In this study Influence of Process Parameters on Intermetallic Layers Thickness and Corrosion Behaviour of Hot-Dip Galvanized Coatings was investigation. The effects of increasing the lead content of zinc bath from 0.02 to 0.065 wt.% and antimony content from 0.006 to 0.018 wt.% on texture, corrosion resistance, surface morphology and intermetallic layers thickness were evaluated. The effect of coating thickness and substrate thickness on intermetallic layers thickness were studied. Optical microscopy and scaning electron microscopy were employed to study surface morphology and intermetallic layers thickness. intermetallic layers thickness recognized by EDS analysis. Coating texture was determined using XRD and corrosion resistance was analyzed using salt spray and Tafel polarization tests. Results show that increasing the antimony and lead content of zinc bath decreases the corrosion resistance. Also increasing the lead content increase the gamma layer thickness. Increasing the antimony content of zinc bath result in the decrease the relative intensity of (00.2) basal planes. By increasing the antimony and lead content of zinc bath corrosion resistance would be decreased. Such decreasing in basal component relative intensity, roughness and increasing the gamma layer of the coating would result in the decreasing of coating corrosion resistance. The effect of force variations in skin pass rolling process on texture, corrosion behaviour and roughness of coatings show that by increasing the force of skin pass rolling the texture coeficient (CT) of (00.2) basal plane decreased but (CT) of prismatic planes increased. Furthermore by increasing the force of skin pass rolling corrosion resistance decreased. Increasing skin pass force would also cause an increase in surface roughness and microcracks in the coating. Such increasing in prismatic component texture coefficient, roughness and microcracks of the coating would result in the decreasing of coating corrosion resistance. Key Words galvanized steel sheet, intermetallic layers, texture, corrosion, skin pass rolling, roughness