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Galvanizing for Corrosion Protection

Semih Genculu, PE

Course Outline

This 2-hour online course is prepared for engineers to help them understand the basics of one of the most common corrosion protection mechanisms. The galvanizing process, the coating structure and uniformity, the various coating designations and their corresponding corrosion properties will be discussed.  Factors affacting coating thickness and appearance will be explained along with the problems to avoid during galvanizing. The performance of zinc coating in various environments will be detailed.

This course includes a multiple-choice quiz at the end, which is designed to enhance the understanding of course materials.

Learning Objective

At the conclusion of this course, the student will:

Intended Audience

This course is intended for engineers from all disciplines as zinc-coated steel is commonly used in all types of industries.

Benefit for Attendee

Attendees of this course will not only become knowledgeable about the benefits of galvanizing, the various designations of hot-dip galvanized coatings, and their relative corrosion resistance, but become familiar with the factors to consider to make sure that zinc coated parts are appropriate for the type of application and the service environment.

Course Introduction

Corrosion of exposed steel results in billions of dollars in damage every year, and can also pose major safety concerns. Fortunately, hot-dip galvanizing is an extremely effective solution to the problem.  Barrier protection is perhaps the oldest and most widely used method of corrosion protection (paint is an example of barrier protection).  It acts by isolating the metal from electrolytes in the environment.  Two important properties of barrier protection are adhesion to the base metal and abrasion resistance.  By understanding the dual protection mechanisms zinc offers, engineers can specify and design longer lasting products.

Course Content

The course content is contained in the following PDF file:

Galvanizing for Corrosion Protection

Please click on the above underlined hypertext to view, download or print the document for your study. Because of the large file size, we recommend that you first save the file to your computer by right clicking the mouse and choosing "Save Target As ...", and then open the file in Adobe Acrobat Reader. If you still experience any difficulty in downloading or opening this file, you may need to close some applications or reboot your computer to free up some memory.

Course Summary

Hot-dip galvanizing provides excellent barrier and cathodic protection.  The principal reasons for the use of zinc as a protective coating for steel are: 1) It corrodes much more slowly than steel in natural environments, and 2) It galvanically protects steel when small discontinuities develop in the coating since it behaves as a sacrificial anode due to its relative position to steel in the galvanic series. The corrosion loss of a hot dip zinc coating is generally considered to be linear, hence the life expectancy of the coating is proportional to its thickness.

Related Links and References

Industrial Galvanizers-Specifiers Manual
Steel Door Institute,
American Galvanizers Association,
Zinc: Its Corrosion Resistance, International Lead Zinc Research Organization
ASM Handbook, Volume 5, Surface Engineering


Once you finish studying the above course content, you need to take a quiz to obtain the PDH credits.

Take a Quiz

DISCLAIMER: The materials contained in the online course are not intended as a representation or warranty on the part of PDH Center or any other person/organization named herein. The materials are for general information only. They are not a substitute for competent professional advice. Application of this information to a specific project should be reviewed by a registered architect and/or professional engineer/surveyor. Anyone making use of the information set forth herein does so at their own risk and assumes any and all resulting liability arising therefrom.