There is always a common misconception that any zinc coating can be termed as hot dipped galvanization but this is in fact not the case as pre-galvanizing is also a popular method to make galvanized steel. So what are the differences between them and which one possesses more advantages? Let&#;s find out below.
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First of all, we need to know how to define the 02 most popular methods to make galvanized steel: hot-dip galvanization & pre-galvanizing.
Hot dipped galvanization is a process where the metal is dipped into a molten pool of zinc. To make galvanized steel using this method, we need to follow 4 steps: clean the surface, fluxing, hot-dipping & cooling down.
Pre-galvanizing is also known as the mill galvanizing. This process is very close to the hot dipped galvanization but performed at the very first stage of production. It always occurred at the steel mill on the materials that already have a specific shape or before being cut into sizes and processed.
Pre-galvanizing involves some steps of hot dipped galvanization such as cleaning the surface, dipping into a hot zinc liquid bath combining with the recoiling process.
Hot dipped galvanization is an economical choice if you are finding a solution that can be executed on both simple and complex shapes. It is often used on objects that have been fabricated beforehand but yet to be galvanized and the hot-dipped galvanization plays as the last step.
Meanwhile, pre-galvanizing, as its name implies, is performed at the first stage of production. Hence, it mainly occurred at the mills, and the results of the process will be cut into size and fabricated later.
As making a protective coating for the steel and metals in the main object of the galvanizing process, we can not miss out on comparing the coating finish of the 02 methods to make galvanized steel.
Both methods result in a uniform thickness for the coating. However, the hot-dipped galvanization produces a thicker layer of protection than the pre-galvanization does. The minimum average thickness of hot-dip galvanized steel is of 45-85μm while it is between 20 and 30 μm for the pre-galvanized products&#;. \ \
As hot dipped galvanization requires dipping the whole steel/metals into the molten vat of zinc, the galvanized steel coming out from this process has a continuous coating over the surface. Pre-galvanizing is performed at the first stage before the sheets are cut into sizes and pieces so the cut edges are not coated.
The first steps of these 02 processes of making galvanized steel are both cleaning the surface, either mechanically, chemically, or both. Hence, the bond between the base metal (steel) and the protective coating is metallurgical and strong.
Coating formability for these 02 processes is totally different. As pre-galvanizing is performed at the mills, any coating applied on its results can be done without damaging the layer. However, coating formability applied on hot-dip galvanized steel is not advised as it may damage the protective coating of the products.
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The hot dipped galvanization forms a typically bright finish for the galvanized steel, though it can be also variable. As for the pre-galvanizing process, it produces a uniform bright finish for the coating.
After the hot-dip galvanizing process, there are 03 alloy layers end up being produced on the base metal. These layers are metallurgically bonded to the steel and become an integral part of the steel itself, which forms a perfect protective coating.
The pre-galvanizing process produces galvanized steel with thinner coating, which makes it a bit prone to corrosion.
The hot-dip galvanizing process protects steel in three main ways, but perhaps the most notable way is by acting as a sacrificial coating for the steel. The zinc in the protective coating plays as an anode for the steel. After experiencing hot-dip galvanization, the protection ability is enhanced as the zinc now becomes an integral part of the steel.
Meanwhile, as the pre-galvanized products have thin coatings and will be cut later to sizes and shapes, the sacrificial protection can be as good as hot-dip galvanized steel.
Experiencing over 20 years of development in international markets and currently possess 03 factories with a production capacity of over 600,000 tons annually, Chinh Dai Steel produces and supplies galvanized steel products that tick all these boxes.
The galvanized steel products of Chinh Dai Steel (such as galvanized rolled steel coils, pipes, purlins and other fabricated products) are made from high-quality imported materials with the zinc coating from Z120 &#; Z275. Our products also meet international standards such as ASTM (A500, A53 & A513) AS / NZ , JIS G, and EN . You can easily check the origins of every product on its own labels with QR codes.
Galvanized steel is coated with zinc to create a physical and chemical barrier that prevents corrosion. Galvanized steel has a longer lifespan and reduced maintenance costs over its life.
There are two types of Galvanized steel available, Hot-dipped and Electro-galvanized. The major difference between these two types is the production method.
Hot-dipped galvanized steel is dipped into a vat of molten zinc, which coats the steel. The galvanized steel is removed and allowed to cool. Structural shapes such as angles and channels are frequently hot-dipped. Hot-dip galvanization yields a strong, thick coating but generally has a dull gray finish. Hot-dip galvanization is known to have a very long life averaging between 20 to 50 years.
As its name indicates, Electro-galvanized steel is a plating process where the steel is placed in an electrically charged solution of zinc and saline. This causes the zinc to chemically bond to the conductive steel. Electro-plating is frequently used for coiled sheet steel, which is later formed into shapes such as c-purloins, and corrugated sheets or can be formed and welded into pipes and tubes. Often a UV-resistant polymer is applied after electro-plating to further protect the steel and provide a paintable surface that does not need to be primed. Generally, the layer formed by electro galvanization is extremely thin; hence the life expectancy of the layer is less than that of hot dipped material.
Manufacturers galvanize products in different ways to accommodate their intended purpose. Building materials designed for structural support are commonly hot-dipped to ensure durability and longevity. Products that are easily replaceable, like outdoor furniture and gardening tools, are more likely to be electro galvanized.
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