Design for Hot Dip Galvanizing

General Design Guidelines

Welded pipe sections
Closed sections must never be incorporated. Sections should be
Certain rules must be followed when interconnected using open mitered joints as illustrated in “A” or
designing components for galvanizing, but interconnecting holes should be put in before fabrication, as in “B”.
the rules are readily applied and in many Alternatively, external holes may be positioned as shown in “C”, a
cases they are simply those which are method which is often preferred by the galvanizer, since quick
visual inspection shows that the work is
good practice to ensure maximum safe for galvanizing.
corrosion protection.
Pipe ends must be left open,
or provided with removable
Tubular fabrication,
Adoption of these guidelines will ensure plugs. B
the safety of galvanizing personnel, ease hollow structurals Holes 3/4 inch
Small tubular fabrications or larger
the galvanizer’s task and produce Vent holes must be provided, preferably 25% of must be vented with holes
internal diameter for sections up to 6 inches in not less than 3/8” in diameter.
optimum quality galvanizing. If in doubt diameter. This percentage can be dependent on
concerning preferred design details, the shape of the fabrication, and consultation with
Galvan at the design stage is recommended.
check with Galvan Industries, Inc. A C
Holes 3/8
Size and Shape Alternatively, V-notches can be cut in ends Open mitered joints inch or
larger
of members before welding.

Almost any component can be galvanized

by designing and building modules to Close unwanted vent holes with lead plugs filed flush with surrounding material.
suite available galvanizing facilities, but it
is wise to check work dimensions with
your galvanizer at an early design stage. Overlapping surfaces Vent hole is 1/4” in diameter for
Avoid narrow gaps between plates, every 15 sq. in. of overlap area.
overlapping surfaces, and back-to-
back angles and channels.
Safety
When small overlaps are
unavoidable, seal edges by welding.
Vessels and hollow sections including
those in smaller diameter tubular When left unsealed, small overlaps
may trap pickle acid which can later
fabrications must vented to atmosphere escape to discolor or damage the
for the safety of galvanizing personnel and g g
galvanized coating. A. Satisfactory

to prevent possible damage to the article.

At galvanizing temperatures, moisture
trapped in closed sections is converted Large overlapping surfaces
If contacting surfaces cannot be avoided, a
rapidly to superheated steam, generating hole 1/4” in diameter for every 15 sq. in. should
explosive forces unless vented. be placed in one of the members, and the
perimeter of the contacting area should be
continuously welded. The vent hole in one
About Galvan Industries, Inc. member will ensure the safety of galvanizing
personnel and prevent damage to the article.
B. Satisfactory C. Unsatisfactory
Since 1958, Galvan Industries has
provided the ultimate in corrosion control
to steel fabricators and manufacturers. Vent holes least 2” in diameter
Tanks and closed vessels for each 17 cubic feet.
The first hot-dip galvanizing operation in When internal and external surfaces are to be galvanized, at least
the Carolinas, the company has grown to one filling and one draining hole must be provided with a vent
diagonally opposite to allow the exit of air during emersion. Holes
become the largest capacity contract should be at least 2” in diameter for each 17 cubic feet. Internal
galvanizer in the Southeast. baffles should be cropped. Manholes should finish flush to prevent
trapping excess zinc.

For details, or to place an order, call When vessels are not

vent to be galvanized inside,
Galvan Industries at 1-800-277-5678, extended vent pipes
Fax (704) 455-5215; e-mail: must be fitted, to allow Internal baffles cropped top and bottom to
air to exit above the
[email protected]. level of molten zinc in
allow free passage of zinc and to prevent
trapping of air. Flanges should finish flush
the galvanizing bath. inside.

Vent pipes connect tank

PO Box 369 interior to atmosphere.
7320 Millbrook Road
Harrisburg, North Carolina 28075 cropped internal baffle
www.galvan-ize.com
Strengthening gussets and webs
Welded strengthening gussets and webs on columns and beams,
and strengthening gussets in members fabricated from channel End plates
sections should have corners cropped or holed. Provide holes at least 1/2 inch in
1. to prevent the entrapment of air in pickets and corners diameter in end plates on rolled steel
allowing complete access of pickle acids and molten zinc to shapes, to allow access of molten zinc in
the entire surface of the work, and the galvanizing bath and drainage during
2. to facilitate drainage during withdrawal from acid and withdrawal.
anizing bath
rinse tanks, and from the galvanizing

Alternatively, holes
placed as close to
corners as possible.
1/2-inch holes placed as close
to the corners as practical.
cropped corners

cropped gussets

Clearance for moving parts Distortion

Drop handles, hinges, shackles, shafts, and spindles Distortion can be prevented or minimized by:
require provision of minimum radial clearances as detailed 1. Use of symmetrical designs
in the table below, to allow for the thickness of the 2. Use of relatively uniform sections
galvanized coating. 3. Use of accurately preformed members to avoid locked-in stresses
4. Use of balanced or staggered welding to avoid locked-in stresses
Shaft diameter Minimum clearance 5. Large, open fabrications and tanks may require temporary cross
up to 3/8” 1/32” stays to prevent distortion during galvanizing.
3/8” to 1” 1/16”
More than 1” 1/16” to 3/32” Thick angle
Use of symmetrical
sections minimizes
distortion during
galvanizing.

Internal threads and nuts Avoid combining

must be tapped oversize after Clearance thick and thin
galvanizing to accommodate materials. Thin sheet
the thickness of the galvanized
coating on the stud or bolt.

Galvanized coating on the

nut provides corrosion
protection for the internal
thread. Materials suitable for galvanizing
Bolt or Minimum All ferrous materials are suitable including stainless steel parts and
stud overtapping sound, stress-free castings.
diameter female thread
up to 7/16”” 0.016” Brazed assemblies may be galvanized, but check first with Galvan. Soft
3/8” to 1” 0.021” soldered assemblies cannot be galvanized.
Over 1” 0.031”

Identification markings Combinations of

Forr permanent identification, ferrous surfaces
usee heavily embossed, punched Fabrications containing a
or welded lettering, For combination of castings and
mporary identification, use
temporary other steels, and rusted or mill
avily embossed metal
heavily scaled surfaces must be
gs wired to the work.
tags abrasive blast cleaned before
galvanizing.

Weld ends only

Weld slag
Weld slag must be removed by
chipping, grinding, abrasive blast
cleaning flame cleaning or using
a pneumatic needle gun.

Provision for handling

Do not use paint. Work not suitable for handling with chains, baskets, hooks or jigs must be
Seal-welded tag
provided with suspension holes or fittings. If in doubt, check with Galvan.

Galvan Industries, Inc. • Phone 1.800.277.5678 • Fax 704.455.5215 • [email protected]