Mitigation of Weldment Cracking of Highway Steel Structures due to the Galvanizing Process

Structural supports for signs, luminaires, and traffic signals and other highway steel structures are generally galvanized to prevent corrosion and provide a long service life. However, recent investigations have revealed incidents of cracking in weldments of galvanized structures that appear to be induced during the galvanizing process. When placed in service, structures with such flaws will exhibit short service life and pose safety concerns. There was a need to identify the factors contributing to the occurrence of weldment cracking during the galvanizing process of steel highway structures and to propose improved design, materials, and construction specifications to help mitigate such cracking. This information will ensure that galvanized highway structures provide the intended service life and eliminate related safety concerns. The objective of this research was to propose improved design, materials, and construction specifications of galvanized steel highway structures to mitigate weldment cracking caused by the galvanizing process. This research was concerned with structural supports for signs, luminaires, and traffic signals and bridge superstructures (other than decks).


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  • Status: Completed
  • Funding: $499975
  • Contract Numbers:

    Project 10-94

  • Sponsor Organizations:

    Federal Highway Administration

    1200 New Jersey Avenue, SE
    Washington, DC  United States  20590

    American Association of State Highway & Transportation Officials (AASHTO)

    444 North Capitol Street, NW, Suite 225
    Washington, DC  United States  20001

    National Cooperative Highway Research Program

    Transportation Research Board
    500 Fifth Street, NW
    Washington, DC  United States  20001
  • Project Managers:

    Hanna, Amir

  • Performing Organizations:

    University of Kansas, Lawrence

    2600 Learned Hall
    Lawrence, KS  United States  66045
  • Principal Investigators:

    Li, Jian

  • Start Date: 20140701
  • Expected Completion Date: 20200331
  • Actual Completion Date: 20200331
  • Source Data: RiP Project 37711

Subject/Index Terms

Filing Info

  • Accession Number: 01543617
  • Record Type: Research project
  • Source Agency: Transportation Research Board
  • Contract Numbers: Project 10-94
  • Files: TRB, RIP
  • Created Date: Nov 19 2014 1:02AM