Design & Fabrication

2
Design & Fabrication
3
4
Materials Suitable for
Hot-Dip Galvanizing
5
Hot-Dip Galvanized Fasteners
Hot-dip galvanized
fasteners are
recommended for joining
HDG structurals
6
The Galvanizing Reaction
Click to play animation
Flash Player Required
7
Typical Zinc-Iron
Alloy Layers
Irregular Zinc-Iron
Alloy Layers
Coating Microstructures
8
Steel Reactivity
9
Coating Growth
Other factors that effect the growth of the
coating
Other chemical components of steel besides
silicon:
Phosphorus
Manganese
Steel Surface Roughness
10
Appearance of HDG
11
Combining Different Materials
12
Dissimilar Thicknesses
Different thickness
Zinc bath
temperature at
different times

Similar thickness
Maintain original
shape
13
Weld Rod Chemistry
Just as the base steel
chemistry influences
coating growth, so
does the chemistry of
the weld rod.
Si < 0.04% or
0.15 < Si < 0.22
14
Welding Procedures
& Flux Removal
15
Seal-welding
The viscosity of
molten zinc prevents
it from entering gaps
of 3/32 and smaller.
Solutions used to
clean the steel can
penetrate small gaps

16
Welding after Galvanizing
American Welding Society
Remove coating 2-4 away from weld area
Repair area using ASTM A 780
Welding Galvanized Steel
Slower welding speeds, higher energy input
Damage galvanized coating in the Heat-
Affected Zone (HAZ), repair is necessary
17
Cold-Working
Severe cold-working
of steel increases the
likelihood for strain-
age embrittlement.
ASTM A 384
Keep bend radii as
large as possible, but
at least 3 times the
section thickness

18
Galvanizing Oversized Pieces
Progressive Dipping
19
Material Handling
20
Venting & Drainage
Cropped Corners
(Preferred)
Holes Close to Corners
(Alternatively)
21
Cropped Corners
22
Venting & Drainage
Drain
Vent
23
Venting & Drainage: Base Plates
24
Venting & Drainage
Vent Drain
25
Venting & Drainage: Tanks
Vent diagonally opposite fill hole
Cropped internal baffle (top & bottom)
26
Venting & Drainage: Tanks
27
Examples of Good Tank Design
Good
Design
Poor
Design
Flush interiors
provide good
drainage
Trapped
Zinc
28
Minimizing Distortion
29
Temporary Bracing
Large diameter, thin-walled pipe may require
temporary bracing to prevent possible distortion.
Temporary Bracing
30
Castings
Castings usually
require some form of
mechanical cleaning
to remove
encapsulated sand
particles from
crevices.
31
Marking
32
Masking
Compound used to prevent the galvanized
coating from forming in certain areas of the steel
(a.k.a. stop-offs)
Threads
Areas to be welded
Studs
Not 100% effective and adds significant labor in
application and removal after galvanizing