Reliable connections in structural steel assemblies must accompany superior corrosion protection. Hot-dip galvanized (HDG) coatings produce maintenance-free corrosion protection for many years. The structural connections must provide equivalent corrosion protection as well as structural integrity to ensure maintenance-free performance. A solid structural connection is ensured by providing corrosion protection for the bolt and nut connection and providing clearance for the HDG coating special treatment of the nut. A critical factor in structural connections is the slip factor for the faying surfaces. This article discusses recent changes made by AASHTO to the design parameters for HDG faying surfaces and the increased clearance holes for connections using bolts with a diameter above 1 inch. …