully prepared before galvanizing so
they will be legible after galvanizing and not jeopar-
STAMPED/WELDED TAG dize the integrity of the zinc coating.
SEAL-WELDED TO MEMBER D
DE
EL Do not use paint, grease, or oil-based markers to
W
apply addresses, shipping instructions, or job num-
bers on items to be galvanized. Pickling acids do not
remove oil-based paints and crayon marks, resulting
D D
DE PE in extra work for the galvanizer to properly prepare
EL ED AM
W ST
D/ CH the steel for galvanizing.
PE TTA RE
AM A I
ST TAG BY W Detachable metal tags or water-soluble markers
should be specified for temporary identification.
Figure 30 Where permanent identification is needed, there are three suitable alterna-
tives for marking steel fabrications to be hot-dip galvanized. Each enables items
to be rapidly identified after galvanizing and at the job site (see Figures 29
through 31).
Stamping the surface of the item using die-cut deep stencils or a 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 (13 mm)
high and 1/32 inch (0.8 mm) deep to ensure readability after galvanizing.
This method should not be used to mark fracture critical members (see
Figure 30).
A series of weld beads may also be used to mark letters or numbers direct-
Identify by stamping the ly on the fabrication. It is essential that all welding flux be removed in
surface of the item using order to achieve a quality galvanized coating (see Figure 29).
die-cut deep stencils or a
series of punch marks 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 galva-
Figure 31 nized and the wire will not freeze to the work when the molten zinc solid-
ifies. If desired, tags may be seal-welded directly to the materials (see
Figure 31).

REPAIR OF DAMAGED GALVANIZED SURFACES

Sometimes hot-dip galvanized coatings are damaged by excessively
rough handling during shipping or erection. Welding or flame cutting also
may result in coating damage. When limited areas are damaged, the use of
low melting-point zinc alloys, inorganic zinc-rich paints, or zinc metallizing
is recommended to protect the area. ASTM A 780, Practice for Repair of
Damaged and Uncoated Areas of Hot-Dip Galvanized Coatings, details
A deep stenciled steel tag
acceptable methods of reconditioning damaged areas.
firmly affixed to the fabrica-
tion with a minimum #9
gauge steel wire

20
AFTER-GALVANIZING CONSIDERATIONS
Wet Storage Stain Prevention
When galvanizers know that galvanized items will be stacked or stored
in humid environments, application of a post-galvanizing treatment
designed to inhibit wet storage stain, or white rust, often is suggested.
Wet storage stain is an attack on the galva-
nized coating that produces white compounds of
zinc oxide and zinc hydroxide. It is caused by
retention of condensation or runoff water
between contacting surfaces when air circulation
is poor. While the attack is frequently superfi-
cial, its appearance may be objectionable. The
galvanizer can discuss simple treatments that
can be applied at the galvanizer’s facility. AGA’s
publication, Wet Storage Stain, provides more
details about the prevention and treatment of wet
storage stain.
Painting
If the steel is scheduled to be painted after
galvanizing, it is important to alert the galvaniz-
er in order to eliminate any post-galvanizing
treatments such as water quenching that inter- Poor storage, shown here,
fere with paint adhesion. can lead to wet storage
stain
Painting over galvanized steel, also known as a duplex system, is fre-
quently used for aesthetics, identification or warning, camouflage, or added
corrosion resistance under severely corrosive conditions.
The success of a duplex system largely
depends on the surface preparation of the galva-
nized steel immediately prior to painting.
Notifying the galvanizer of plans to paint aids in
the success of a duplex system.
For more information about painting over
galvanized steel, refer to the AGA publication
Duplex Systems: Painting Over Hot Dip
Galvanized Steel.

Painting over galvanized

steel provides a highly cor-
rosion-resistant coating and
aesthetic flexibility

21
 RELATED SPECIFICATIONS
American ASTM A 36 Specification for Structural Steel
Society of ASTM A 123 Specification for Zinc (Hot-Dip Galvanized) Coatings on
Testing and Iron and Steel Products
ASTM A 143 Practice for Safeguarding Against Embrittlement of Hot-
Materials Dip Galvanized Structural Steel Products and Procedure
for Detecting Embrittlement
ASTM A 153 Specification for Zinc Coating (Hot-Dip) on Iron and
Steel Hardware
ASTM A 384 Practice for Safeguarding Against Warpage and
Distortion During Hot-Dip Galvanizing of Steel
Assemblies
ASTM A 385 Practice for Providing High Quality Zinc Coatings (Hot-
Dip)
ASTM A 563 Specification for Carbon and Alloy Steel Nuts
ASTM A 572 Specification for High-Strength Low-Alloy Columbium-
Vanadium Steels of Structural Quality
ASTM A 767 Specification for Zinc-Coated (Galvanized) Steel Bars for
Concrete Reinforcement
ASTM A 780 Practice for Repair of Damaged and Uncoated Areas of
Hot-Dip Galvanized Coatings
ASTM B 6 Specification for Zinc
ASTM D 6386 Practice for Preparation of Zinc (Hot-Dip galvanized)
Coated Iron and Steel Product and Hardware Surfaces for
Painting
ASTM E 376 Measuring Coating Thickness by Magnetic-Field or
Eddy-Current (Electromagnetic) Test Methods

Canadian G 40.8* Structural Steel with Improved Resistance to Brittle

Fracture
Standards G 40.12* General Purpose Structural Steel
Association *Superseded by G 40.20/G 40.21 General Requirements
for Rolled or Welded Structural Quality Steel
G 164 Galvanizing of Irregularly Shaped Articles

Further Reading Duplex Systems: Painting Over Hot Dip Galvanized Steel
American Galvanizers Association, Aurora, Colo., 1998.
and Related Inspection of Products Hot Dip Galvanized After Fabrication
Materials American Galvanizers Association, Aurora, Colo., 1999.
Recommended Details for Galvanized Structures
American Galvanizers Association, Aurora, Colo., 1990.
Welding Galvanized Steel
American Galvanizers Association, Aurora, Colo., 1992.
Wet Storage Stain
American Galvanizers Association, Aurora, Colo., 1997.

22
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