Hot-Dip Galvanising

Home > Hot-Dip Galvanising

ABOUT GALVANIZING

Hot-dip galvanization is a form of galvanization. It is the process of coating iron and steel with zinc, which alloys with the surface of the base metal when immersing the metal in a bath of molten zinc at a temperature of around 449 °C (840 °F).

When exposed to the atmosphere, the pure zinc (Zn) reacts with oxygen (O2) to form zinc oxide (ZnO), which further reacts with carbon dioxide (CO2) to form zinc carbonate (ZnCO3), a usually dull grey, fairly strong material that protects the steel underneath from further corrosion in many circumstances.

Why Hot Dip Galvanizing?

Talk to anyone in the hardware and construction industries, and ask them about what is that one concern that drives them to the wall – (not literally of course!) In all likelihood, the answer will be “the quality, longevity, and performance of the metals in use.  

Hot-dip galvanizing has come a long way since it was first invented 150 years ago. The popularity of the process is because of the many qualities and traits it endows steel with. Above all, hot-dip galvanizing is termed as steel’s “best friend” for it endows it with anti-corrosion properties.

At Hylite, we receive numerous inquiries and requests for improving the quality of their steel objects and structures, and we recommend our best-selling solution – hot-dip galvanizing. One of the foremost reasons why hot-dip galvanizing continues to receive increasing endorsement is because it is the only process that facilitates metallurgical bonding between two metals. The amalgamation ensures enhanced anti-corrosion and durability. In other words, hot-dip galvanizing is the secret behind steel’s agility, quality, function, and performance. If these are qualities that you’d like to infuse in your steelworks, then why not opt for hot-dip galvanizing, and let us do it for you? 

Building design and construction process — step by step

The process of hot-dip galvanizing results in a metallurgical bond between zinc and steel, with a series of distinct iron-zinc alloys. A typical hot-dip galvanizing line operates as follows:

Steel is cleaned using a degreasing solution. This removes oil/grease, dirt, and paint.

The degreasing solution is rinsed off the steel in water (optional if acidic degreaser is used).
The steel is pickled in an acidic solution to remove mill scale.
The pickling solution is rinsed off with water
A flux, often zinc ammonium chloride is applied to the steel to inhibit oxidation of the cleaned surface upon exposure to air. The flux is allowed to dry on the steel and aids in the process of the liquid zinc wetting and adhering to the steel.
The steel is dipped into the molten zinc bath and held there until the temperature of the steel equilibrates with that of the bath.
The steel is cooled in a quench tank to reduce its temperature and inhibit undesirable reactions of the newly formed coating with the atmosphere.
The galvanized steel is finished by removing any sharp edges, spikes and burrs which may have formed during galvanizing and any uncovered areas repaired and inspected for quality Benefits Of Galvanizing

Benefits Of Galvanizing

Galvanized steel is widely used in applications where corrosion resistance is needed and is considered superior in terms of cost and life-cycle.

Like other corrosion protection systems, galvanizing protects steel by acting as a barrier between steel and the atmosphere. However, zinc is a more electropositive (active) metal in comparison to steel. This is a unique characteristic for galvanizing, which means that when a galvanized coating is damaged and steel is exposed to the atmosphere, zinc can continue to protect steel through galvanic corrosion, it self-repairs when damaged, sacrifices itself to protect the base metal.

Our hot-dip galvanizing services are a bestseller because there are a lot of individual clients and companies that want to prolong the lifespan of their steel appliances and applications. Hot-dip galvanizing has earned a reputation and popularity because it helps steel to last up to 20 years. What’s more, the performance and quality stay intact throughout, and very little maintenance is required. 

Hot dip galvanizing offers coverage both externally and internally within hollow sections, is environmentally sustainable, has good impact and abrasion-resistance and a maintenance-free life of 50 years or more. Galvanized steel is widely used in applications where corrosion protection is needed.
Our hot-dip galvanizing services are a bestseller because there are a lot of individual clients and companies that want to prolong the lifespan of their steel appliances and applications. Hot-dip galvanizing has earned a reputation and popularity because it helps steel to last up to 20 years. What’s more, the performance and quality stay intact throughout, and very little maintenance is required.
  • The uniqueness of the hot-dip galvanizing process makes it an attractive go-to service. Metals not only get coated but also get subjected to metallurgical-binding which helps them to develop improved resistance and durability thereby making steelworks easy-to-ship, handle, and handle.
  • With hot-dip galvanizing you do not have to worry about the coating uniformity or toughness. When steel objects and applications get dipped into the molten liquid, every awkward and unreachable nook and corner will get coated. Rest assured, when the process ends, the coating will be uniform, there will be complete coverage, and the coating will be tough.
  • Galvanized coatings take (almost) forever to reveal any wear and tear. In other words, galvanized steel has “long life and low maintenance” written all over it.
  • Hot-dip galvanizing is a cost-effective option. As opposed to painting which is an expensive process, galvanizing is more affordable, and the results last longer. What’s more, the process is automated, does not demand much more, and is not time-consuming thus.
  • The main reason why most engineers and architects readily recommend hot-dip galvanizing for steel is that the maintenance costs are very low, and because the process is heavily-regulated, the margin was error is very slim, and the process gets completed within a few hours.
  • Steel that has undergone hot-dip galvanizing is easy-to-construct and easy-to-inspect.

Applications of Galvanized Steel

Galvanized Steel has versatile applications. It can be installed outdoors and indoors, wherever higher service life of the steel is required and corrosion protection is needed to maintain functionality of the product.
The galvanization process occurs through an electrochemical action, where the surface of a metal is coated with a highly corrosion resistant material such as zinc on steel or iron products. An alternate method is known as hot dip galvanizing. Where articles are submerged and then coated with hot zinc, this method is used to usually galvanize steel sheets.
We at Hylite Group offer our clients premium service as a recognized brand that provides hot dip galvanizing in Mumbai . Our staff work to ensure the quality of our products is top notch and we are a well-known name amongst galvanizers in Mumbai and also galvanizers in pune.
The list of items that can be galvanized varies and according to your requirements, items that belong in the household category such as buckets, tubs and other types of containers can be put through the galvanization process, thereby ensuring a long corrosion free life!
In the constructional and engineering fields, machine part, tools, tanks, ships, and even wires can be galvanized to ensure long term use. 

There are several different methods in which the galvanization process can occur. Zinc is widely used to prevent corrosion and that too has multiple different types of zinc coating, each with its own set of unique characteristics.

Steel metal is a rather popular and common material that is utilized in various industry, to ensure that steel can be durable and long lasting, manufactures, and the constructional industry therefore, opt for galvanized products.

Most common methods are:

  • Thermal Spray (Metallizing)
Semi -molten zinc (or an alloy containing zinc) is sprayed on to the steel or iron item, using a wire or powder heated by a flame, or an arc spray or even a plasma heat source. This method allows a thick layer of coating to be applied on the item during the process, up to 1500 g/m2. This galvanization process can be done manually or mechanically and it is most often processed in a factory. Items are always prepped before undergoing the galvanization process. They are subjected to a grit blast, in which the surface is cleared of sand and other materials that could prevent a smooth finish.
  • Hot dip galvanization
Widely and a popular method of galvanizing, immersion of products in hot zinc allows for a fool proof method of covering every inch of the product, both inside and outside, with a protective coating. After the items are removed from the bath, the drying process occurs which leads to the zinc to cool and leaves the final zinc galvanized layer.
  • Sheet galvanizing (Continuous Sheet Galvanizing)

A coil-to-coil process that is used to bond zinc on layers of steel sheets, wires, or strips. The continuously moving ribbon applies a fine thickness of zinc on the sheets, and the thickness of the coating can reach up 1.70 inches to 72 inches, depending on your requirements. To prepare for this process, the material is annealed, a treatment process where metals are heated until they are glowing and then allowed to cool at room temperature, this is done to ensure that no foreign particles are attached to the articles in the process to undergo galvanization.

Sheets that have been galvanized using this process are used in the automobile industry for in car bodies, roofing for residential projects and piping.

  • Electroplating
This process isn’t meant for large scale items, but rather everyday use items. Electroplating galvanization coats the item with a fairly thin layer of zinc by passing a constant stream of electric current through the electrolyte solution. With a complex process, and various equipment this method provides just the right amount of coating necessary for items such as fasteners and what not.
Some of the major consumers of galvanized steel are the following industries

Wind energy

Power & Transmission

Solar energy

Construction

Automobiles

Telecommunications

Electrical

Roadways & Infrastructures

Railways & Metro projects

Large scale industrial plants

Our Plant Locations

Hylite Group has in all 3 galvanizing lines strategically located to cater to industries in the Mumbai- Pune region.
HYLITE GALVANISERS PVT LTD, Chakan

Bath size: 7.5 m long x 1.5 m

deep x 0.9 m wide

Plant Capacity : 2000 MT/Month

HYLITE GALVANISERS, MIDC Pimpri

Bath size : 3.25 m long x 1.2 m

deep x 0.8 m wide

Plant Capacity : 300 MT / Month

HYLITE ELECTROPLATERS PVT LTD, Navi Mumbai

Bath size : 1.0 m long x 1.0 m

deep x 0.7 m wide

Plant Capacity : 100 MT / Month

Why Galvanize at HYLITE ?

The Hylite group is a one stop solution to all coating needs. Even when it comes to galvanizing we are the only sundry galvanizing company who has 3 baths of different sizes to cater to a variety of customers irrespective of job specifications, size and location.

OUR SKILL AND EXPERTISE

Knowledge Sharing

Design for Hot Dip Galvanising

Inspection of work before dispatch to the Galvaniser

Fabricated assemblies, casting and other components for hot dip galvanising should be inspected and any significant surfaces identified before dispatch to the galvaniser to ensure that the following points conform to design requirements. This may avoid costly rectification and delays at the galvinishing plant.

Call us and get it done

When you hire us, you know you’re getting highly qualified professionals who have the expertise and experience to make sure your project is done properly and functions.
WeCreativez WhatsApp Support
Our customer support team is here to answer your questions. Ask us anything!
👋 Hi, how can I help?