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When it comes to galvanizing steel, there are a few different ways to do it. While each method has its own practical uses, we still believe that hot-dip galvanizing is the best choice for ultimate corrosion protection. The main reason for this is that there is a big difference between hot dip galvanized and galvanized materials. When you want to ensure the integrity of your project, you want to be sure you use the best method and materials.
Before we explain why hot-dip galvanizing is still your best option for strengthening and protecting steel, let&#;s quickly look at some of the most common, alternative methods of galvanizing steel.
This method of galvanizing trades a zinc bath for an electrolyte solution, which the steel is covered in prior to being treated. While the steel is resting in the electrolyte solution, an electric current is applied, which converts zinc ions into zinc metal that adheres to that steel. This scientific process creates a thin layer of zinc. However, because the coating is so thin, the material can still be susceptible to corrosion.
This process is a combination of hot-dip galvanizing and annealing, which is a heat treatment that alters the microstructure of a material to make it more durable. So, galvannealing still uses hot-dipping, but by annealing at the same time, the resulting steel has more of a matte grey finish. The resulting coating is a combination of both zinc and iron. It can be great for manufacturing products or for welding but is not the best choice for infrastructure projects that demand tougher materials and corrosion protection.
As the name implies, pre-galvanizing is similar to hot-dip galvanizing but is completed as the first stage in production instead of a final stage. Most often used to quickly coat sheet metal, the material is cleaned and treated before being run through the molten zinc bath and then immediately recoiled. While this expedited process does coat the material, the protective layer is cut during fabrication. This leaves any areas where cutting occurred uncoated and vulnerable to rust and corrosion.
There are three big reasons we still recommend hot-dip galvanizing over other methods:
Hot-dip galvanizing is still the best option for ultimate corrosion protection. This is because of the thickness of the coating and because of when the coating is applied.
Other methods of galvanizing do not allow the steel to bond with the zinc in the same way. This means the resulting coating is not as thick or strong as that produced by hot-dip galvanizing. Without the thickness to protect the material, the coating can be just as weak as any other protective option that cannot stand the test of time.
The other main reason hot-dip galvanizing provides better corrosion protection is that the coating is applied during the fabrication process before the steel is installed. This means that any areas that are cut or damaged during installation will still have a protective coating. Other methods of galvanizing, like pre-galvanizing, coat the steel before it is cut and fabricated. This leaves any areas that are cut or damaged during installation vulnerable to rust and corrosion.
While steel that is galvanized through other means is only suitable for specific types of projects, hot-dip galvanized steel can be used for a variety of building projects. This is because the material is tough, making it able to withstand more wear and tear. It can withstand extreme temperatures better than the materials produced by other methods of galvanization. Its shiny appearance makes it suitable for exterior and interior projects.
It can also be used in a variety of industries, like construction, automotive, and even food and beverage. This is different from the materials other galvanizing methods produce, which are often created for a very specific purpose. When you are trying to stick within a set timeframe and budget, it is better to work with materials that can be used widely in a pinch than to stock up on materials that are only suitable for specific environments.
Hot-dip galvanizing is one of the most economical means of protecting steel. This is for a few reasons. By galvanizing the steel during or after fabrication, you save time transporting materials back and forth. You receive materials that are ready to go and can be cut without fear of hurting the integrity of the product.
Hot-dip galvanizing is also more durable, which means it will last longer and does not need to be replaced as often. This protects your investment by ensuring that the materials you purchase can be used for a longer period of time. In the long run, hot-dip galvanizing is cheaper because you do not need to replace the materials as often.
The American Galvanizers Association has a great Life Cycle Cost Calculator tool that you can use to calculate the initial and life cycle cost of hot-dip galvanizing versus other corrosion protection options.
There are a few different methods of galvanizing steel, but we still think hot-dip galvanizing is the best choice. This is because hot-dip galvanizing provides the best corrosion resistance, is more versatile in use, and is more economical in the long run. When it comes to protecting your steel investment, hot-dip galvanizing is the way to go.
At South Atlantic, we are experts in all things hot-dip galvanizing. After 50 years working with galvanized materials and advising builders, architects, engineers, and project managers, we know exactly what products will work best for your specific project and can make sure you have them on time, and on budget.
You can learn more about us on our website, then contact us here to start a conversation: southatlanticllc.com/contact.
No matter how big your project is, we&#;ve got you covered.
Part of an ongoing series on Galvanized Steel
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. There are several galvanizing processes available, but the most commonly offered and used method is called hot-dip galvanizing.
Galvanized steel is among the most popular steel types because of its extended durability, having the strength and formability of steel plus the corrosion protection of the zinc-iron coating. The zinc protects the base metal by acting as a barrier to corrosive elements, and the sacrificial nature of the coating results 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, construction, and so on. Below, we aim to provide a comprehensive description of how galvanized steel is processed, different galvanization methods, its benefits, and how it is used in these various industries.
The company is the world’s best Hot Dip Galvanized W-Beam Guardrail supplier. We are your one-stop shop for all needs. Our staff are highly-specialized and will help you find the product you need.
The steps in the galvanizing process are as follows:
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!
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.
About National Material L.P. &#; With more than 3,000 employees from a multinational portfolio of companies, NMLP provides engineered metal products which include aluminum extrusion and stainless steel rolled product companies to automotive, aerospace, construction, defense, electrical, and industrial markets. Request a Quote Online or give us a call (U.S.) 847-806-
If you want to learn more, please visit our website Galvanized Highway W Beam Guardrail.