Galvanizing Design

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Designing Steel

When designing or fabricating steel, there are often certain requirements that must be considered. Hot-dip galvanized steel has a specific set of design and fabrication considerations to ensure a quality finished project. Incorporating these design and fabrication specifics will help ensure the best quality coating and the most durable finished project.

The design and fabrication considerations for hot-dip galvanizing differ from other coatings, but are simple to implement with experienced operators. Whether designing a galvanized project for the first time, or the 1000th time, the key component to a successful project is communication from all parties. 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.
Every station at Canadian Galvanized has a foreman, who supervises efficiency and ensure quality project completion.

In fact, we are so committed to quality, that we have a NCSO and QC specialist on staff fulltime.


Most ferrous metals can be galvanized. Items can range from threaded nuts and bolts, cast iron to hot or cold rolled steels. Items too large for the kettle can be run by method of double or multi-dipping.

Design requirements for galvanizing include proper holes for filling and draining hollow structures while allowing for air to escape from within. Proper holes are crucial not just to the effectiveness of the galvanizing but too the safety of the individuals running the material. Sealed pipe or HSS can and will explode in the kettle if holes are not provided.

For optimal quality when galvanizing pipe handrail, internal vent holes are suggested and preferred; however, there must be a way to visually check them.

To ensure that welded sections will galvanize properly all welding flux residues must be removed at the time of fabrication. Avoid using welding rod high in silicon or use un-coated electrodes when possible.

Painted materials or materials with a lacquer coating must first be sand blasted or wheelobrated as they will not clean properly in any solution.

When fabricating materials with overlapping surfaces, back-to-back plate, angle or channel be sure to completely seal and weld all edges to avoid acid from leaching onto the surface during the galvanizing process.

If the sealed area is greater than 12 square inches, a small hole is necessary to relieve pressure from between the pieces.


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