large parts zinc plating

Zinc Plating for Large Parts

HOME OF KING KONG - The largest Zinc Plating Line in North America

Largest Zinc Plating Line

Gatto’s large parts zinc plating line, King Kong, has 27 foot long tanks and cranes that can lift up to 8,000 pounds. We provide the following finishes for extra large parts:

Clear Trivalent Chromate (RoHS) Up to 24 Up to 200 27' Long; 8,000 pounds*
High Corrosion Clear Trivalent Chromate (RoHS) Up to 120 Up to 500 27' Long; 8,000 pounds*
*Actual processing capacity may be slightly less than the dimesion shown.


King Kong has a tank size of 27’ Long X 4’ Wide X 8’ Deep, making it the Largest Zinc Electroplating Line in the US. This gives Gatto the capability to Zinc plate extra-long or heavy parts that nobody else can, while maintaining our same high level of quality and service with quick turnaround times.


Our extra-large tank capacity helps us add value to our customers by:

  • Plating larger sections or entire assemblies, rather than multiple small components, which can reduce assembly and manufacturing costs.
  • Providing a more consistent finish and better aesthetics since there is no “double dipping” required for oversized parts.
  • Lead time reduction through improved processing efficiency due to larger tanks.

High Corrosion Clear bars


Our oversized tanks are ideal for the following applications:

  • Threaded Rod
  • Chassis
  • Long Hydraulic Tubing
  • Heavy Parts - up to 8,000 lbs
  • Long Parts
    • Hex Shafts
    • Bar Stock
    • Tubing
    • Threaded Rod
  • Large Frames
    • Electronic Enclosures
    • Cabinets
    • Server Racks
    Clear Zinc III
  • Large Plates
    • Machine Bases
    • Robotics Components
  • Large Weldments
    • Material Handling Pallets
    • Safety Cages
    • Conveyor Systems
  • Large Machined Parts
    • Hydraulic Blocks
    • Hinge Pins
    • Bridge Anchor Blocks


Our extra- large capabilities also provide manufacturers with an effective alternative to galvanizing and painting for large parts in need of corrosion protection. Since electroplated zinc is a controlled process that utilizes an electrical current to transfer zinc onto a part, it delivers a thinner coating with less dimensional variation. This makes electroplated zinc ideal for parts with threads or other critical dimensions.

While Gatto does not offer hot dip galvanizing, it is applied by dipping steel parts into a bath of molten zinc which causes a metallurgical reaction resulting in a corrosion resistant coating. Although Hot Dip galvanizing is effective against corrosion, it often creates a less consistent finish and can add significant thickness to a part. Parts with tight tolerances will typically need to be re-worked.


Consider Zinc Electroplating Over Galvanizing if...Benefits of Zinc Plating
Hot Dip is chosen due to size alone.

Some parts are too large to be coated by most Zinc Platers, so hot dip galvanizing is chosen because of size constraints alone (average galvanizing tank is 40 feet long).

Since Gatto can process oversized parts Zinc Plating can be an acceptable alternative

A thin, uniform coating is required Some parts have critical dimensions. TypicalZinc Plating thickness ranges from .0002” to .0010”. This will provide sufficient corrosion protection for many applications with minimal impact on dimensional tolerances.
Parts have threads, small holes or blind recesses Zinc Plating will not fill holes and recesses or create heavy build- up on threads. This results in less post processing after finishing.
Warpage/distortion due to high temperature is a concern

During Zinc Plating, parts are subject to temperatures of only 150 degrees Fahrenheit or less. There is no risk of warping or part deformation.

Sometimes, to prevent part warpage during hot dip galvanizing, temporary supports are installed prior to processing and removed after processing.

There are pre and post finishing costs associated with installing and removing supports to prevent part warpage Since the process of Zinc Plating does not cause warping, it may be a good alternative when pre and post coating processing costs are high.
Parts have moving components Zinc Plating generally will not increase the part thickness enough to seize up moving components that are assembled prior to coating.
Masking is required to prevent coating build up

Some parts require detailed masking to prevent heavy buildup in certain areas.

Zinc Plating provides a uniform finish and may be a suitable alternative for eliminating this additional processing cost.

Parts require significant post processing to clean up unwanted Zinc build up

Hot dip galvanizing can leave an accumulation of unwanted zinc on finished parts.

Since Zinc Plating provides a uniform coating it eliminates the need for costly post coating clean-up of parts.

Drain holes and venting are required.

Hot dip galvanizing exposes parts to extreme temperatures, causing pressure to build up inside hollow components. To avoid serious damage to parts or injuries to workers, vents and holes must be present to release the air pressure.

Venting is not necessary with Zinc Plated components.