Although galvanized steel is one of the most commonly used materials around the world, there are interesting facts that you might have never heard of. For example, do you know that 2 out of every 3 tons of steel are from recycled steel? And up to 95% of some kind of steel will be surely used again.
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There are more tidbits about galvanized steel that might surprise you, which will be introduced to you today.
Galvanized steel is manufactured from galvanizing. After the process, the newly formed zinc-iron coating protects the base metal made from steel. This coating enhances the durability & strength of the steel itself by the corrosion protection. It also changes the steel’s appearance by giving it a rugged look.
Overall, after going through the galvanizing process, the steel becomes stronger and harder to scratch and corrode; which makes it an ideal material for outdoor usage.
Thanks to the galvanization process, galvanized steel is ready to use, costs little to maintain, lasts longer than other protection, resists rust well and has a complete protection.
You can find galvanized steel in several industries thanks to its amazing advantages.
For more information about galvanizing and galvanized steel, clickhere.
The word ‘galvanize’ & ‘galvanizing’ didn’t come out of nowhere. It refers to any electrochemical processes, which is typical of an Italian scientist, Luigi Galvani.
Lived in the eighteenth century (-), Luigi Galvani was not just a premier physicist but also a famous physician, philosopher, and biologist of his time. He was the one to discover that animal tissues respond to tiny electrical currents. This result was gained from an experience when he applied electrical currents on a frog’s legs and was so significant that all kinds of electrical currents were known as ‘galvanic’.
50 years later, Sir Humphry Davy discovered that when zinc is in contact with iron in an electrochemical process, it could protect iron from rusting. The procedure then became known as ‘galvanizing’.
Zinc is the must-have element in galvanizing process instead of other metals as it oxidizes and experiences acid corrosion “sacrificially” to steel, which makes a protective coating for underneath metal.
Zinc protects the metal from the atmosphere, which reduces the chance of corrosion. It also provides a perfect cathodic protection. If there is any harm to the metal, the zinc coating will handle it all.
Galvanized steel is an inexpensive material that lasts a lifetime. It’s ready to use when you buy it, while only costs a few cents per pound more than untreated steel. The treatment of the steel in the construction site might cost four to five times as much as galvanized steel.
The galvanization process gives the steel a perfect protection from rusting and corrosion that might last for 50 years or even longer, which is not the case with either stainless steel or structural steel.
With the evolution of technology, galvanized steel, together with the galvanizing process, has evolved fast over the years.
For now, galvanization is more of an electro-deposition term than electrochemical. Although zinc is still the primary material used in the process, there are new advanced technologies to protect metal from elements.
Besides the hot-dipped galvanizing process, there are more alternative ways to galvanize the metal. Electrogalvanization, sherardizing, ‘dry galvanizing’ or ‘shot blasting’… are other ways that are now used to protect metal from corrosion and outside forces.
If you think galvanized steel is only used in construction, you are totally wrong.
Since the last century, galvanized steel has become an important go-to material for the auto industry, thanks to its amazing advantages. It solves the painful problems for the users with the great rusting, corrosion and scratches protection in nuts, nails, and bolts.
Galvanized steel is also used for outdoor applications such as pipes, bus stop benches, balconies, staircases, ladders, cattle fences, other products… that other materials are not strong enough. You can even find galvanized steel in the lighting column that provides nighttime lighting for roadways.
Thanks to the amazing advantages that galvanization offers, galvanized steel and galvanizing applications might be just about everywhere you look. It is one of the oldest building and manufacturing materials in the world, but it evolves continuously to meet new demands. And if you are looking for a sustainable material for your project, you might now know where to start.
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:
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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.
Are you interested in learning more about Galvanized Steel Sheet In Coil? Contact us today to secure an expert consultation!