Zinc Plating for Large Parts
King Kong – The Solution for Plating on Oversized Parts
Plating large parts is a challenge for most shops, at Gatto it’s our specialty. That’s why we built King Kong, North America’s largest zinc plating line. With 27-foot tanks and an 8,000-lb crane, we can process almost any size component.
Finishes offered:
- Clear Zinc
- High-Corrosion Clear Zinc (for extended protection)
Capacity:
- Handles components up to 27 ft long or 8,000 lbs
- Actual Tank Size: 27’ Long x 4’ Wide x 8’ Deep
Standards:
- ASTM B633
- ISO 2081
- JDMF23
- 1E0397
- CNH MAT0310
- And many other OEM Specifications
Avoid Late Shipments
We plate oversized parts every day, so your long and heavy components move through our line efficiently without special adjustments or extra setup time. When parts arrive, we schedule them immediately and move them into production so lead times stay short and predictable.
- Extra Large Tanks - Our 27ft tanks and heavy-duty handling equipment allow us to process a wide range of oversized components, including long lengths of tubing and rod, heavy machine plates, large frames, cabinets and enclosures
- No Downtime For Setup- King Kong is dedicated to large parts, so it is ready the moment your shipment arrives, eliminating the need for modifications or special setup that can delay processing.
- Multiple Plating Stations- Gives us ample capacity to run high volumes of large parts, even full truckloads, while maintaining average 5-day lead times.
- Central U.S. Location- Provides a direct route to many major U.S. cities, helping reduce freight time and transportation cost by shipping directly to your end customer.
Better Parts for a Lower Cost
When large parts can plate in one piece, the entire process is more efficient. Fewer steps and less handling reduce opportunities for issues. King Kong’s 27 foot tanks allow long tubing, heavy weldments, frames, and large assemblies to plate in full lengths or larger sections, eliminating extra steps created by tank-size limitations.
Advantages of Plating Large Parts as One Piece
- Reduced Labor & Production Cost – Eliminating the need to section, cut, re-weld, or double-process long parts reduces fabrication time and avoids additional labor costs that sectioning creates.
- Lower Freight Costs – Full-length tubing and assemblies ship on fewer pallets with less packaging, less handling, and lower transportation charges.
- Stronger Assemblies – Keeping a part in its original form preserves structural integrity. Fewer seams mean fewer potential failure points.
- Fewer Design Constraints – Engineers can rethink product designs because they are no longer constrained by smaller plating tanks.
- More Consistent Finishes – Plating as one piece provides more uniform appearance and thickness, while eliminating visible seams that are common with double-dipping or plating in smaller segments.
With King Kong, oversized parts are plated the way they were designed so they remain strong and consistent without unnecessary labor, freight, or rework.
How Capacity Improves Finish Quality
Capacity matters because it provides the space and control needed to plate large parts correctly. King Kong was built with five large plating stations, allowing us to process large parts, and large quantities of them, at the same time. The line is designed to accommodate a wide range of part sizes and configurations without creating bottlenecks or forcing workarounds.
King Kong was built for large, heavy components, so parts aren’t forced into tight or improvised setups. Our available tank space and proper handling equipment allow components to be safely moved and repositioned during processing, which directly improves finish quality:
- Better Coverage – Parts can be repositioned during plating to improve coverage on challenging areas.
- Proper Drainage – Large tanks allow parts to be angled for effective drainage, reducing the risk of trapped solution.
- More Uniform Coatings – Assemblies can be plated in larger sections, or as a single piece, resulting in more consistent zinc thickness with less streaking or buildup.
With multiple large plating stations available, large-volume shipments move into production efficiently rather than waiting for tank availability. For customers, this means faster turnaround, more predictable lead times, and efficient processing, even for large quantities of oversized parts.
We Process For All Industries
From tubing suppliers to data centers, we provide large part plating across industries.
Steel Service Centers
We process long lengths of specialty steel products, including tubing, threaded rod, angle iron, and bar stock. Many steel service centers use our plating services to supply customers with pre-plated material. By drop-shipping directly to their customers, they reduce freight costs and deliver finished material faster.
Facility Equipment
We plate dock system components, structural supports, folding gates, guard rails, and barriers. Our large tanks make zinc plating a viable alternative where paint or hot-dip galvanizing is often the only option.
Data Centers & Electrical Infrastructure
We plate wire basket tray, ladder rack, Unistrut, and electronic enclosures with standard zinc coatings. Our large tanks and high-capacity lines are built to move high volumes of long-length products efficiently.
Material Handling
We plate large, fabricated racks and pallets used on assembly floors, along with components for conveyor systems. Customers rely on us to handle the size and weight of these structures efficiently.
Machinery & Heavy Equipment
Large machines and equipment require large components. We process oversized weldments, heavy machine bases, frames, and safety cages using equipment designed specifically for large, heavy parts.
Electronics and Devices
We regularly process frames, cabinets, housings, and electronic enclosures for a wide range of equipment and devices. These components support applications across defense, medical testing, laboratory equipment, energy storage, semiconductor manufacturing, nuclear power, and data center infrastructure.
Rethinking Hot-Dip Galvanizing for Large Parts
Large components are often hot-dip galvanized or painted simply because standard zinc plating tanks can’t accommodate their size. King Kong changes that.
Our large plating tanks give customers the option to choose zinc electroplating for oversized parts when it’s the right fit for their application. This is important for parts with critical dimensions, complex geometry, or features that may require significant cleanup after hot-dip coating.
For components prone to warping or excessive buildup, electroplated zinc offers greater control, providing a more predictable option for large parts that previously had limited coating choices.
Why Zinc Electroplating May Be A Better Option than Hot-Dip or Paint
- Thinner, Controlled Coatings Zinc electroplating applies a thin, uniform coating (.0002”–.0010”) that protects without interfering with critical features like threads or moving features, unlike hot-dip or paint which can be too thick for tight tolerances.
- No Heat-Related Distortion Low-temperature processing avoids the warping and deformation that can occur with hot-dip galvanizing.
- Less Cleanup and Rework No heavy buildup, vent or drain holes, or post-processing cleanup common with hot-dip.
- More Durable Than Paint Zinc plating won’t chip or scratch like paint, which can expose base metal and lead to further corrosion across the part.
- Lower Cost in Some Applications Zinc plating can be more economical once rework and long-term maintenance are considered.
If part size has limited your finishing options to hot-dip galvanizing or paint, King Kong makes zinc electroplating a viable alternative for large components.
Located in Chicago, we reach 65% of the U.S. in a day, lowering freight costs, reducing lead times, and enabling direct shipping to your customer.
With 210,000 sq. ft., we process full truckload orders efficiently, keeping parts organized and on schedule with dedicated staging, processing, and tracking.
Flaking, bleed-out, poor adhesion, we catch plating issues early before they turn into costly problems.
From fast quotes to clear answers, we simplify the plating process so you can focus on the rest of your project.
Contact Our Plating Experts
Whether you know exactly what you need or just need to talk it through, we’re here to help with quick turnaround times and expert guidance.