A hot-dip galvanized coating is relatively easier and cheaper to specify than an organic paint coating of equivalent corrosion protection performance. The British, European and International standard for hot-dip galvanizing is BS EN ISO 1461, which specifies a minimum coating thickness to be applied to steel in relation to the steels section thickness e.g. a steel fabrication with a section size thicker than 6 mm shall have a minimum galvanized coating thickness of 85 µm.
Galvanized steel is widely used in applications where corrosion resistance is needed without the cost of stainless steel and is considered superior in terms of cost and life-cycle. It can be identified by the crystallization patterning on the surface (often called a "spangle").
Hot dipped galvanized wire is used in making cages, wire mesh, Cable armoring wire, construction, handicrafts, product packaging, and daily civilian and other fields. Also be used in various fields such as building, handicraft, wire mesh, galvanized hook net, wall screen, highway fence, product packaging, and daily civilian.
Hot Dipped Galvanized Wire
Benefits of hot-dip galvanized steel
For over 100 years, hot-dip galvanizing has been specified to combat corrosion in steel; however, as new markets have emerged, the specifications and uses of galvanized steel have evolved. While there is inherent corrosion resistance any time hot-dip galvanizing is used, there are many other benefits including low initial and life cycle costs, durability, longevity, usability, versatility, sustainability, and aesthetics that have led to the specification of galvanized steel.
Steel is a rich, efficient building material that provides specifiers with design freedom. However, for projects that are exposed to atmospheric and other harsh environments, it is vital that steel is coated to prevent corrosion. Large construction projects often aim for a design life of 50-100 years, highlighting the need for durable, long-lasting protection against corrosion. Hot dip galvanising (HDG) provides three levels of corrosion resistance for steel: barrier protection, cathodic protection, and zinc patina.
Hot dip galvanizing, like other coatings, isolates the steel from the environment and provides basic barrier protection. The intermetallic compound layer of the zinc coating bonds tightly (~3600 psi) to the base steel, making damage difficult. Galvanising also provides cathodic protection, which means that the zinc sacrifices itself to protect the steel beneath. Even if the coating is scratched, the surrounding zinc will continue to resist corrosion of the steel.
In addition to the barrier and cathodic protection, hot dip galvanising has a third level of protection - zinc patina. When zinc is exposed to the environment, it naturally forms a by-product on the surface, which slows down corrosion and acts as an additional environmental barrier. When the zinc patina is fully developed, the corrosion rate of hot-dip galvanized steel is approximately 1/30th of that of steel in the same environment.
Another aspect of hot-dip galvanising has proven to be unparalleled in its durability, even in harsh conditions. This is due in part to the abrasion resistance, uniform protection, and complete coverage of the galvanized coating. The layer of intermetallic compound formed in the galvanising kettle is metallurgically bonded to and harder than the base steel, while the top layer of pure zinc is more ductile and able to absorb impact. Together, these zinc-coated layers provide unparalleled wear resistance.
Hot-dip galvanizing also provides uniform protection and complete coverage. The zinc coating grows perpendicular to the steel, so corners and edges have the same thickness as flat surfaces. Furthermore, the total immersion process ensures hollow and tubular structures are coated and protected, inside and out. This complete, uniform coverage means there are no easy targets for corrosion to attack.
Hot-dip galvanized (HDG) steel is versatile and readily available. Galvanizers are found throughout North America, and thanks to the factory-controlled process, a wide variety of steel shapes and sizes can be hot-dip galvanized 24/7/365 - rain or shine. Furthermore, zinc solidifies upon withdrawal from the bath, so there are no delays for curing when schedules are tight. On the other hand, hot-dip galvanized steel can be easily stored or stocked outside, without degrading the coatings integrity, until it is ready to be erected.
Hot-dip galvanized steel is made of two primary components zinc and steel. Both are natural, abundant elements in the Earths crust; in fact iron ore is the 4th most abundant element, and zinc is the 24th. In addition to being abundant, both steel and zinc are 100% recyclable without the loss of any chemical or physical properties. This means they can be used as zinc and steel (or galvanized steel) again and again - creating an infinitely renewable resource.
Hot Dipped Galvanized Wire
Hot-dip galvanized steel is often utilized in some of the harshest environments imaginable, yet it provides maintenance-free longevity for decades. The corrosion resistance of hot-dip galvanizing varies according to its surrounding environments, but generally corrodes at a rate of 1/30 of bare steel in the same environment. The most common exposure for hot-dip galvanized steel is in the atmosphere. According to real-world studies and data, hot-dip galvanizing can provide more than 70 years of maintenance free corrosion protection in the most corrosive atmospheric exposure (industrial).
In addition to the atmosphere, hot-dip galvanizing is commonly used to protect steel embedded in soil and/or concrete or submerged in water. Though the corrosion mechanisms and life expectancy is different in each, galvanized steel has a proven track record of longevity in all of these environments.
Zinc exists naturally in the air, water, and soil in abundance. Furthermore, zinc is essential to all life - from the smallest microorganisms to humans. As previously stated, zinc and steel are both 100% recyclable without the loss of properties - making galvanized steel an infinitely renewable material.
In addition to the natural, abundant elements that create hot-dip galvanized steel, the material has little impact on the environment. Maintenance-free longevity means no additional energy or resources are required while galvanized steel is in use. Eliminating maintenance also eliminates emission or waste outputs, as the only thing the hot-dip galvanized coating adds to the atmosphere are zinc byproducts, which already exist there naturally. Therefore, the environmental impact of hot-dip galvanizing is isolated to the production phase of the material, and extrapolated over the decades of service, until ultimately the steel and zinc are recycled.
Sustainable development is the social, economic, and environmental commitment to growth and development that meet the needs of the present without compromising the ability of future generations to meet their own needs. As the social pressure continues to mount to construct the built environment sustainably, specifiers are becoming more invested and analytical in the materials they choose. Hot-dip galvanized steel's maintenance-free longevity provides positive environmental and economic benefits to future generations.
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