Prior to fabrication, communication between the galvanizer, designer and fabricator will ensure that all materials are galvanized safely, economically and effectively. Most ferrous metals can be galvanized. Items can range from treaded nuts and bolts, cast irons 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 uncoated 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 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.