We explore the distribution, morphology and structure of zirconium hydrides formed using different cooling rates through the solid state Zr+[H] → Zr + hydride transus, in fine and blocky alpha Zircaloy-4. We observe that cooling rate and grain size control the phase and distribution of hydrides formed. The blocky alpha (coarse grain, > 200 μm) Zircaloy-4, has a smaller grain boundary area to grain volume ratio and this significantly affects nucleation and growth of hydrides as compared to fine grain size (∼11 μm) material.