5 Benefits of Galvanized Steel - Metal Exponents

What are the benefits of galvanized steel?

1. Cost-effective
2. Better durability
3. Minimal maintenance
4. Good surface finish
5. Corrosion-resistant

There are many benefits of galvanized steel that you should know about. If you’re using steel metal for many purposes, you need to consider if they can withstand different environmental factors.

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Not all metals without a protective layer of coating can be protected against different types of corrosion, like cracking, pitting, leaching, and more. If you want to make the most out of your steel product, you should highly consider having it galvanized. Better yet, buy galvanized steel products like pipes, rebars, and beams. Continue reading to learn more.

What is galvanization?

As mentioned before, galvanization involves the application of a layer of zinc coating to steel and iron alloys. This is because of the highly-concentrated iron content in steel which can make products of this kind more prone to rusting. Through galvanization, alloys can be better protected against forms of destruction and erosion that may form on their surfaces.

Although there are many kinds of galvanization techniques such as hot-dip, electrogalvanization, thermal spraying, and sheet galvanizing, hot-dip is arguably the most common form.

Cost-effective

One of the advantages of galvanized steel is that it is considerably more cost-effective compared to other coating options. Because the process is so simple, steel product manufacturers and suppliers don’t have any problem when it comes to galvanizing different steel products.

Hot-dip galvanization is not only the most common but also the most affordable. The process only involves three simple stages, such as surface preparation, galvanizing proper, and then product inspection. Here’s how.

• First, manufacturers would have to clean the surface of the steel specimen. The time it takes to do this depends on the size of the material. Cleaning removes unwanted substances that can hamper the galvanizing step.
• After a thorough cleaning has been completed, the steel will now be dipped into a hot molten zinc bath that maintains a temperature range of 435 to 455 degrees Celsius. A metallurgical reaction allows the zinc to bond with the material.
• Manufacturers would then conduct inspections on the product to ensure that no defects take place. It is now ready to be distributed for supply.

Better durability

When you’re buying any kind of steel, whether it be for structural, functional, or decorative purposes, you want to make sure that the steel product is durable. This is so you won’t have to spend too much money on simply getting steel supplies for your intended project.

Unlike other types of steel coating techniques, galvanizing also offers better durability. You can be sure that any galvanized steel product that you will use won’t have to be constantly replaced. They can retain their shape and form for a long time, even when they are met with abrasives or any other substances that can impact the shape and form of the steel.

Minimal maintenance

When you’re buying unprotected metal products, say for your plumbing system, you may become more prone to maintenance issues. If you’re not using galvanized iron pipes for this aspect of your building space, for example, you may experience more frequent problems such as leaks and busted pipes.

Maintaining your pipes can be time-consuming and can take a lot away from the other important things that you need to take care of, during the day. With this in mind, galvanized steel pipes present you with a less labor-intensive solution for your current piping problems.

The zinc layer that has been properly bonded to the alloy’s surface protects the metal from any kind of damage. You won’t have to constantly have to inspect, maintain, and reinstall your piping network just to maintain its full-functioning.

Good surface finish

Steel products are not only good for structural purposes, but they can also make a great addition to any contemporary space. If you’ve long been wondering how to incorporate metals in your house’s exteriors or interiors, then galvanized steel might just be the key.

You can make steel a part of residential spaces or building structures, by using them as exposed structural steel, railings, beams, columns, furniture, and the like. With zinc coating, these steel materials are made infinitely more attractive and durable because of their decorative surface finish.

You can easily complement your steel accents and fixtures with other designs and elements that you want to place in your space, without having to think too much about what color best suits the alloy.

Corrosion-resistant

You shouldn’t underestimate just how well galvanization protects any steel product against corrosion — arguably one of the enemies in the metal fabrication industry.

For example, exposed steel surfaces might experience a sped up wear and tear of the material. When this happens, the material may no longer be conducive for application. Corroded steel pipe fittings, in particular, may no longer be attached to the pipes. Structural beams, on the other hand, may pose dangers to the entire structure.

With a corrosion-resistant layer such as zinc, it’s far safer to continue making use of the steel, as long as its surfaces are intact. They would also still be able to retain their high-performance qualities, making them perfect for high-temperature and high-pressure applications.

Key Takeaway

Knowing the benefits of galvanized steel can help you gain a better sense on the kind of steel products that you should always be looking out for. Although steel already has a few key desirable properties, the addition of the galvanization technique improves its durability, surface finish, functionality, and corrosion-resistance.

The next time you’re purchasing steel materials, see if your supplier can accommodate galvanization. This method is relatively easy to do and will provide you with cost savings that you simply have to take advantage of.

 The steps in the galvanizing process are as follows:

• 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.

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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.

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