May. 13, 2024
Part of an ongoing series on Galvanized Steel
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What is Galvanizing?
Galvanizing, or galvanization, is a manufacturing process where a coating of zinc is applied to steel or iron to offer protection and prevent rusting. The most commonly used method is called hot-dip galvanizing.
Galvanized steel is among the most popular steel types because of its extended durability. It combines the strength and formability of steel with the corrosion protection of a zinc-iron coating. The zinc protects the base metal by creating a barrier against corrosive elements, resulting in a long-lasting and high-quality steel product.
This versatility makes it applicable to a variety of projects and industries, including agriculture, solar, automotive, and construction. Below, we provide a comprehensive description of how galvanized steel is processed, different galvanization methods, its benefits, and its uses in various industries.
The steps in the galvanizing process are as follows:
What are the advantages of galvanized steel?
Many industries utilize galvanized steel primarily because of its numerous benefits:
Low initial cost: Compared to most treated steels, galvanized steel is immediately ready for use when delivered, requiring no additional surface preparation, inspections, painting, or coatings.
Longer life: With galvanization, industrial steel can last over 50 years in average environments and over 20 years with severe water exposure. The increased durability also enhances the product’s reliability.
Sacrificial anode: The surrounding zinc coating protects any damaged steel. The zinc will corrode first, offering sacrificial protection to the damaged areas.
Rust resistance: The zinc coating acts as a protective barrier against moisture and oxygen, making galvanized steel resistant to damage, including in sharp corners and recesses.
Different methods of galvanizing
Several processes for galvanizing steel include:
Hot-Dip Galvanizing
The primary method is hot-dip galvanizing, where steel or iron is dipped in molten zinc at around 860°F (460°C). After the metal is pulled from the bath, it reacts with oxygen to form zinc oxide, which further reacts to form zinc carbonate, creating the final protective coating. This method is economical and can be executed quickly on both simple and complex shapes.
Galvannealing
Galvannealing combines the annealing and hot-dip galvanizing processes to produce a zinc-iron alloy coating, creating a matte gray finish. This coating is conducive to welding and excellent for paint adhesion.
Pre-galvanizing
Pre-galvanizing involves rolling sheet metal through a cleaning agent and then through molten zinc. This process allows rapid galvanization of steel sheet coils with a more uniform coating.
Electrogalvanizing
This method does not involve dipping in zinc but uses an electric current to apply an electrolyte solution to the steel, depositing zinc onto the metal surface.
Galvanizing advanced high-strength steel
For more information about the galvanization process for advanced high-strength steel, visit our partner National Galvanizing.
What industries utilize galvanized steel?
Galvanized metals are used everywhere!
Many cars and bicycles bodies are made from galvanized metals. Some drinking water pipes, nuts, bolts, tools, and wires are also galvanized. Galvanized steel is used in modern "steel frame" buildings and structures like balconies, verandahs, staircases, and walkways. It's the ideal choice for outdoor projects, including fences, roofs, and walkways.
With our partner Heidtman Steel, National Galvanizing runs a 245,000-square-foot facility offering pickling, galvanizing, galvannealing, and slitting, providing unparalleled responsiveness to meet market demands.
About National Material L.P. – With more than 3,000 employees from a multinational portfolio of companies, NMLP provides engineered metal products, including aluminum extrusion and stainless steel rolled products, to automotive, aerospace, construction, defense, electrical, and industrial markets. Request a Quote Online or call (U.S.) 847-806-7200
What is galvanized steel used for?
With over 150 years of history, galvanized steel is used in various environments, proving its performance in road, rail, energy plants, oil and gas, agriculture, water and waste, sports and leisure, and more. It's crucial for buildings, bridges, facades, gates, balconies, and sculptures.
What are the advantages of galvanized steel?
1. Galvanizing is Durable
A galvanized coating offers one of the most durable forms of corrosion protection. An average coating thickness of 85 microns can protect a steel structure for nearly 100 years. In coastal environments, an 85-micron coating can still deliver a life expectancy of 30 years or more.
2. Galvanizing is Sustainable
Galvanizing provides long-term durability with a relatively low environmental burden. Studies show that investing in long-term corrosion protection like galvanizing reduces the economic and environmental costs associated with repeated maintenance painting. This benefits social housing projects and public infrastructure, where future maintenance costs are a concern.
3. Galvanizing is Cost-effective
The true cost of protecting steel from corrosion involves the initial cost and the lifetime cost. Galvanizing is often perceived to be more expensive than it is. Studies show that a good quality, grit blast, and three-coat paint system is 35% more expensive than hot-dip galvanizing.
4. Galvanizing is Proven
Galvanizing is a reliable and trustworthy method with a history spanning over 160 years. It is rigorously tested and monitored, providing evidence-based performance data through tools like the UK’s national corrosion map.
5. Galvanizing is Reliable
Galvanizing is a straightforward and controlled process, producing a consistent coating.
Hot dip galvanizing is defined by a single standard – EN ISO 1461. Unlike paint coatings, the metallurgical bond formed through galvanizing becomes part of the steel itself. The process occurs automatically, providing dependable protection from day one.
6. Galvanizing is Honest
Corrosion protection that works from day one. If your galvanized coating is visible, it’s working.
Once the coating is present, it protects immediately. It’s impossible for the coating to fail from underneath, unlike other coatings that may adhere to residual contaminants. Over time, a complex, stable, and protective layer forms, ensuring long-term protection.
7. Galvanizing is Predictable
A galvanized coating offers predictable corrosion protection, weathering in a linear fashion.
The standardized galvanizing process produces a consistent coating thickness, measurable throughout its lifetime. This ensures predictable protection, with the lifespan of a galvanized coating easily forecasted.
8. Galvanizing Offers Complete Coverage
Galvanizing creates a strong bond between zinc and steel, forming a coating that covers even the most vulnerable areas. The hot dip galvanizing process ensures complete coverage, including internal surfaces of hollow components, preventing corrosion from the inside out.
9. Galvanizing is Tough
Galvanizing is highly resistant to abrasion and mechanical damage. Due to its unique metallurgical bond, it offers exceptional performance across multiple layers, making it chip-resistant and particularly suited to high-frequency industrial wear environments.
10. Galvanizing Offers Three Way Protection
Hot Dip Galvanizing protects through:
1. A Physical Barrier:The galvanized coating is a durable barrier that protects steel from atmospheric conditions.
2. Sacrificial Protection:The coating corrodes slowly and preferentially, protecting the steel.
3. Prevention of sideways creep:Even if the coating is locally compromised, sideways creep is prevented, unlike with paint coatings.
11. Galvanizing has a Fast Turnaround
With proper communication, steel can be galvanized within 24 hours. The galvanizing process itself is quick, taking only a few minutes to dip steel into molten zinc. Thorough preparation ensures maximum efficiency.
The total process from cleaning, rinsing, fluxing to dipping and cooling takes only a few hours. By arranging in advance, the typical turnaround for hot dip galvanizing can be about three days, but it is possible to get it done within 24 hours.
Turnaround time can be minimized by:
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