What Is Galvanized Steel?
Galvanized steel is standard iron that has a layer of zinc on it to protect against corrosion. This coating is often used to help lower future maintenance costs in industrial environments.
Galvanization happens by submerging clean metal into a bath of molten zinc. This creates one of the most durable metal coatings available today.
Corrosion Resistance
Galvanized steel has a high level of corrosion resistance, which is why it is used in numerous applications. This is due to its ability to protect the underlying metal from corrosive elements such as water and oxygen. The zinc in the coating acts as a barrier that Galvanized steel sheet for construction prevents the water or oxygen from interacting with the iron in the underlying metal.
This makes it ideal for use in outdoor environments where moisture is a concern. It also offers good protection in marine environments, though it is not as durable as stainless steel when exposed to seawater. It will corrode up to five times faster than stainless steel in saltwater and up to 10 times as fast in tropical seawater.
The zinc also acts as a sacrificial metal in the galvanic corrosion process, which prevents the underlying steel from corroding. This is why galvanized steel lasts much longer than uncoated metal. The zinc layer is even capable of reversing the effects of corrosion in some cases, which makes it a great choice for projects that will be regularly used or exposed to the weather.
Galvanized steel is also easy to maintain. It can be cleaned easily using soapy water and is able to be painted or coated with other materials, making it an excellent option for any project that needs durability.
Durability
Galvanized steel has proven to be extremely durable in a variety of environments and conditions. It can withstand decades of exposure to the elements, including seawater and salt, making it an excellent choice for construction and transportation infrastructure projects.
The most common method of galvanizing is hot-dipping, which involves dipping standard steel into molten zinc. This creates a layer of zinc that protects the steel from corrosion. The metal also has an appealing appearance that can withstand scuffs and other physical abuse. The coating also makes it easier to weld the steel, and the rough surfaces provide excellent adhesion for paints.
Unlike aluminum, which can corrode in some environments, galvanized steel does not rust. This is a crucial difference between the two metals, as aluminum needs proper design, maintenance, and protection to perform well in some applications. Galvanized steel, on the other hand, offers durability and longevity that are unmatched by other materials.
Additionally, the galvanization process produces one of the longest lasting coatings in the industry. This is because the metallurgical diffusion reaction creates a uniform coating that is just as thick on corners and edges as flat surfaces. This helps to prevent damage from accelerated corrosive attack, which is often caused by brush- or spray-applied coatings that thin at these junctures. This makes galvanized steel a cost-effective solution for most industrial applications.
Appearance
Galvanized steel, or galvanization, is a manufacturing process in which zinc is coated on steel and iron to offer protection and prevent rusting. The coating metallurgically bonds to the base metal, protecting it from corrosive elements like acids, caustics and alkalis, gases, and moisture. This protects the base metal by acting as a sacrificial anode, which also increases durability and longevity.
This process is very effective in preventing corrosion because the zinc in the coating offers superior barrier properties than the iron alone. This is particularly useful in harsh environments and conditions, such as coastal or urban areas. The coating also offers unparalleled protection, with a thick, tough protective layer that covers every surface of the metal, including sharp corners and crevices.
There are several different galvanization methods, but the hot-dip method is by far the most popular and common. In this method, the steel or iron is dipped in a pool of molten zinc, which creates a metallurgical bond to the base metal and offers protection from corrosive substances.
Other methods include sherardizing, which is similar to hot-dip galvanization but is performed at the initial stage of production and allows for larger coils to be galvanized with a more uniform coat than traditional hot-dip. Another method is electrogalvanizing, which uses an electric current to cause the zinc coating to metallurgically bond with the base metal.
Cost
The cost of galvanizing is relatively low compared to other forms of corrosion protection. It is a popular choice for large structural steel elements like bridge structures and steel framing in buildings. It is also ASTM threaded steel used in a number of smaller components, including nuts and bolts, electrical cables, and more. The zinc-iron alloy coating of galvanized metal is very durable, and it prevents corrosive elements from reaching the underlying steel. This makes it a great choice for long-term use in harsh environments.
Although some specifiers may believe that hot-dip galvanizing is more expensive than other materials, this perception is unfounded. Due to the stability of the price of zinc and process efficiencies, galvanizing is actually often less expensive on an initial basis than many other corrosion protection systems.
When choosing a corrosion protection system for your project, it is important to consider the total cost of ownership. The cost of the system should include its initial purchase and installation, as well as its ongoing maintenance costs. This will allow you to determine which solution is the most affordable in the long run. Careful design can help you choose the right corrosion protection system for your needs and budget. For example, using galvanized steel instead of aluminum will reduce future maintenance costs and save you money in the long run.