Distortion is the buckling of a thin, flat steel plate or other flat material such as wire mesh (Figure 17). Distortion occurs when steel tries to move to accommodate thermal expansion. Since the steel is welded in place it cannot move. This creates a high stress level often relieved by distortion of the part. Best practice to avoid distortion dictates fabricating parts with similar steel thicknesses, and/or temporary bracing. For more on minimizing distortion, please see the AGA’s publication The Design of Products to be Hot-Dip Galvanized after Fabrication. Distortion is acceptable, unless it prevents the part from fulfilling its intended use. Many distorted thin steel sheets can be bent after galvanizing to bring the part to an acceptable final condition.
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