The Art Galvanizing Works, Inc.

Cleveland, Ohio

Design & Fabrication 


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{Design & Fabrication}







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Additional Product Design Considerations for Galvanizing


    When welded items are galvanized, both the cleanliness of the weld area after welding and the metallic composition of the weld itself affect galvanizing quality and appearance. Some welding techniques that lead to good results include:   

  • Use of an uncoated electrode where possible,

    Thorough removal of all welding flux residues if a coated electrode is used,

  • A welding process that produces little or no slag,

  • A submerged arc method for heavy weldments,

  • Selection of welding rods providing a deposited weld that is composed of the same materials as the parent metal, and

  • Avoiding welding rods that are high in silicon.

     Materials that have been galvanized may be welded easily and satisfactorily by all common welding techniques. The American Welding Society (AWS) has produced a book that details all aspects of welding galvanized items. In general, anything that can be welded before galvanizing can be welded with relative ease after galvanizing. A copy of the AWS recommended welding practices is available from Art Galvanizing or the AGA.


     Hot dip galvanizing is a well established and widely used process for coating mechanical fasteners and welded joints. The prime mechanical fasteners used for making field connections in steel are bolts that conform to ASTM A 307, A 325, and A 394 and are galvanized in accordance with ASTM A 153/A 153M and CSA standards. Bolted galvanized structural joints can be designed for both bearing- and friction-type connections. Galvanized joints of this type have an outstanding performance history. A wide variety of structures have been built using hot dip galva­nized steel and connected using galvanized steel bolts. Art Galvanizing has over 75 years of experience in galvanizing various bolts, screws, and other fasteners including A490 and Grade 8 Bolts.      


    Galvanized articles are easily and successfully painted. The two factors critical to success are proper post-galvanizing surface preparation and proper paint system selection. Galvanized steel is painted for a number of reasons: aesthetics, safety mark­ing, and the desire for even longer lasting protection. Galvanizers must be notified if galvanized steel is to be subsequently painted so they can avoid applying a post gal­vanizing treatment that would affect paint adhesion.

    A corrosion protection system consisting simply of galvanizing provides long-term, cost-effective corrosion protection. Often the expected service life of the galva­nized coating actually exceeds the design life of the structure it protects. However, a duplex system, one consisting of properly selected and applied paint over galvaniz­ing, greatly extends the period that effective corrosion protection is provided. A use­ful rule of thumb is that a duplex system will provide effective corrosion protection for one-and-one-half-times the service life of the sum of the service lives of the indi­vidual systems. For example, if the life of the galvanized coating in a particular envi­ronment is 35 years and the expected service life of the paint system is 10 years, the expected service life of the duplex system will be 67.5 years [i.e., 1.5 (35+10)]. While such duplex systems often will have a premium first cost, they are usually the lowest life-cycle cost solution. They may be the only feasible solution for. structures in aggressive environments where later in-service painting is extremely difficult or impossible.

    The synergy of duplex systems in corrosion protection stems from three known factors:  

  • The paint film extends the life of the galvanized coating by providing addi­tional barrier protection to the zinc layers,
  • An underlying layer of zinc tends to prolong the life of a paint coating by preventing an underlying layer of corrosion from developing, and

  • The corrosion products of zinc and its alloys further retard paint coating damage by sealing cracks and pores in paint films.

      Two publications, Duplex Systems: Painting Over Hot Dip Galvanized Steel, and Practical Guide .for Preparing Hot Dip Galvanized Steel for Painting are available from Art Galvanizing or the AGA. They provide more complete and detailed information about duplex systems. In addition to providing a wealth of technical details and a discussion of the suitability of a number of different types of paints for application after galvanizing, these publications also present a number of specific applications and color photographs of duplex systems.

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Please contact us at:

3935 Valley Road
Cleveland, Ohio 44109
Phone: (216) 749-0020
Fax: (216) 749-0030

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