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Galvanising & Powder Coating

Design, Manufacture, and Installation of Outdoor Steel Facilities

Outdoor sports and play facilities suffer from exposure to weather, impact, and frequent use. Because of this, ensuring their durability and longevity is essential.

But how can we ensure these facilities last longer? This is where many people ask: “What is hot dip galvanising, and why do I need it?” Hot dip galvanising is a process that makes a great difference on addressing the challenges of outdoor environments by offering protection to steel structures.

FROM START TO FINISH

How does the Hot Dip Galvanising Process Work?

When the fabricated steel arrives at the galvanising facility, it is hung by wire or placed in a racking system, which can be lifted and moved through the process by overhead cranes.

Hot dip galvanising follows a 7-step process, starting with three main cleaning steps: degreasing, chemical cleaning, and fluxing. Fluxing is the final surface preparation step, where any remaining oxides will be removed. It will coat the steel with a protective layer to prevent any further oxide formation prior to galvanising. Proper surface preparation is critical before entering the zinc bath, as zinc will not react with unclean steel.

After the zinc bath, the steel is transferred to a finishing area where excess zinc is removed, and the coating is inspected before cooling. Following this, the steel is ready for powder coating, which will give a coloured protective finish.

01.

Caustic Degreasing Tank

The steel first is immersed in a caustic cleaning solution, to remove dirt, oil, and organic residues.

02.

Caustic Rinse Tank

The steel is rinsed to remove any remaining cleaning solution before moving to the next steps.

03.

Acid Pickling Tank

Then, the acidic cleaning bath will remove mill scale and iron oxide, providing a more thorough clean.

04.

Acid Rinse Tank

The fabricated steel is left for rinsing to remove any leftovers.

05.

Flux Tank

During fluxing, it will coat the steel with a protective layer to prevent any further oxide formation prior to galvanising.

06.

Molten Zinc Bath

Once this is completed, the fabricated steel is dipped into a zinc bath.

07.

Hot Finishing Area

The steel is transferred to a finishing area where excess zinc is removed, and the coating is inspected before cooling.

QUALITY AT THE FOREFRONT

Why is galvanising effective?

Long-term
Longevity

Galvanised coatings on steel could last up to 70 years, depending on environmental conditions.

Lowest
Lifetime Cost

Galvanising offers a lower long term cost, giving steel a long life and durability, reducing costs associated with its maintenance.

Corrosion
Protection

Hot dip galvanising provides a corrosion protection with a layer of zinc which acts as a protective barrier.

Self-healing
Protection

Galvanising allows zinc coating to self-repair small scratches through protective chemical reactions.

RECOGNISED INDUSTRY STANDARDS

Standards and Quality

Hot dip galvanising processes are compliant to the International Standard European standards. This ensures full coverage of the steel surface which paint and spray may not reach.

  • Certified to EN ISO 1461 standards
  • Steel surface is fully covered
  • Uniform coating
  • Corners coating
  • Narrow gaps coating
  • Hollow sections coating

The Finishing Touch

Powder Coating & Colour Options

Once the galvanising process is complete, your steelwork is ready for powder coating, a high-quality coloured finish that combines aesthetics with an additional layer of protection.

Powder coating is applied electrostatically and cured under heat, bonding to the galvanised surface to create a tough, smooth finish that resists chipping, scratching, and fading. When combined with hot-dip galvanising, this is known as a duplex systemwidely regarded as the gold standard for outdoor steel in demanding environments.

Colour Options

All Lightmain products are available in a wide range of colours using the RAL colour system, the international standard used by architects, specifiers, and designers. This gives the flexibility to match an existing facility, meet a planning requirement, or simply choose something that looks great in your space.

Below are some of our most requested RAL colours; custom RAL colours are available upon request. You can speak to our team about lead times and options.

RAL6005

RAL5002

RAL5005

RAL3001

RAL9005

RAL6005

RAL5002

RAL5005

RAL3001

RAL9005

Why Powder Coating Matters Outdoors:

  • UV-resistant finish reduces colour fade over time
  • Provides an additional barrier against moisture and corrosion
  • Available in virtually any RAL colour
  • Consistent colour across all components, even across separate orders
  • Complements galvanising to dramatically extend the working life of the structure

YOUR QUESTIONS ANSWERED

Frequently Asked Questions

Clear answers to the most common questions about hot-dip galvanising, including durability, corrosion protection, standards, costs, and project timelines, so you can move forward with confidence.

If you can’t see the answer to your question, please feel free to get in touch.

No, powder coating is not mandatory, as the hot dip galvanising process alone provides long-term corrosion protection. However, powder coating is recommended both for aesthetics and to provide an additional layer of protection, particularly in high-use or coastal environments.

Yes. Hot-dip galvanising performs reliably across a wide range of environments including rural, urban, and industrial locations. It is also well-suited to coastal and high-humidity environments, where exposure to salt air and moisture would rapidly accelerate corrosion in untreated steel. The thickness of the zinc coating provides robust, long-term protection regardless of weather conditions.

Yes. This is known as a duplex system for corrosion protection, where steel is galvanised first and then powder coated. It combines the corrosion resistance of galvanising with the appearance of powder coating.

All Lightmain products can be powder coated in a wide range of colours using the RAL colour system — the international standard used by architects, designers, and specifiers. We offer a standard palette of our most popular colours, and custom RAL colours are available upon request. Speak to our team about options and lead times.

When applied over a hot-dip galvanised surface as part of a duplex system, powder coating can last significantly longer than when applied to bare steel — often 20 years or more depending on the environment and level of use. We use UV-resistant coatings to minimise colour fade, particularly important for facilities in open, sun-exposed locations.

A duplex system is where steel is both hot-dip galvanised and powder coated. The galvanising provides the primary corrosion barrier, while the powder coating adds a second layer of protection and gives the structure its colour. Combined, the two finishes work together to extend the lifespan of the coating well beyond what either would achieve alone — making it the recommended finish for most outdoor sports and play facilities.

READY TO DISCUSS YOUR PROJECT

It All Starts With a consultation!

If you are exploring options, comparing suppliers or need early guidance for tenders, get in touch.

There is no obligation, and no pressure to proceed, just clear, practical advice.

(0114) 282 1259

Aizlewood Mill, Nursery Street, Sheffield, S3 8GG

enquiries@lightmain.co.uk