Technical advice on Galvanizing

Our expert team can work with you to  optimise the design of your steel components and achieve the most consistent galvanizing finish. With over 35 years of hot dip galvanizing experience, we know how to get the best results.

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Small changes can make a big difference

Our customer relations team are happy to review your work and provide advice to achieve the best galvanizing results. Simply fill in the contact form to the right or click on the button to contact us.
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Optimising Design for galvanizing

Consistently good galvanized steel products will be produced when the design and fabrication take into account the way galvanizing is done.  If we can give advice to the design engineer, materials engineer, specifier and fabricator it will ensure  high quality galvanized products, minimum cost and faster delivery.

Steel items to be processed must fit into the pre-treatment tanks and galvanizing bath. However, this is not limited to the physical dimensions of the bath, because we can use multiple dipping techniques to galvanize products larger than the bath.

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 the design engineer should ensure that the pieces can be suitably fabricated for high quality galvanizing . Adopting the following design practices will ensure the safety of galvanizing personnel, reduce coating cost, and produce optimum quality galvanizing .

Molten zinc and all processing solutions must be able to enter and drain from fabrications without difficulty

Your work may require additional holes for hanging, venting and draining. Just imagine you are dipping your work into a large tank of water and the work has to go completely under the water without any air trapped inside. Then, when the work is lifted out, all of the water has to drain out again. This is what needs to happen to allow for galvanizing. Work with openings to prevent air pockets and to allow full draining is the basis of good design for galvanizing. Click the below image to view and print the design for galvanizing wall chart

Advice on Design for Galvanizing

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Galvanizing very large items

If your work is too big to fit into the galvanizing bath in one dip then it may be possible to galvanize with double-end or double-depth dipping. This procedure involves lowering the item into the bath so that half or more of its length or depth is dipped in the zinc bath. Once the zinc coating is applied to the first “half” of the item, it is raised from the bath and turned so the remaining ungalvanized part can be dipped in the bath. Please note that in this procedure an overlap of zinc coating will occur and may cause a visible “join line”.
Advice on Double-end dipping

Double-end dipping

Have questions about whether your work can be galvanized by double-end dipping?

If you have product that is over 12.5 metres in length or 3.2 metres in height, contact our Customer Service team for advice.

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Use modular design for structures that are too large to galvanize even with multiple dips

By building large structures in modules for later assembly, using bolts or welding, they can be of unlimited size. Modular design techniques often produce economies in manufacture and assembly through simplified handling and transport.
Weld areas in structures assembled by welding after galvanizing must be properly repaired to give corrosion protection equivalent to the galvanized coating.

Safety for Galvanizing

Advice on Galvanizing DangersDuring galvanizing, improperly designed structures can explode and cause serious injuries to galvanizing personnel. Explosions are caused by moisture trapped inside pockets turning to super heated steam as it enters the molten zinc galvanizing bath.

For the safety of galvanizing personnel and the quality of your job, vessels or hollow structures which incorporate enclosed sections must have provision for adequate venting and draining for galvanizing .

Correct venting ensures that the entire internal surface of work is properly galvanized and fully protected. This also ensures that lighter items will not float in the zinc bath due to trapped air pockets. Closed vessels which are not to be galvanized inside, such as certain types of heat exchanger, must be provided with snorkel-type vent pipes long enough to project above the level of pickling, fluxing and galvanizing baths when the work is fully immersed. Contact our customer service staff for more information on the venting requirements.

Download Safety Wall Chart

Advice on Safety in Venting for Galvanizing Wall Chart

Galvanizers Association

For more galvanizing information on the web

Visit the Galvanizers Association of Australia web page.
Galvanizers Association