Galvanized Steel: Types, Uses, Benefits - National Material Company

 The steps in the galvanizing process are as follows:

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• The steel is cleaned in a degreasing solution
• After being cleaned, the steel is pickled by being lowered into a vat of diluted hot sulfuric acid
• The steel is then fluxed in an aqueous solution (typically zinc-ammonium chloride)
• After the flux, the steel is galvanized through immersion in a vat of molten zinc
• Afterward, the steel is inspected for consistency and a complete coating

What are the advantages of galvanized steel?

Many different industries utilize galvanized steel primarily because it has such a wide array of benefits for industries to take advantage of, including having:

Low initial cost compared to most treated steels. In addition, galvanized steel is immediately ready to use when delivered. It does not require additional preparation of the surface, inspections, painting/coatings, etc. sparing companies more costs on their end.

Longer life. With galvanization, a piece of industrial steel is expected to last more than 50 years in average environments, and can last over 20 years with severe water exposure. There is no maintenance required. The increased durability of the steel’s finished product also increases the product’s reliability.

The sacrificial anode ensures that any damaged steel is protected by the surrounding zinc coating. It doesn’t matter if the steel section is completely exposed; the zinc will still corrode first. The coating will corrode preferentially to the steel, creating a sacrificial protection to the areas that are damaged.

Rust resistance from the zinc coating. The iron elements in steel are incredibly prone to rusting, but the addition of zinc acts as a protective buffer between the steel and any moisture or oxygen. Galvanized steel is very protective, including sharp corners and recesses that couldn’t be protected with other coatings, making it resistant to damage.

Different methods of galvanizing

As stated above, there are several different processes for galvanizing steel.

Hot-Dip Galvanizing

The first and foremost method for galvanization is hot-dip galvanizing. The process is very similar to what the name suggests! In this method, steel or iron is dipped in a molten pool of zinc that maintains a temperature of around 860°F (460 °C). This molten bath begins a metallurgical bond between the zinc and the receiving metal. After the metal is pulled from the bath, it reacts to being exposed to the atmosphere, and the pure zinc mixes with oxygen to form zinc oxide. The zinc-oxide further reacts to carbon dioxide and forms zinc carbonate, which makes up the final protective coating on the material. The tell-tale sign of a hot-dipped galvanized material is the presence of a crystalline-like pattern on the surface, sometimes referred to as “spangle.”

The hot-dipped galvanizing method is an economical choice that can be quickly executed on both simple and complex shapes. 

The new coated material can be worked and machined in a similar fashion to uncoated materials. Galvanized steel can be used in high-temperature applications up to 392 °F, but use in temperatures exceeding that level will cause the zinc-carbonate layer to peel off. 

Galvannealing

Galvannealing is the outcome of combining the annealing and hot-dip galvanizing processes in order to produce a specialized coating on steel. The process of galvanization is performed via hot-dipping and instantaneous annealing, which produces a matte gray finish.

Galvannealed steel is a zinc-iron alloy product, where the base metal is coated by the hot-dip process, then heated to induce alloying between the molten zinc coating and the steel. The resulting finish is a dull matte surface. Galvannealed steel is conducive to welding and the surface is excellent for paint adhesion.

Pre-galvanizing

Also similar to the hot-dip galvanizing method, but performed at the very first stage of production. Pre-galvanizing is a process that involves rolling the sheet metal through a cleaning agent to quickly prime material for galvanizing. Then, the metal is passed through a pool of molten liquid zinc and is immediately recoiled. The primary advantage of this method is that coils of steel sheet can be rapidly galvanized on a large scale with a more unified coating than the traditional hot-dipped method.

Electrogalvanizing

The most unique of these outlined methods, electrogalvanizing does not involve dipping the material in a molten vat of zinc. Instead, an electric current is introduced to an electrolyte solution that is applied to the steel, which reduces positively charged zinc ions to zinc metal – which is then deposited on the positively charged steel. Like pre-galvanizing, this method is typically done at the first stage of production.

Galvanizing advanced high-strength steel

For more information about the galvanization process for advanced high-strength steel, as well as our partner National Galvanizing, please click here.

What industries utilize galvanized steel?

Galvanized metals are used everywhere!

The bodies of cars and many bicycles are made from galvanized metals. Some drinking water pipes are still made from galvanized steel. Cool rolled sheet metal is also frequently galvanized. Nuts, bolts, tools, and wires of all kinds are now galvanized because it is a cheap process, and helps boost the metal’s lifespan!

Galvanized steel, in particular, is often what is used in modern “steel frame” buildings. Galvanized steel is also used to create structures like balconies, verandahs, staircases, ladders, walkways, and more. Galvanized metal is the ideal choice if your project will live outside after it’s done. Fences, roofs, outdoor walkways, these are all great choices for galvanized metal!

• Wind & solar industries – Solar projects must have a continuous workflow once installed and any repairs/maintenance results in disruption to service (a.k.a. revenue loss). This means that hot-dipped galvanized steels are popular in solar projects for their corrosion protection. It is also popular for its ‘environmental’ friendliness because it does not produce emissions and ensures decades without maintenance. For example, it is often utilized in the agriculture industry because the equipment is susceptible to being easily corroded, creating a demand for tougher, more resilient equipment. Hot-dip galvanized steel provides corrosion protection that can often last for decades, even when exposed to the harsh environment of farming.

• Automotive industry – Though only used on luxury models up until the s, the use of zinc-coated bodies for automobiles is now the norm in auto manufacturing. The ‘body-in-white’ of a car makes up about 80% of the body, all using galvanized steel. The rust -resistance of galvanized steel is also a good marketing tool for the automotive industry because it can provide ‘anti-rust warranties’ to customers.
• Construction industry – Whether for residential or commercial, the durability of galvanized steel has made it popular for over a century in the construction industry. It is also selected for construction because of its aesthetics; The ‘shine’ that galvanized steel provides gives it a contemporary feel and is popular in modern architectural designs. Also, it isn’t just used for large structural pieces but things like fencing, gutters, rails, tubing, poles, and much more.
• Telecommunication industry – lines are not an easy maintenance job, they are tall and often difficult to reach. Hot-galvanized steel can be used on wiring and equipment boxes which decreases the risk of damage and need for maintenance at all.

Well, there you have it! With our partner Heidtman Steel, National Galvanizing  runs a 245,000-square-foot facility, featuring pickling, galvanizing, galvannealing, and slitting, all in one location, convenient to major markets. This combination of capabilities provides our customers with unparalleled responsiveness to meet the ever-changing demands of today’s market.

Galvanized steel wire can be considered as a very important product used in all construction works. What is galvanized steel wire? Why is it commonly used in everyday life?

In the article below, we invite you to join MRS Steel to learn basic information as well as common applications of galvanized steel wire.

What is galvanized steel wire? Let's find out through the article below

What is galvanized steel wire?

What is galvanized steel wire? Galvanized steel wire is a type of steel wire that has a shiny white color, high toughness, and durability and is a product widely used in the fields of electricity, industrial production, and construction. Galvanized steel wire is usually produced from low-carbon steel through a process of heating and drawing into wire. Galvanized steel wire is usually very small in size, thin, and rolled into large coils for easy transport. Galvanized steel wire features a smooth or ribbed surface, with average production diameters from 0.4mm to 14mm. The average weight of a roll of galvanized steel wire usually ranges from 200 to 459 kg/roll.

Galvanized steel wire is widely used in everyday life

Classification of galvanized steel wire

The above section has given you information about what is galvanized steel wire? Next, we invite you to learn about the popular types of galvanized steel wire.

Currently, galvanized steel wire is classified based on the galvanizing method. Therefore, galvanized steel wire is divided into two main types: hot-dip galvanized steel wire and electrolytic galvanized steel wire. Currently, zinc plating is produced with matte or gloss plating technology according to standards TCVN , JIS G305, ASTM A475 or according to customer requirements. For everyone to better understand these two types of galvanized steel wire, please follow the classification table below.

Classification table of 2 main types of galvanized steel wire

Advantages of galvanized steel wire

Galvanized steel wire is increasingly used not only in the construction industry but also in other industries. So why is galvanized steel wire so commonly used? Let's find out below.

• High applicability: Galvanized steel wire is used in many industries such as construction, handicrafts, industry,...
• Corrosion resistant: The outer galvanized layer increases the oxidation resistance of the steel wire, making it difficult for the steel wire to corrode and extending the product lifespan.
• Low cost: The cost of galvanized steel wire is often cheaper than aluminum or copper wire. Therefore, they often bring lasting economic value to users.
• Long lifespan: Galvanized steel wire has a lifespan of over 50 years in normal weather conditions and 20–25 years in environments with many corrosive substances, such as industrial parks, coastal areas,...

Galvanized steel wire is plated with an outer layer of zinc to help protect the product better

Application of galvanized steel wire

As an essential material in the construction field, along with serving human life, galvanized steel wire is found almost everywhere around us. Here are a few applications of galvanized steel wire:

• Application in the construction industry: Mainly widely used in the construction industry, such as reinforcing houses, apartments, swimming pools,...
• In civil use: used to bind goods, make barns for the livestock industry,...
• In production: used to weave types of mesh such as chain-link fencing, welded steel mesh,...
• Also used in industrial production, handicrafts, and other fields.

Hot-dip galvanized steel wire is often used to make welded wire mesh

MRS Steel - The best way to procure affordable galvanized steel wire from Vietnam for international markets

MRS Steel is known as an enterprise specializing in providing galvanized steel wires from famous brands in Vietnam. MRS Steel always puts customer satisfaction first, taking it as its operating motto. Accompanying MRS Steel, you will receive:

• High-quality products with a low price.
• Experienced and enthusiastic staff.
• Fully meet the essential needs that customers set out within the allowable range.

MRS Steel has provided you with information about what is galvanized steel wire and its applications in life. If you need to buy galvanized steel wire, please contact us via (+84) 769 112 358 or leave your information here, we will contact you as soon as possible. To stay updated on market news and the global steel situation, readers can explore more in-depth, valuable articles in the Steel News section of MRS Steel!