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Aladdin Mohammed — Hot-Dip Galvanizing Expert and Operations Manager, standing in his office with his galvanizing factory visible through the window.

Hot-Dip Galvanizing Expert & Plant Developer

AladdinMohammed

Operations Manager  ·  Plant Developer & Commissioning Engineer  ·  Author

21+
Years of Experience
9
Plant Projects
3
Plants Operating
10+
Countries of Exposure
Scroll
The Story

From the Production Floor
to Plant Ownership

I started my career in hot-dip galvanizing in 2005 as a production engineer — standing on the kettle floor, learning every part of the process from the inside out. That hands-on foundation is what defines everything I have built since.

Over two decades, I have developed, commissioned, and managed galvanizing plants across Egypt and Saudi Arabia, working with facilities of every scale — from compact manual lines to large, fully automated structural plants with 15-metre kettles and closed chemical systems.

Today I manage three galvanizing operations simultaneously, each serving a different market segment: heavy structural steel, medium fabrications, and centrifuge galvanizing for fasteners and small parts. Alongside plant operations, I have spent the past several years writing what I believe is the most complete technical and business reference ever produced for the hot-dip galvanizing industry.

I believe in knowledge that actually works on the floor — not theory disconnected from practice, but engineering insight built from direct operational experience. That is the standard I hold myself to in everything I do.

"The kettle does not care about your theory. It respects only what you understand about the metal, the zinc, and the heat."
— Aladdin Mohammed
Career Journey

Twenty-One Years
in Hot-Dip Galvanizing

2005
Production Engineer — First Steps
Galvanizing Industry · Egypt
Entered the galvanizing industry directly on the production floor. Learned bath chemistry, surface preparation, coating control, and the day-to-day realities of running a molten zinc operation. The foundation of everything that followed.
2007–2012
Senior Production & Process Engineer
Galvanizing Plants · Egypt
Took responsibility for full production operations, including quality control, chemical management, zinc reconciliation, and process optimization. Began leading improvement projects and managing production teams. Gained deep competency in ASTM and ISO standards compliance.
2012–2017
Plant Development — Greenfield & Upgrade Projects
Egypt & Saudi Arabia
Led the design, procurement, construction, and commissioning of multiple galvanizing plants from zero. Built plants in different configurations — manual, semi-automated, and fully automated — across both structural and fastener galvanizing. Also managed full renovation and capacity-upgrade projects on existing facilities, including extending kettle lengths and converting fuel systems.
2017–2022
Senior Operations & General Manager
Galvanizing Operations · Saudi Arabia
Managed large-scale structural galvanizing facilities in the KSA market, overseeing full P&L responsibility, production KPIs, team leadership, and customer quality systems. Developed pricing models, cost control frameworks, and zinc reconciliation methodologies that are now part of my book.
2022–Now
Multi-Plant Operations Owner & Manager
Three Active Plants
Currently managing three galvanizing plants simultaneously: a diesel-fired manual structural plant, an LPG semi-automated large-format structural plant, and a fully automated LPG centrifuge plant for fasteners and small parts. Each plant serves a distinct market segment and operates as an independent profit centre.
2024–2026
Author — Technical Reference Book
Published October 2026 · Paperback on Amazon
Wrote and published the industry guide Hot-Dip Galvanizing: Science, Operations & Profitable Management — a 24-chapter comprehensive reference covering corrosion science, the full HDG process, plant design from zero, and running a profitable galvanizing business. The only book in the industry that combines all four dimensions in a single volume.
Plant Portfolio

Built, Upgraded &
Currently Operating

Every plant I have built or run has sharpened my understanding of what works in practice and what fails under real production pressure.

5
Plants Built from Scratch
Full greenfield development: site assessment, layout design, equipment procurement, civil construction supervision, commissioning, trial runs, and handover to production. From first concrete to first commercial batch.
4
Plants Renovated & Upgraded
Brownfield improvement projects: capacity expansion, fuel system conversions, automation upgrades, kettle replacements, chemical line redesign, and fume extraction installations. Minimum disruption, maximum upgrade.
3
Plants Currently Operating
Three active operations running simultaneously — covering structural steel, medium fabrications, and centrifuge galvanizing for fasteners. Each managed independently with its own team, KPIs, and cost control system.
Kettle Experience Range
1.6 mFasteners
6.5 mCompact
10 mMedium
15 mLarge
16.5 mHeavy
Current Plant Portfolio
Plant 1 — Compact Structural
Manual Structural Line
  • Kettle6.5 × 1.2 × 2.2 m
  • FuelDiesel
  • AutomationAdvanced Manual
  • Cranes2.5 + 2.5 t
  • MarketMedium & small structural, cable tray
Plant 2 — Large Structural
Semi-Automated Heavy Line
  • Kettle15 × 2 × 3 m
  • FuelLPG
  • AutomationSemi-Automated
  • Cranes10 + 10 t
  • MarketAll structural steel types
Plant 3 — Centrifuge Line
Fully Automated Spin Line
  • Kettle1.6 × 1.2 × 1.5 m
  • FuelLPG
  • AutomationFully Automated
  • Cranes1 + 1 t
  • MarketFasteners, bolts, nuts, washers
Global Exposure

Operations & International
Plant Inspections

Studying galvanizing facilities internationally — from European flagship operations to Asian manufacturing scale — has given me a reference point for what world-class looks like.

Operated & Managed

Egypt Saudi Arabia

Full operations management, plant development, and commissioning across multiple facilities in both markets, spanning two decades of continuous production experience.

Visited & Inspected Internationally

Turkey Italy Germany Belgium Netherlands China Qatar UAE

Plant visits, technology assessments, and knowledge exchange with galvanizers in Europe, Asia, and the Middle East — from Galvallia-standard European facilities to China's largest manufacturing operations.

Published Work

The Definitive HDG
Industry Reference

Front cover of Hot-Dip Galvanizing: Science, Operations & Profitable Management by Aladdin Mohammed

Hot-Dip Galvanizing:
Science, Operations & Profitable Management

Process, Plant Design, Operations, and Business — From Zero to Start-Up

The only book in the hot-dip galvanizing industry that combines academic foundation, full process expertise, greenfield plant development, and complete business operations in a single volume. Written from direct operational experience — not from a library, but from the kettle floor.

24 Chapters
6 Appendices
4 Core Parts
610 Pages
Buy on Amazon About the Book
Areas of Expertise

What I Bring to Every
Galvanizing Challenge

⚗️
Process Science & Bath Chemistry
Zinc bath control, alloy additions, dross and ash management, temperature optimization, and coating metallurgy. Understanding why the process behaves the way it does — not just what buttons to press.
🏗️
Greenfield Plant Development
Full project lifecycle from site feasibility and layout design through equipment procurement, civil construction, commissioning, and first production. Five plants built from zero, in two countries.
🔧
Renovation & Capacity Upgrade
Brownfield improvement: kettle replacements, kettle extensions, fuel conversions (diesel to LPG), automation upgrades, closed-line retrofits with scrubbers and zinc dust filters, and process rebalancing.
📋
Quality Systems & Standards Compliance
ASTM A123/A123M-24, ASTM A153/A153M-23, ASTM A780/A780M-20, ISO 1461:2022. Full quality management systems including non-conformance handling, customer complaints, and supplier qualification.
📊
Cost Control & Zinc Reconciliation
Zinc consumption benchmarking, dross and ash recovery analysis, chemical optimization, fuel efficiency modelling, and variance analysis — the financial discipline that separates profitable plants from loss-making ones.
👥
Operations Management & Team Leadership
Multi-plant management, shift structure design, operator training, KPI dashboards, production reporting, safety culture, and building the team discipline that sustains consistent output over years.
Education & Credentials

Engineering Foundation,
Business Leadership

A metallurgy and materials engineering background, reinforced by formal business education and a wide base of professional certifications — the technical depth and management discipline behind every plant I run.

⚙️
Engineering Degree
Metallurgy & Materials Engineer
Faculty of Petroleum & Mining Engineering — Egypt
🎓
Postgraduate
Two MBA Degrees
Project Management & Business Administration
📐
Certification
PMP® Certified
Project Management Institute (PMI)

Professional Certifications

Welding Quality Management HSE / Safety Lead Auditor Engineering Design Inspection & many more

Let's Connect

Whether you are looking to discuss galvanizing operations, plant development projects, the book, or technical consulting — I am open to conversations with people who are serious about this industry.

Get in Touch LinkedIn Profile Consulting & Plant Projects About the Book