Hot Dip Galvanizing – Design booklet

Source: AGA (American Galvanizers Association)

Introduction
When designing or fabricating steel, there are often certain requirements one must consider. Hot-
dip galvanized steel has its own set of design and fabrication considerations one should be
familiar with before the start of the project. Incorporating the design and fabrication
recommendations will help ensure the best quality coating and most successful projects. The
design and fabrication considerations for hot-dip galvanizing differ from other coatings, but are
simple to follow once you become familiar with them.

Whether designing a galvanized project for the first time, or the 100th time, the key component
to a successful project is communication. It is important to have communication with the
galvanizer very early in the design phase. Early communication may optimize turnaround time,
minimize cost, clarify expectations, and ensure top-quality hot-dip galvanized steel.

Design Considerations
When designing steel for hot-dip galvanizing, certain considerations must be taken into account.
Open communication with the steel fabricator and galvanizer early in the design process will
ensure everyone’s expectations are the same and ultimately met. Adopting the design practices
here, along with those in ASTMA 385 Practice for Providing High Quality Zinc Coatings, will
produce top-quality galvanized steel while reducing coating costs, speeding up turnaround times,
and ensuring the safety of galvanizing personnel.
Bend Diameters for Steel to be Galvanized

Protection against corrosion begins at the drawing board. The corrosion protection system
decided upon must be factored into the design of the product. When the decision is made to hot-
dip galvanize, the design engineer should ensure that the pieces can be suitably fabricated for
highest-quality galvanizing.

Many structures and parts are fabricated using cold-working techniques, including bending. It is
important to understand that, because bending-induced stresses may be released during the
galvanizing process, changes in structural shape and/or alignment (warping and distortion) may
result.

Best practice is to keep bend diameters as large as possible when parts are bent before
galvanizing. A minimum bend radius of three times the section thickness will promote optimum
quality galvanized coating properties. Additional information may be found in ASTMA 143.

Since steel being galvanized is going through a temperature cycle from ambient temperature to
molten zinc’s temperature of more than 800º F (420º C) and then back down to ambient
temperature, mechanical property changes can occur, including an aging of areas on steel parts
where there is a significant amount of cold-working, such as bends. This aging is called “strain-
age embrittlement.”

When the cold-worked and galvanized part is later put in service, a fracture of the bend may
occur. Fractures characteristically occur at the toe of the bend where the highest induced stress
resides.

If bends sharper than three times the section thickness are necessary, thermally heat-treat (stress-
relieve) the article after bending – prior to galvanizing – in order to reduce the retained stress
level in the steel article. To stress-relieve, the part should be heat-treated at 1100º F (593º C) for
one hour per inch (2.5cm) of section thickness.
Considerations for Steel Cold‐worked Prior to Galvanizing

Many structures and parts are fabricated using cold-working techniques (bending, hole-punching,
rolling, shearing). Severe cold-working increases the incidence of strain-age embrittlement. The
effects of strain-age embrittlement may be accelerated by the galvanizing process, because aging
is relatively slow at ambient temperatures but more rapid at the elevated temperatures
encountered in the galvanizing process. (See also Bend Diameters).

In order to minimize the effects of galvanizing on cold-worked fabrications, consider these

guidelines:

• Select steel with carbon contents below 0.25%,

• Specify aluminum-killed steels, which show less susceptibility to embrittlement
than do silicon-killed steels,
• Avoid designs with notches, which increase stress; flame-cutting or sawing is
preferred, particularly for heavy sections,
• Drill, rather than punch, holes in material thicker than 3/4” (19 mm). If holes must
be punched, they should be punched undersize and then reamed an additional
1/8” (3 mm) overall, or drilled to size. Material between 1/4”- 3/4” (6.5-19 mm)
thick is not seriously affected by cold-punching if the punching is done under
good shop practice. Materials up to 1/4” (6.5 mm) thick that have been cold-
punched do not need stress-relieving operations before galvanizing,
• Choose steels with low transition temperatures, since cold-working raises the
ductile-brittle transition temperature and the temperature cycle of galvanizing
may raise it even further.

Where cold-working cannot be avoided, stress-relieve the part at 1100 F (593 C) for one hour per
inch (2.5 cm) of material thickness.

Cold-working also must be taken into consideration with respect to another potential mechanical
change that may occur during galvanizing’s chemical cleaning process: hydrogen embrittlement.
During the chemical reaction between steel, rust, and the chemicals used in the pickling stages of
the galvanizing process, hydrogen is produced, which is then absorbed by the steel. Upon
immersion into the molten zinc, the hydrogen is expelled as gas. If the steel has been severely
cold-worked in a very small region, the hydrogen can be trapped in the steel, causing hydrogen
embrittlement when the part is put under stress during use.

Hydrogen embrittlement is of concern only when the ultimate localized tensile strength of the
cold-worked steel exceeds 150 ksi (1100 MPa). Mechanically cleaning of localized high-strength
steel areas avoids hydrogen embrittlement.

Dissimilar Steel Chemistries

Most ferrous materials are suitable for hot-dip galvanizing. Cast iron, malleable iron, cast steels,
hot-rolled steel, and cold-rolled steels all can be protected from corrosion with zinc applied in the
hot-dip galvanizing process. Weathering steel and certain stainless steels (300 series) also can be
galvanized.

It is important to understand that the chemical composition of the material being galvanized can
affect coating characteristics. However, corrosion protection typically is not affected by these
coating characteristic differences.

Fabrications with varying steel chemistries can form the galvanized coating’s iron-zinc
intermetallic layers at different rates, resulting in a non-uniform coating appearance. Again,
corrosion protection is not affected by non-uniform appearances.
Variations in color and texture do not affect the corrosion protection provided by the galvanized
coating. It is important to understand that upon normal weathering in the environment, the entire
coating commonly evolves to a uniform appearance.

While the overwhelming determinant of coating thickness is steel chemistry, varying surface
conditions and/or different fabrication methods also can affect coating appearance. This is
because different parameters for pickling (immersion time, solution concentrations,
temperatures) and galvanizing (bath temperature, immersion time) are required for:

• Excessively rusted surfaces

• Machined surfaces
• Malleable iron
• Hot-rolled steel
• Cold-rolled steel
• Castings, especially with sand inclusions
• Steel with relatively high levels of carbon, phosphorus, manganese, and/or silicon

To allow for optimum coating development when combining dissimilar steels in a single
fabrication, consider these guidelines:

• Galvanize dissimilar steels separately and assemble after galvanizing

• Avoid the use of old steel with new steel, or combining castings with rolled steel in the
same assembly
• Avoid using excessively rusted, pitted, or forged steels in combination with new or
machined surfaces; if this is unavoidable, a thorough abrasive blast-cleaning of the
assembly (normally before any machining is done) will allow for a more uniform
galvanized coating.

Stainless steels in the 300 series can be galvanized because they contain nickel, which is
necessary to initiate reaction between the steel and the zinc. Stainless steels in the 400 series do
not contain nickel and cannot be galvanized.

Weathering steel also can be galvanized, although it typically contains relatively high amounts of
silicon and will develop thicker coatings that are usually matte gray in finish. The corrosion
protection provided by galvanizing is unaffected by coating appearance.

Dissimilar Metals in Contact with Galvanized Steel

Hot-dip galvanized steel is well suited for use in a variety of environments and fabrications, and
sometimes is placed in contact with different metals including, among others, stainless steel,
aluminum, copper and weathering steel.

When two different metals are in contact in a corrosive environment, one of the metals
experiences accelerated galvanic corrosion while the other metal remains galvanically protected.
Metals near each other in the galvanic series have little effect on each other. Generally, as the
separation between metals in the series increases, the corroding effect on the metal higher in the
series increases as well.

Relative surface areas of contacting dissimilar metals are also relevant in determining which
metal exhibits accelerated corrosion. It is undesirable to have a large cathode surface in contact
with a relatively small anode surface.

Galvanic corrosion occurs when two different metals are in contact in a corrosive environment:
one of the metals experiences an accelerated corrosion rate. The contacting metals form a
bimetallic couple because of their different affinities (or attraction) for electrons. These different
affinities create an electrical potential between the two metals, allowing current to flow.

The metal higher in the galvanic series of metals, the “anode,” provides protection for the metal
lower in the series, the “cathode.”

As can be seen from the galvanic series, zinc protects the lower-order steel.

With respect to contacting surface areas of the two metals, although the corrosion current that
flows between the cathode and anode is independent of area, the rate of penetration at the anode
does depends on current density. Thus, a large anode area in contact with a relatively small
cathode area is generally not problematic. Regardless, environmental conditions remain large
determinants of corrosion rates.
Pre‐galvanizing Considerations for Control of Distortion & Warping

When the decision is made to hot-dip galvanize, the design engineer should ensure that the
pieces can be suitably fabricated for highest-quality galvanizing. Best practice suggests steel to
be galvanized should be symmetrical and of similar thickness.

With proper consideration and understanding of how the hot-dip galvanizing process affects
steel, asymmetrical designs or structures containing sections of unequal thickness can be
successfully galvanized, as can fabrications where cold-working techniques (bending, hole-
punching, rolling, shearing) are employed.

Steel being galvanized progresses through a temperature cycle upon immersion into and
withdrawal from the galvanizing bath. Because parts are immersed at an angle, uneven heating
occurs, creating a temperature profile along the part being galvanized. This temperature profile
allows the steel’s internal stresses to be relieved at different times in the immersion cycle. These
stresses may cause changes in shape and/or alignment (distortion and warping).

The following steps can be taken to minimize this risk:

•
• Use assembly parts that are of equal or near-equal thickness, especially at joints
• Use standard rolled shapes
• Use symmetrically rolled sections rather than angle or channel frames; I-beams
also are preferred to angles or channels
• Galvanize a channel frame with a plate separately and bolt or weld post-
galvanizing
 • Bend members to the largest acceptable radii to minimize local stress
concentration
• Accurately pre-form members of an assembly so that it is not necessary to force,
spring, or bend them into position during joining
• Avoid designs that, because of size, require more than one dip into the molten
zinc bath (“progressive galvanizing,” sometimes called “double-dipping”)
• Relieve welding- or cold-working-induced stresses by heat-treating the part at
1100 F (590 C) for one hour per inch (2.5 cm) of section thickness

Consult your galvanizer regarding the use of temporary bracing or reinforcing.

The guidelines for safeguarding against warping and distortion during hot-dip galvanizing of
steel assemblies are outlined in ASTMA 384.

Part Identification
One of the many benefits of hot-dip galvanizing is that coating integrity is readily apparent: zinc
will metallurgically bond only to clean steel. Coating uniformity is visible as the work is
withdrawn from the molten zinc bath. Surface preparation is of paramount importance in
providing optimum quality zinc coatings.

There are a variety of products used for marking and identification that are not removed during
the chemical cleaning phases of the galvanizing process, including paint, grease and oil-based
markers. Therefore, it is advisable to use other forms of identification including:

• Temporary identification – detachable metal tags (metal barcode tags are also
available) or water-soluble paint or markers
• Permanent identification – stamping, weld beads, and deep stencil marking

Temporary Identification

The most common form of temporary identification is the use of detachable tags. Whether
barcode tags or stamped/stenciled tags, these are often preferred as they stay affixed to the part
throughout the process, but can be removed once the steel is delivered to the job site. Because
they are still readable after all phases of the galvanizing process, tags can facilitate turnaround
time and eliminate lost parts while not affecting the aesthetics of the steel once erected.

Another increasingly popular temporary identification method is the use of water-soluble paint or
markers. The markings will dissolve during the chemical cleaning process at the galvanizer’s
plant. Unlike other markings, which cannot be removed during the cleaning process, this ensures
a fully coated part, but the markings will not be visible after withdrawal from the galvanizing
bath. Often this is acceptable and even preferred; however, sometimes identification is still
needed when delivered to the job site, and thus this temporary marking method would not be
recommended.

Permanent Identification

• Stamping the surface of the item using die-cut deep

stencils or a series of punch-marks toward the center of the piece. The marks
should be placed in a consistent position on each member and should be a
minimum of 1/2” (13 mm) high and 1/32” (0.8 mm) deep to ensure readability
after galvanizing.
• A series of weld beads to mark letters or numbers directly onto the fabrication. It
is essential that all weld flux be removed in order to achieve highest-quality
galvanized coatings.
• Deep stenciling a steel tag (minimum #12 gauge) or a metal barcode tag and
firmly affixing it to the fabrication with a minimum #9 gauge steel wire. The tag
should be wired loosely to the work with a gap of 1/8” (3 mm) so that the area
beneath the wire can be galvanized and the wire does not freeze to the work
when the molten zinc solidifies. If desired, tags may be seal-welded directly onto
the materials.
In order to lower costs and minimize turnaround times, abrasive-blast-cleaning required to
remove marking products not removed by chemical cleaning solutions should be performed at
the fabrication facility.

Masking
In some projects designed for hot-dip galvanizing, there is a desire or requirement for
ungalvanized areas on a steel part. Because hot-dip galvanizing is a total immersion process,
normally all surfaces are cleaned and coated with corrosion-inhibiting zinc. To avoid coating
growth in certain areas, steel masking can be employed.

Because zinc only reacts with clean steel, treating a portion of the steel surface with a material
not removable with chemical cleaning, or masking, can leave areas purposely ungalvanized.
However, masking is not an exact science and additional work may still be required to remove
unwanted zinc.

In most cases, it may be easier to grind off the zinc coating after galvanizing than to mask the
material. There are a number of materials used to mask steel to be galvanized – some more
successfully than others. The American Galvanizers Association has recently conducted a study
evaluating the effectiveness of common commercial products to mask the surface.

Material Handling Considerations

Because hot-dip galvanizing is a total immersion process, material is moved throughout the
facility by overhead cranes and lowered into surface preparation and galvanizing baths.
Galvanizers use a number of chains, wire, and racking fixtures to effectively hang the steel
which are then attached to hoists and cranes to move the steel through the cleaning solutions and
molten zinc.

To ensure proper handling, lifting points should be incorporated into the fabrication design. The
lifting points can be temporary for processing or permanent in the design of the steel. Large
assemblies are usually supported by chain slings or lifting fixtures, while special jigs and racks
are often used to simultaneously galvanize large numbers of similar items. Perforated baskets are
used to galvanize smaller articles such as fasteners and anchors.
Providing lifting points is also important if aesthetics and coating finish are a high priority.
Chain, wire and other holding devices used to support materials being galvanized can leave
markings on the galvanized item, if special lifting supports or holes are not provided. These
markings are usually completely galvanized; and thus not a reason for rejection of the coating.
Uncoated areas due to material handling, removal of temporary lifting points, or chain marks can
be touched up for aesthetic reasons, if desired.

In addition to lifting points, weight of the fabrication should also be considered. Because of the
set up of the handling equipment and maximum load capacities, best practice is to consult the
galvanizer if you plan to galvanize extremely heavy fabrications to ensure effective and efficient
handling.

With respect to providing lifting points, consider the following:

• Where possible, lifting points (see illustration below) should be provided at the quarter
points for symmetrical parts; this avoids chain- or wire-marks on the sides of the parts
• Holes may be included in the design to allow the galvanizer to hang materials from
overhead fixtures

Galvanizing Moving Parts

The galvanizing process involves coating steel with molten zinc. Logically, the
molten zinc metal solidifies as it cools to form the metallurgically bonded corrosion resistant
coating. As the zinc solidifies it can cause moving parts such as drop handles, shackles, shafts,
and hinges to freeze together.
To ensure moving parts’ full range of motion is maintained, best practice is to galvanize prior to
assembly. If the moving parts must be galvanized after assembly, the design should incorporate
increased radial clearance and all hinges to be galvanized should be of the loose-pin type.

In order to allow for full range of motion when galvanizing moving parts, consider the following:

• Galvanized moving parts (such as drop-handles, shackles,

and shafts), a radial clearance of not less than 1/16” (1.5 mm) is suggested to ensure full
freedom of movement.
• After hinges are galvanized, it is recommended an undersized pin be used to account for
the zinc coating. If desired, hinge pinholes may be reamed 1/32” (0.8 mm) after
galvanizing to permit the use of regular-sized pins.
• If the galvanizing process freezes the moving parts, they can be reheated to allow them to
work freely. Reheating may cause localized discoloration of the galvanized coating, but
does not diminish the corrosion protection.

For optimum performance, assembling moving parts after galvanizing is almost always
preferred.

Designing Overlapped Surfaces

Once a decision has been made on what corrosion protection system will be utilized, minor
design adjustments are often necessary. One such instance when hot-dip galvanizing is the
design of overlapped and contacting surfaces. Many fabrications, including those with
overlapped surfaces, are well suited for the galvanizing process; however the design engineer
should ensure the pieces are fabricated for highest-quality galvanizing.

During the galvanizing process, steel is heated from ambient temperature to more than 800 F at a
rapid pace. To prevent trapped moisture or gas from flashing to steam during this heating
process, it is important to properly vent overlapping and contacting surface. Trapped moisture
can result in minor concerns such as localized uncoated areas or more significant damage
including rupturing the fabrication.

Consulting with your galvanizer before fabricating any overlapped piece is highly recommended
as their experience can help you decide between a completely seal-welded joint and a skip-
welded joint.

Consider the following best design practices to minimize issues when galvanizing overlapped
surfaces:

• Seal-welding ensures cleaning solutions cannot become trapped in the weld

area; if skip-welding is used, a gap of at least 3/32” (2.5 mm) must be provided.
• Cleaning solution salts can be retained in tight areas because they cannot be
adequately rinsed; the galvanized coating may be of good quality in adjacent
areas, but humidity encountered weeks or even months later may wet these
acid salts, causing staining of the surrounding galvanized coating.
• When overlapping or contacting surfaces cannot be avoided and are 3/32” (2.5
mm) or less, all edges should be completely seal-welded; zinc’s viscosity prevents
it from entering any space tighter than 3/32” (2.5 mm).
• There should be vent holes in the overlapped areas.

Additional recommendations can be found in the specification ASTMA 385.

Steel Residues

Steel surface preparation prior to galvanizing is of paramount importance in delivering complete,

optimum-quality zinc coatings. Some surface residues, such as mill lacquer, welding slag,
varnish, water-insoluble paints, adhesives, and sand used in the making of castings, are not
removed by the standard chemical cleaning methods involved in the galvanizing process.

Abrasive blast-cleaning, or other mechanical methods, should be used to remove residues that
cannot be chemically cleaned from the steel surface prior to delivering the steel to the galvanizer.
Typically, pipe and tube are coated with organic lacquers very difficult to remove by chemical
cleaning. When pipe comes from the steel supply house, the coating may be tough to identify.
Mill lacquers and varnish require extra effort and time to remove. To lower costs and minimize
turnaround times, any mechanical cleaning should be performed at the fabrication facility.
 There are numerous mechanical cleaning methods used to
remove these common residues, including:

• Abrasive blasting / wheel-abrading

• Barrel and vibratory finishing
• Brush- and hand-finishing
• Grinding and polishing

Contact your galvanizer when planning to use steel coated with lacquer or other products to
determine whether the coating can be removed at the galvanizing plant.

Steel Selection
Considerations for Selecting Steel to be Galvanized

Galvanized coatings are formed by a chemical process during

which steel and zinc metallurgically bond, forming a series of corrosion-inhibiting, highly
abrasion-resistant zinc/iron alloy layers.

The chemistry of the steel being galvanized influences the galvanized coating’s appearance.
Galvanized coatings on steels with common chemistries are typically shinier than are coatings on
reactive steels, which tend to produce matte gray coatings.

Additionally, high-strength steel chemistries for steels with ultimate tensile strength of 150 ksi
(1100 MPa) or more may cause hydrogen embrittlement of the steel after galvanizing.
Galvanized coatings are specified for their corrosion resistance. While a gray or matte
appearance may occur, the corosion protection afforded is no different than that provided by
shinier galvanized coatings. The corrosion resistance of matte coatings, mil for mil, is equal to
the more typical bright, shiny galvanized coating.

When possible, the galvanizer should be advised of the grade of steel selected in order to
determine whether to make accommodations in the galvanizing process.

Though most ferrous materials can be hot-dip galvanized, the chemical composition of the
material affects the characteristics of the galvanized coating.

Steel compositions vary depending on strength and service requirements. Trace elements in the
steel, such as silicon and phosphorus, affect the galvanizing process as well as the structure and
appearance of the galvanized coating. For example, certain elements present in the steel may
result in a coating composed almost entirely of zinc-iron alloy layers with little or no free zinc
layer.

Uniform, shinier coatings are produced by steels with the following chemistries:

• Levels of carbon less than 0.25%

• Levels of phosphorus less than 0.04%
• Levels of manganese less than 1.35%

Silicon (which is present in many steels commonly galvanized even though it is not a part of the
controlled composition of the steel) levels less than 0.03% or between 0.15% and 0.25% have
slower coating growth rates and produce more controlled coatings.

Phosphorus acts as a catalyst during galvanizing, resulting in rapid growth of the zinc-iron alloy
layers. This growth is difficult to control during the galvanizing process.

The characteristics of a coating made up primarily of zinc-iron alloy layers differ from those of a
typical galvanized coating. The zinc-iron alloy coating may have a matte gray appearance
because it does not have an outermost free zinc layer. A primarily zinc-iron alloy coating also
tends to be thicker than a typical galvanized coating. In extreme situations, as the thickness of
this type of coating increases, the coating may experience adhesion problems under external
stress.

Hydrogen embrittlement is of concern for steels of ultimate tensile strength of 150 ksi (1100
MPa). During the chemical reaction between steel, rust and the chemicals used in the pickling
stages of the galvanizing process, hydrogen is produced and absorbed by the steel. The very
small grain structure of high-strength steel prevents the hydrogen from being expelled during
immersion in the molten zinc. When put under stress in use, the steel may become brittle and
fracture.

Steel Surface Considerations

An essential component in creating high-quality galvanized coatings is proper steel surface

preparation. Steel must be near white metal clean for the metallurgical reaction between iron and
molten zinc to occur while in the galvanizing kettle. Some common residues found on steel as
well as surface conditions such as rough surfaces, heat-treating induced surface coatings, rust,
and other contaminants need to be removed prior to galvanizing, as they may inhibit the
formation of a consistent, uniform zinc coating.

It is important to understand the following:

• Rough steel surfaces resulting from fabrication methods or abrasive cleaning processes
may cause thicker zinc coatings,
• Casting surfaces must often be abrasively cleaned to remove sand that will prevent zinc
adhesion,
• Heat-treating steel often introduces a surface coating not removed by conventional
chemical cleaning processes and must be blast-cleaned,
• Steel surfaces that have varying degrees of rusting require varying amounts of time in the
cleaning stages of the galvanizing process, resulting in a variety of surface finishes,
• Welding slag adhered to the steel surface must be removed prior to galvanizing,
• Welding slag adhered directly onto the weld is easily removed by grinding; welding slag
adhered around the weld areas is more difficult to remove and usually cannot be ground
away; other means of mechanical removal, such as blasting, are used to remove this type
of welding slag,
• The use of cutting oil should be minimized when planning to galvanize; if cutting oil use
is unavoidable, the galvanizer should be consulted to determine if normal chemical
 cleaning processes will remove it from the surface or if another means of removal is
necessary.

When welding steel, flux and molten metal particles (weld slag) may splatter away from the weld
pool and adhere to the steel. Although these particles are commonly found on welded steel, they
must be removed prior to galvanizing, because the standard chemical cleaning processes used by
galvanizers do not remove welding slag. Additionally, if welding slag particles are carried over
to the zinc bath, they will cause coating defects and areas that may be susceptible to corrosion
problems. Welding slag particles not removed may lead to exposed areas unprotected from
corrosion.

Venting & Drainage Considerations for Steel to be Galvanized

In the hot-dip galvanizing process, steel is completely coated with corrosion-inhibiting zinc,
which forms a highly abrasion-resistant metallurgical bond with the base steel. In order to ensure
that all interior and exterior surfaces are protected from corrosion, entire steel fabrications are
lowered into and raised out of cleaning solutions, flux solutions, and molten zinc metal. In order
to facilitate interior and exterior cleaning and coating, it is necessary to provide holes in
fabrications to be galvanized.

The primary reason for vent and drain holes is to allow air to be evacuated from within and
around the fabrication, allowing it to be completely immersed in the cleaning solutions and
molten zinc and for the excess zinc and solutions to drain out and away from the part.

The secondary reason is that if fabrications to be galvanized are not properly vented, cleaning
solutions or rinse waters trapped in overlapping or contacting surfaces flash to steam. The
resulting pressure increase (up to 3600 psi [25MPa]) can rupture the fabrication. Additionally,
trapped moisture that flashes to steam can result in localized uncoated surfaces.

Because items being galvanized are immersed in and withdrawn from all cleaning solutions and
molten zinc at an angle, vent holes should be located at the highest point and drain holes at the
lowest point as mounted during the galvanizing process.

Proper Venting and Drainage Hole Placement and Dimensions for Tubular
Fabrications
 • Galvanizers need to be able to visually confirm and inspect venting in
complicated pipe assemblies, such as handrails.
• It is recommended tubular structures be completely submerged in one dip in the
galvanizing kettle to minimize potential internal coating problems, which,
because of the size and shape of the item, may be difficult to discover during
inspection.
• The diagrams above illustrate recommended designs for tubular fabrications and
hollow structures. The vent dimensions are the minimum require

Proper Venting and Drainage Hole Placement and Dimensions for Handrails

Paragraph numbers correspond with number references on the following illustration:

1. External vent holes must be as close to the weld as possible and must be 25% the
size of the internal diameter of the pipe, but not less than 3/8” (10 mm) in
diameter.
2. Internal holes should be the full internal diameter of the pipe for the best quality,
lowest cost galvanizing.
3. Vent holes in end sections or in similar sections must be 1/2” (13 mm) in diameter.
4. Ends should be left completely open. Any device used for field-erection that
prevents full openings on ends of horizontal rails and vertical legs should be
galvanized separately and attached after galvanizing.
Proper Venting and Drainage Hole Placement and Dimensions for
Rectangular Tube Truss

• Each vertical member should have two

holes at each end, 180 degrees apart, in line with the horizontal members. Hole
locations for the vertical members should be as shown in A and B.
• 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 cross-
sectional area.

End-plates – Horizontal

1. The most desirable fabrication is completely open.

2. If H + W = 24” (61 cm) or larger, the area of the hole, plus clips, should equal 25%
of the area of the tube (Area = H x W).

• If H + W is between 16” and 24” (41-61 cm), the area of the hole, plus clips,
should equal 30% of the area of the tube.
• If H + W is between 8” and 16” (20-41cm), the area of the hole, plus clips, should
equal 40% of the area of the tube.
• If H + W is less than 8” (20 cm), the tube should be left open.

Venting and Drainage Hole Placement and Dimensions for Pipe Truss 3” (8
cm) & Larger

Vertical Sections

Hole locations for the vertical members should be as shown in Examples A and B.
 • Each vertical member should have two holes at each end and 180 degrees
apart, in line with the horizontal members as indicated by the arrows. The size of
the holes preferably should be equal and the combined area of the two holes at
either end of the verticals (Areas C and D or Areas E and F) should be at least
30% of the cross-sectional area.

End-plates – Horizontal

1. The most desirable fabrication is completely open with the same hole diameter
as the tube’s internal diameter.
2. Equal substitutes would have openings as shown and would be at least 30% of
the area of the internal diameter.

Venting and Drainage Hole Placement/Dimensions for Pipe Columns &

Girders, Street Light & Transmission Poles

(With base-plates and with or without cap-plates)

Location of Opening

1. The most desirable fabrication is to have the end completely open, with the
same diameter as the section top and bottom.
2. This is an equal substitute if the full opening is not allowed.
3. This is an equal substitute if the full opening is not allowed.
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 base-plate: two half-
circles 180 degrees apart and at opposite ends of the pole.
Dimensions

Openings at each end must be at least 30% of the cross-sectional area of the pipe, for pipe 3” (8
cm) and greater and 45% of the cross-sectional area for pipe smaller than 3” (8 cm).

1. End completely open

2. Slot A = 3/4 inch (19 mm), Center Hole B = 3 inches (7.6 cm) in diameter
3. Half Circle C = 1 3/4 inch (4.5 cm) radius (examples of sizes for 6 inch (15 cm)
diameter section)
4. Oval Opening = 1 3/4 inch (4.5 cm) radius
5. Half Circle D = 5/8 inch (1.9 cm) radius

Proper Venting and Drainage Hole Placement and Dimensions for Box
Sections

The figure shows the location of holes and clipped corners, which must be flush. Using the
following formulas, the table shows typical sizes of holes.

Internal Gussets

• Space at minimum of 36” (91 cm)

Box Sections

• If H + W = 24” (61 cm) or larger, the area of the hole, plus clips, should equal 25%
of the cross-sectional area of the box (Area = H x W).
• If H + W is between 16” and 24” (41-61 cm), the area of the hole, plus clips,
should equal 30% of the cross-sectional area of the box.
• If H + W is between 8” and 16” (20-41 cm), the area of the hole, plus clips, should
equal 40% of the cross-sectional area of the box.
• If H + W is less than 8” (20 cm), leave completely open, with no end-plate or
internal gusset.
The table below is for square box-sections only. For rectangular sections, calculate the required
area and check with the galvanizer for positioning of openings.

Box Size Holes A-Dim (H + W)

48” (122 cm) 8” (20 cm)

36” (19 cm) 6” (15 cm)

32” (81.3 cm) 6” (15 cm)

28” (71 cm) 6” (15 cm)

24” (61 cm) 5” (12.7 cm)

20” (50.8 cm) 4” (10.2 cm)

16” (40.6 cm) 4” (10.2 cm)

12” (30.5 cm) 3” ( 7.6 cm)

Proper Venting and Drainage Hole Placement and Dimensions for Tapered –
Single Arm

The small end A should be completely open.

Pole Plate End

1. The most desirable fabrication is to have the end completely left open.
2. For acceptable alternatives, the half-circles, slots, and round holes must equal
30% of the area of the internal diameter of the pole end of the tapered arm for
3” (8 cm) and larger internal diameters. The opening must equal 45% of the area
of the pole end of the tapered arm if the internal diameter is less than 3” (8 cm).
Venting and Drainage Hole Placement/Dimensions for Enclosed & Semi‐
Enclosed Products

• When both internal and external surfaces are to be galvanized, at least one
fill/drain hole and one vent hole must be provided.
• The fill/drain hole should be as large as the design will allow, but at least 3” (8
cm) in diameter for each cubic yard (10 cm in diameter for each cubic meter)
of volume. The minimum diameter is 2” (5 cm).
• In tanks, internal baffles should be cropped on the top and bottom or provided
with suitable drainage holes to permit the free flow of molten zinc.

• Provide vent holes of the same size diagonally opposite the fill/drain hole. This
allows the air to escape.
• Manholes, hand holes, and openings should be finished flush inside to prevent
trapping excess zinc.
• Items such as vessels or heat exchangers galvanized on the outside only must
have snorkel tubes or extended vent pipes. 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 would provide a better-galvanized
product. If a change is needed to facilitate galvanizing, the least expensive time to make the
change is before fabrication.

Proper Hole Placement and Dimensions for Drainage

 • Where gusset plates are used, generously cropped corners provide for free
drainage. When cropping gusset plates is not possible, holes at least 1/2” (13
mm) in diameter must be placed in the plates as close to the corners as possible.
• To ensure unimpeded flow of solutions, all stiffeners, gussets, and bracing should
be cropped a minimum of 3/4” (19 mm).
• Provide holes at least 1/2” (13 mm) in diameter in end-plates on rolled steel
shapes to allow molten zinc access during immersion in the galvanizing bath and
drainage during withdrawal.
• Alternatively, holes at least 1/2” (13 mm) in diameter can be placed in the web
within 1/4” (6 mm) of the end-plate. To facilitate drainage, end-plates should
have holes placed as close to interior corners as possible.

Welding Before Hot-Dip Galvanizing

Unless a welded structure is too large for the galvanizing kettle, best practice is to weld prior to
galvanizing to ensure the entire structure is coated with corrosion-inhibiting zinc. Throughout
North America, variously sized hot-dip galvanizing kettles are available, allowing a broad scope
of structural fabrications to be galvanized. However, as with any fabrication to be galvanized, it
is important for the steel’s surface to be entirely clean for zinc to react with the steel.

Two contaminants welding can introduce on the steel surface are weld flux and weld slag. It is
important these residues be removed from the surface before sending to the gavlanizer as the
chemical cleaning solutions of the process cannot remove them. Best practice for welding
articles to be galvanized is to use an uncoated electrode to prevent flux deposits. If using a flux-
coated electrode is unavoidable, mechanical cleaning will be necessary to prepare the steel for
galvanizing.

Anti-spatter sprays should also be avoided when possible, as they also leave behind contaminants
on the surface not removed by chemical cleaning. In order to minimize costs and turnaround
times, removal of any surface contaminants from welding processes that chemical cleaning will
not eliminate should be performed at the fabrication facility.