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document updated 11 years ago, on Oct 19, 2013

Coating steel with zinc is generally referred to as "galvanizing". It's one of the most commonly-used ways to rust-protect steel. ALL bolts and nuts you get in the hardware store are zinc-coated.

There are a variety of industrial processes used for zinc coating, and they differ considerably in terms of cost and durability.

zinc electroplating (AKA electrogalvanizing)

Pros: Zinc electroplating can almost be done on your kitchen table. It requires less harsh chemicals than other processes. [1] [2] [3] [4] [5]

Cons: It results in a much thinner layer of zinc than hot-dip, and the substrate bond is much weaker (see that link's table — 500psi compared to 3,600psi).

Because the zinc layer is sacrificial, thickness and durability are inherently linked.

hot-dip galvanizing

Cons: It requires a several vats of extremely hot, extremely toxic, and extremely expensive chemicals. It's hard to do this in a small workship.

Pros: Results in a thick layer. Considered one of the best zinc coatings.