Hot Dip Galvanizing is one of the most commonly and economically practised metallic coating to protect iron and steel from corrosion attack. However, there have been very few studies and research done in Malaysia. This project studies and identifies the problems arising from Hot Dip Galvanizing process practised in local plants. Subsequently, constructive proposals are provided to upgrade the productivity, quality and safety of the industry. The experimental works are done to study the properties of specimens gathered from various local galvanizing plants. The results of the experimental investigations show that bath composition, immersion time, pre-fluxing, post treatment and also gauge of steel are the main factors which greatly influence upon the appearence, coating thickness, corrosion resistance, properties and metallorgraphy of the galvanized coatings. Addition of 5%A1 promotes the spangle formation and also suppresses the excessive growth of zinc-iron alloy layers. However of 55%A1 improves the corrosion resistance. He also shows different appearance and metallorgraphy. The coating thickness increases parabolically with the immersion time. The use of ammonium chloride is able to reduce dross formation effectively. It is also proven that the painted galvanized steel shows excellent corrosion resistance in salt spray test. The higher the gauge to be galvanized, the heavier the coating weight is obtained.