In our previous posts, we’ve covered the basics of galvanizing, essential design considerations, and materials suitable for galvanizing along with modular design techniques. Now, let’s focus on general fabrication guidelines and best practices for designing items to maximise durability. 

General Fabrication Guidelines 

Proper fabrication is key to ensuring high-quality galvanized coatings and long-lasting steel structures. 

Eliminate Undrained Areas: 

Design fabricated assemblies to avoid undrained areas where water and debris can collect, leading to localised corrosion. Good venting and draining design ensures that water can drain off, optimising the durability of the structure. 

Weld Areas: 

The silicon content in some welding rods can cause localised grey coatings and/or be more proud of the surface when galvanized. While these coatings may be thicker, they do not negatively affect the coating’s lifespan. To minimise this effect, use low silicon welding rods and ensure welding slags are removed mechanically before galvanizing. 

Specific Fabrication Rules: 

– Ensure all steels and casting material can be galvanized. 

– Consult your galvanizer for unusual or complex shapes. 

– Follow guidance on venting and draining, especially hollow sections. 

– Use butt welds instead of lap welds when possible. 

– Avoid using silicon-containing anti-splatter paints. 

– Provide extra clearance on mating surfaces and ensure proper lifting points are included. 

Design for Durability 

General Rules: 

To maximise the durability of galvanized items, follow these design rules: 

– Avoid horizontal boxed sections, ledges, seams, and flat undrained areas. 

– Use rounded internal corners to prevent detritus build-up. 

– Eliminate crevices and unnecessary openings. 

– Avoid contact with copper, brass or uncoated steel/iron to prevent bimetallic corrosion. 

– Ensure proper ventilation to reduce condensation risks. 

– Use inhibitive jointing compounds in extreme humidity conditions. 

– Design for easy maintenance access where needed. 

By following these general fabrication guidelines and designing for durability, you can ensure that your galvanized steel structures will last longer and perform better. This concludes our series on basic design guidelines for galvanizing. We hope you find these insights valuable and apply them in your future projects for optimal results.