Category Archives: Galvanizing Steel

Differences Between Hot-Dipped Galvanization & Pre-Galvanizing

Differences Between Hot-Dipped Galvanization & Pre-Galvanizing

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Galvanizing is one of the widely used methods for protecting metals from corrosion. It involves applying a thin zinc coating to a thicker base metal like iron metal. The process helps to shield the metal from the surrounding environment. When a metal undergoes galvanization, it does not experience any corrosion. However, without the zinc coating, the metal remains exposed to the elements and potentially oxidizes and corrodes faster. There are several ways of galvanizing metals, including hot-dipped galvanization and pre-galvanizing.

Hot-Dipped Galvanization vs. Pre-Galvanizing: What Are They?

As the name suggests, in hot-dipped galvanization, experts dip the steel in hot, molten zinc. When the zinc coats the steel, a metallurgical reaction occurs between the iron component of the steel and the hot zinc. The reaction known as the diffusion process occurs when the coating collects perpendicular to every surface, creating a uniform thickness.

When the expert removes the steel from the zinc bath, it reacts with the oxygen in the air to form zinc oxide. It then reacts with carbon dioxide and forms the final protective coating of zinc carbonate. With multi-layered zinc coating and iron-zinc alloy, the steel becomes corrosion-resistant.

Pre-galvanizing, also called mill galvanizing, is another galvanizing process close to ho-dipped galvanizing. However, this process occurs at the very first stage of production. The process takes place at steel mills that have a specific shape. Pre-galvanizing involves a few steps of hot-dip galvanizing, like cleaning the surface, hot zinc bathing, and recoiling.

Key Differences Between Hot-Dipped Galvanizing and Pre-Galvanizing

Differences Between Hot-Dipped Galvanization & Pre-Galvanizing

Application Comparison

Hot-dipped galvanization is an economical choice that you can execute on simple and complex shapes. Experts use it on objects fabricated beforehand and yet not galvanized. The hot-dipped galvanization plays the last step.

On the other hand, a metal requires undergoing pre-galvanizing at the first production stage. It mainly occurs at the mill and later undergoes cutting into size and fabrication.

Coating Comparison

Since the galvanizing process involves the application of a protective coating for the steel and metals, it is essential to consider the coating finish of the two methods of manufacturing galvanized steel.

Coating Thickness

Although both methods result in uniform thickness, the hot-dipped galvanization produces a thicker layer of protection than the other method.

Coating Continually

Hot-dipped galvanizing requires dipping the entire steel and other metals into the molten vat of zinc. The galvanized steel comes with a continuous coating over the surface. On the other hand, pre-galvanizing requires performing before cutting the sheets into perfect sizes and pieces; therefore, the cut edges do not undergo any coating.

Coating Formability

Since the process of pre-galvanizing undergoes at the mills, any coating applied after cutting the metals does not damage the layer. On the other hand, coating formability applied on hot-dipped galvanized steel is not advisable, as it might damage the protective coating of the products.

Coating Appearance

The hot-dipped galvanization forms a bright finish for the galvanized steel, which might or might not be uniform. On the other hand, the pre-galvanizing process produces a uniform bright finish for the coating.

There are numerous differences between hot-dipped and pre-galvanizing processes. Understanding the differences helps in choosing suitable methods and products for different projects.

Electro Galvanised Steel

Electro Galvanized Steel Vs Galvanized Steel

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Suggested Topic: Know the Differences Between Electro Galvanised Steel and Galvanised Steel

Galvanization is the process where you apply a protective coating of zinc on the iron or steel to prevent it from rusting. While doing this method, one should take proper care of the same. This process can be hazardous to the person if not done correctly. It will also cause damage or malfunction of the equipment, instrument, and many more.

Before choosing the process, one must indulge in thorough research and understand the difference between electro-galvanized steel and galvanized steel. Knowing the difference can help a person to be safe while selecting the right and most appropriate method and product according to the specific requirement and needs of the business. Otherwise, it can just be a waste of money and time.

Difference between electro-galvanized steel and galvanized steel

Here are some basic differences between galvanized steel and electro-galvanizing.

  • In the case of galvanized steel, one needs to follow up a rigid cleaning process. This process is also known as the 7-bath process. But when it comes to electro-galvanizing, one need not have to follow such stringent cleaning methods.
  • To achieve the galvanized steel coating, the steel is said to get dipped in the molten zinc bath at a temperature variation of 460° c. But for the electro galvanization, the steel gets prepared in a cathode in the electrolytic cell that forms a coating while using the electroplating process.
  • Electro-galvanizing indeed has a very low life ranging from several months to a few years. But in the case of galvanized steel, the average lifespan is between 20 years to 50 years. However, electro galvanization produces an excellent finish. But the galvanized steel offers an unpleasant and dull finish.
  • Above all, the coating thickness of the galvanized steel is about 80 to 100um. Also, the thickness depends entirely upon the dipping duration. The composition and the roughness of the steel affect the same. When it comes to electro galvanization, the coaching thickness is about 10 to 12 um. The current density and the temperature of the electrolyte determine the thickness of the coating in this case.
  • The galvanized steel offers a non-uniform coating. But in the case of electro-galvanized steel, one can expect a uniform coating.

 Cost

When it comes to the cost, galvanized steel, having a normal coat thickness, becomes 40% more expensive than electro-galvanized steel. The electro-galvanized steel has a normal coat thickness, which makes it a lot affordable. The cost happens to increase proportionately with the higher coating thickness.

It becomes extremely necessary for a person to choose a reputed company to select either electro-galvanized steel or galvanized steel to get top-class service.

Why Choose Tanya Galvanizers

Tanya Galvanizers provides the best quality service and products according to your needs and requirements. Whether it is electro-galvanized steel or galvanizing steel, we are the leading name in the market.

Since we have decades of industry experience, we provide the best solution for your requirement. If you are looking for either electro-galvanized steel or galvanized steel, we would be happy to help you.

 

Reason for Galvanizing Steel Structure

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Are invested in a business dealing in steel or an individual looking for solution to protect steel structure? Well in that case you are just browsing the right page at the moment. Today we are going to walk you through galvanization of steel structure and how it will help you protect your steel.  

What is Galvanization of Steel?

The galvanization of steel highlights coating a steel object by submerging it into a bath of molten zinc. The bath of molten zinc showcases temperatures around 840°F (449°C). Once removed from the bath, the zinc coating on the steel’s exterior reacts with oxygen in the atmosphere to form (ZnO) Zinc oxide. This Zinc oxide further reacts with carbon dioxide in the atmosphere to form a more compact protective layer known as (ZnCO3) Zinc carbonate. This Zinc carbonate reflects a dull grayish film, which is relatively stable and adheres tightly to the surface of the steel. This in turn helps you protect your steel from natural calamities and external elements. 

Now that we have understood what is galvanization of steel, lets walk you through why you need it for your steel structure.

Reasons for Galvanizing Steel

Galvanization of steel structure has multiple advantages other than protecting the metal from damages. These benefits include:

  • Sustainability
  • Durability
  • Proven Quality
  • Cost Effectiveness
  • Honesty
  • Reliability
  • Complete Coverage
  • Predictability
  • Triple protection
  • Toughness
  • Longevity 
  • Protection from natural elements and more

These benefits clearly signifies, in order to protect you steel structure, galvanization is a must process that you should opt for. So if you are looking for a perfect protection for your steel structure you can get in touch with us. We would be happy to help you. 

Why Choose Us

At Galvanizer our team work relentlessly to come up with innovation’s that can deliver you ultimate experience of galvanized products. Our multi-lateral testing and development process ensures delivering our client premiere quality of galvanizing process. With decades of industry experience we offer nothing but the best. We provide assistance in helping you select the best solution for your metal business. To know more on service and business related inquiry get in touch with us.

galvanizing-steel-is-sustainable-and-a-must-for-your-business-

Galvanizing Steel Is Sustainable And A Must For Your Business

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Businesses all around the world are shifting towards the use of steel rather than iron for a more durable and long lasting structure. One of the main reasons behind this is the longevity that comes with galvanized steel and quality that galvanized delivery even when it comes in contact with reactive agents. It is because of these long lasting properties of galvanized steel along with its noble property it is used and opted across different industries. If you are into business where requirement of durable metal is a must, then you should look forward to invest in galvanized steel for sustainability and larger flexibility for your business. 

Let’s introspect what is galvanized steel and why it is a must for your business.

What is Galvanized Steel?

Galvanized steel is a type of metal that has been developed by coating layer of zinc onto steel. This coating of zinc on to steel is carried out using two galvanizing process hot dip galvanizing and cold galvanizing. In either of cases Galvanized steel is developed with the purpose of protecting against rust and corrosion. It is based on the requirement of business one should select wisely whether to use hot or cold galvanized steel to fulfill their business requirement. 

How Galvanized Steel provides Benefits and Flexibility to your Business

Galvanized steel has multiple usages in a business and can be used to replace even other materials that are deemed expensive or damaged. The supplement of galvanized steel not only provides economical resolution but also provide larger flexibility to business because of its properties. Some of the major benefits of using Galvanized steel are reflected below:

  • Sustainability
  • Durability
  • Proven Quality
  • Cost Effectiveness
  • Honesty
  • Reliability
  • Complete Coverage
  • Predictability
  • Triple protection
  • Toughness
  • Faster Turnaround  

These benefits signified by the galvanized steel ensure a quality advantageous position for your business. Let’s introspect how each of these quality ensure sustainability of galvanized steel, making it a must for your business. 

Sustainability of Galvanized Steel 

The long-term durability provided by galvanizing is achieved at relatively low environmental burden in terms of energy and other globally relevant impacts. One of the main reason behind this being non galvanized steel or other metals has to be maintained from time to time against corrosion and followed up with color to ensure long lasting vendetta. The usage of galvanized steel ensure protection against corrosion resulting in lower maintenance cost ensuring usage of the budget elsewhere, while protecting the environment from harmful fumes of re-coloring over and over again.  

Durability of Galvanized Steel

A galvanized coating is one of the most durable forms of corrosion protection on the market. One of the main reasons behind this is galvanized steel ensures removal all kind of impurities from within the steel. Further, with the process of galvanizing, steel results in getting an additional coating of 85mm if the steel used is 6mm thick. This 85mm coating is corrosion proof against majority of rusting and corrosive agent for a long period of time, making the galvanized steel long lasting and durable.  

Proven Quality of Galvanized Steel

Galvanizing is all around us, with the galvanizing of steel different industry recording increased production over the years. From the smallest to the largest elements, galvanized steel define itself from time to time as trustworthy and reliable, with a track record and proven performance, which is rigorously tested through expert monitoring and performance data collection defining 0.01m² corrosion rates for every 10km².

Cost Effectiveness of Galvanized Steel

The cost of protecting steel from corrosion takes into consideration two important elements, the initial cost of protection and the lifetime cost. On a comparison scale of coloring to that of galvanizing the cost of galvanizing showcases 35% lower lost based on average of initial cost and life time cost. This results in large scale saving for businesses in long run resulting in a cost effective solution for the business.   

Honesty of Galvanized Steel

The metallurgical bond that is framed when steel is plunged into liquid zinc; an aroused covering offers direct, secure assurance consistently. Hot galvanizing sans uncontaminated steel for the rusting cycle to reappear, it is because of this reason failure from underneath with galvanizing steel is almost impossible, making the galvanized steel an ideal material for all season. This surety of protection ensures a consistent honesty of with the usage of galvanized steel. 

 

Reliability of Galvanized Steel

Galvanizing of steel is a relatively controlled process. This makes the coating a consistent, process. It is because of this reason galvanizing steel is most reliable when it comes to corrosion protection. It is mainly because galvanizing is a metallurgical process that creates a metallurgical bonding rather than chemical or mechanical bonding making the zinc and steels a single structure. This ensures a thorough reliability with galvanized steel.  

Complete Coverage of Galvanized Steel

Galvanizing creates a metallurgical bond between steel and zinc, forming a coating that will last for generations.  This provides superior strength besides superior coverage, so that galvanized steel structures remain protected, even in their most vulnerable areas. This ensures that the structure is protected from inside out even in case of exposure to extreme corrosive condition, providing complete coverage with the usage of galvanized steel on any structure.

Predictability of Galvanized Steel

Galvanized coating on steel showcases a predictable protection against corrosion weather in a linear fashion. The thicknesses of the coating are measurable and offer life spans that can be relied on and forecasted easily. Using this methodology forecasting for coating thickness based on gauge size of the steel and linear predictability calculating possible of corrosion if any is much easier in galvanized steel, making it ideal for usage and predictable for types of usage.

Triple Protection of Galvanized Steel

The usage of galvanized steel ensures triple protection with its usage in the following ways:

  • Physical Barrier: A galvanized coating provides a physical barrier which is metallurgically bonded, and prevents the underlying steel from being exposed to atmospheric conditions.
  • Sacrificial Protection: A galvanized coating will corrode preferentially and slowly highlighting cathodic protection. It is because scratches on galvanized steel do not require repair work, and in case areas do become exposed to humidity and other corrosive elements, the galvanized coating will corrode preferentially and at a slower rate than the underlying steel.
  • Prevention of sideways creep: In the unusual event that a galvanized coating is locally compromised and bare steel is exposed, the zinc coating will limit damage and prevent a form of corrosion known as sideways creep, which in turn will protect the steel by slowing down the overall corrosion process.

This highlights the triple approach to protection with the usage of galvanized steel. 

Toughness of Galvanized Steel

Galvanizing has an abrasion resistance up to ten times better than organic paint coatings. The hot dip process is unique, producing a coating which is bonded metallurgical to the steel.  As a result, galvanized steel has superior resistance to mechanical damage during handling, storage, transport and erection. This unique metallurgical bonding ensures compact toughness to the galvanizing steel making it in uniquely applicable for all possible requirements.

Faster Turnaround for Galvanized Steel

Galvanizing is not a time-consuming process and in reality, it takes just a few minutes to dip prepared steel work into molten zinc to form a durable, reliable coating. This in turn makes the availability of galvanized steel much faster compared to other metals making it an ideal material for usage since it has a fast turnaround time.

Other than these major benefits that your business can have with the usage of galvanized steel, it also reflects other major advantages as below:

  • Low initial cost
  • Longevity
  • Sacrificial anode
  • Multiple approach to galvanizing process as per requirement

With these additional advantages over the existing benefits highlighted above it is clearly visible how galvanized steel can provide a sustainable solution to a business ensuring it a must requirement in business for greater flexibility and edge over natural agents & calamities and other business competitors.  

If you are looking for galvanized steel requirements in your business, then look no more come to us at galvanizer for best in quality galvanized steel. 

Why Choose Us?

At Galvanizer our team work relentlessly to come up with innovation’s that can deliver you ultimate experience of galvanized products. Our multi-lateral testing and development process ensures delivering our client premiere quality of galvanizing process. With decades of industry experience we offer nothing but the best. To know more or to order from us get in touch with us.