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Galvanizing is the process of applying a zinc coating to steel to provide a rust protection layer. Iron will readily react with oxygen to form iron oxide (rust), and the zinc layer forms a protective barrier around the iron to protect it and improve the longevity of the steel.
The two most common methods of galvanizing steel are Hot Dip and Electrostatic Galvanizing.
Hot Dip Galvanizing is the process of coating steel by directly dipping it into a bath of molten zinc. The steel will need to go through a series of steps to ensure complete coverage of a good quality zinc layer. The steps generally include:
The product of Hot Dip Galvanizing provides a relatively thick zinc layer.
Electrostatic Galvanizing is the process of coating steel in zinc by using electroplating. This involves submerging the steel (which acts as a cathode) and an inert anode in an aqueous solution containing dissolved zinc salts. A current is then forced from the steel cathode, through the aqueous zinc solution, and to the inert anode. By forcing this electric current through the steel, the dissolved zinc is plated on top of the steel and provides a complete barrier.
The product of Electrostatic Galvanizing will provide a relatively thin zinc layer.
While the hot dip and electrostatic galvanizing methods differ considerably, the differences in the final product can be summarized into three key areas.
What are Common Applications for each Method?
Hot Dip Galvanized products are used in almost any application that benefits from a low production cost and a long life. This is especially relevant for any steel products that will be exposed to the weather. Typical examples include:
Electrostatic Galvanizing tends to be utilized for more specialized purposes that require a smooth finish or tight tolerances. These include:
Steel strand can be used in the production of a variety of different products including wire rope, aircraft cable, and structural cable for bridge and building support. The construction of steel cable consists of thin steel wires that are stranded together to give the cable the perfect blend of strength and flexibility. Different constructions allow steel cable to be used in a number of different industrial, commercial, recreational, and military applications.
For extreme environments where exposure to moisture, salt water, or corrosive or caustic chemicals is possible, the correct type of stainless steel cable is the preferred choice. For most applications, a galvanized zinc coating will offer some form of corrosion resistance and still provide the strength and flexibility characteristics desired by the end-user.
However, the term &#;galvanized&#; can be confusing for the end-user as there are a number of options for providing protection to the base metal. In this article, we&#;ll be reviewing two different galvanization processes&#;electro galvanization and hot dip galvanization.
There are a number of cable distributors who carry one type of product and mark it as &#;galvanized,&#; but don&#;t specify whether it&#;s electro galvanized or a hot dip galvanized product. This can lead to confusion for the end-user when they&#;re comparing galvanized cable quotes because the price and corrosion-resistance can vary between products of equal specifications.
At Mazzella, we stock and distribute wire rope and cable in stainless, electro galvanized, and hot dip galvanized coatings. Our goal for this article is to explain the differences between the two types of galvanized coatings, and identify the advantages, disadvantages, and proper applications for each product type.
Electro galvanization is a form of zinc electro plating where a thin layer of zinc is electrically and chemically bonded to steel in order to protect against rust and corrosion.
During this process, bare steel wires are fully immersed in a saline/zinc bath and electricity is used to move electrons from the zinc (anode) and bond them to the steel (cathode). In this case, the zinc acts as a barrier layer on top of the steel to prevent corrosive substances from reaching the underlying steel or iron. The wires are then formed into strands and then the strands are helically formed into the finished cable or wire rope configuration.
When the process is complete, the finished coating is smooth, drip-free, and shiny&#;making it ideal for architectural applications or other applications where its aesthetic characteristics would be of value. However, once it&#;s exposed to the elements, the finish can quickly deteriorate.
If you want to learn more, please visit our website Electro Galvanized Wire.
Electro galvanized cable should be used in applications with limited exposure to harsh or extreme environments. It offers minimal corrosion protection, but in instances where it&#;s fully exposed to the elements, it will begin to corrode much faster than hot dip galvanized.
The main advantage to electro galvanized cable is that it&#;s the most cost-effective solution. For construction sites, it can be used as perimeter cable or as a barrier or tie-off cable for employees working at heights. For applications where it may experience field use for a few weeks or a few months, it can then be safely disposed of once the project is complete.
If exposure to the elements is minimal, it can be used in architectural applications for aesthetic purposes due to its naturally bright and shiny finish.
In hot dip galvanized cable, each uncoated steel wire is immersed in a molten zinc bath. Prior to dipping, the wires are put through a rigorous 7-step caustic cleaning process and then dipped into the molten zinc at a temperature of around 860°F/460°C. As it&#;s withdrawn from the molten bath, the material cools and forms a coating of zinc on the steel. The wires are then formed into strands and then the strands are helically formed into the finished cable or wire rope configuration.
Hot dip galvanizing provides much better corrosion resistance than electro galvanization because the zinc coating is typically 5 to 10 times thicker. For outdoor or caustic applications where corrosion-resistance is required, hot dip galvanized cable is the clear choice.
Because it offers superior corrosion resistance compared to electro galvanized cable, hot dip galvanized cable can be used for any application where the cable will be exposed to the natural elements or a caustic environment. Hot dip galvanized cable can be used for fencing or perimeters for construction sites, parking garages, farm and livestock facilities, and much more.
Hot dip galvanized wire rope can also be used for lifting and rigging in crane application and with outdoor winches or pulley systems. Professional zip lines are also another popular use as the cable can withstand corrosion in moist and humid environments.
The term &#;galvanized&#; only tells the end-user that some type of corrosion-resistant coating has been applied to the steel material. However, suppliers don&#;t always specify whether the cable they&#;re selling is an electro galvanized or a hot dip galvanized product.
Hot dip galvanized will always be more expensive than electro galvanized product because of a more labor intensive galvanizing process and because it offers greater resistance to rust and corrosion.
If you&#;re looking for a cost-effective option for a short-term project, or need a cable that won&#;t be exposed to the elements, then electro galvanized cable or wire rope would be the best choice for you.
In order to specify the right type of cable for your next project, do your research and work with a reputable and knowledgeable distributor. This will help ensure that the correct and most appropriate products are purchased for your budgetary and performance requirements.
At Mazzella, we sell all different types of wire rope, aircraft cable, and structural cables. We carry stainless, electro galvanized, and hot dip galvanized products and our highly-trained Lifting Specialists can help you determine the right type of steel cable or wire rope for your application. If you&#;re interested in learning more about the different cable products we carry, or need a quote for your next project, contact us today.
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