Although the terms galvanized steel and hot-dipped galvanized steel are sometimes used synonymously, they refer to different steel coating techniques. Hot-dipped galvanization involves submerging the steel in molten zinc, whereas galvanized steel is coated with a protective layer of zinc through electroplating.
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The main difference is in how they are applied; hot-dipped coating offers a stronger, thicker layer that works especially well in abrasive situations. Conversely, less demanding circumstances are appropriate for galvanized steel. Choosing the appropriate material for production or building requires an understanding of these differences.
This article will discuss the difference between hot-dipped galvanized steel and galvanized steel in terms of purpose, process, advantages, and disadvantages.
A specialized procedure known as hot-dipped galvanizing involves immersing clean steel in molten zinc. Layers of zinc-iron alloy are produced by the metallurgical interaction of iron and zinc. Because of this reaction, a strong covering is created, which eventually becomes a part of the steel itself. The complete coating provided by the immersion in molten zinc offers improved resistance to corrosion and a shield against external influences. With this process, robust steel is produced that may be used in a variety of manufacturing and construction applications.
The purpose of hot-dip galvanization is to prevent corrosion in metal. This method creates a protective coating that stops corrosion by submerging steel or another metal in molten zinc. The sacrificial nature of zinc further protects the underlying material from external factors. This process, which is well-known for its effectiveness, provides a strong and long-lasting barrier against corrosion, making it the go-to option in many sectors in which longevity in a metal is essential.
Hot-dipped galvanization boasts various advantages such as:
Some disadvantages of hot-dipped galvanized steel include:
An electrolyte solution is used in place of a zinc bath during the process of coating steel to create galvanized steel. Zinc ions are converted into a metal layer that sticks to the steel. This happens due to the electric current which is applied to the solution-immersed steel during treatment. Though the thinness of the material leaves it susceptible to corrosion over time, this scientific process yields a protective zinc covering. Steel is more resilient to environmental deterioration thanks to this novel galvanizing technique.
The purpose of galvanizing is to provide corrosion resistance to steel. A protective barrier is formed by coating steel with a thin layer of zinc through an electrochemical process. Zinc sacrificially corrodes before steel, preventing rust and corrosion. This method significantly extends the life span of steel structures, making them more durable in various environments. Galvanized steel finds extensive use in construction, automotive, and manufacturing industries, in which resilience to the elements is crucial for longevity and performance.
Galvanizing offers some significant advantages for structural steel protection:
Some disadvantages of galvanized steel include:
The particular needs of the application will determine whether to use galvanized or hot-dipped steel. Steel is submerged in molten zinc during the hot-dip galvanization process, which produces a thicker coating ideal for heavy-duty applications. Galvanizing, on the other hand, produces a thinner coating that is perfect for general applications by using an electrolyte solution. Think about things like the project budget, the environment, and the requirement for increased corrosion resistance. For less-demanding applications, galvanizing offers a cost-effective solution that balances protection, while hot-dipped is best suited for harsh conditions.
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Hot-dipped galvanizing and galvanizing differ in their processes. Hot-dipped galvanizing involves immersing steel in molten zinc, to form a thick, robust coating through a metallurgical bond. This process requires heating the zinc to a liquid state, ensuring complete coverage when dipping the steel piece. Galvanizing, on the other hand, utilizes an electrolyte solution in which steel is immersed, and an electric current converts zinc ions into a thin protective coating. The key distinction lies in the application method: hot dipping involves molten zinc, while galvanizing relies on an electrolyte solution and electrochemical reactions.
Many industries use galvanizing and hot-dip galvanizing to prevent corrosion. The thicker coating that results from immersing steel in molten zinc is what makes hot-dip galvanizing ideal for heavy-duty uses including: buildings, bridges, and marine structures. Galvanizing is appropriate for a variety of applications, including: outdoor constructions and domestic objects. It uses an electrolyte solution to create a thinner coating. The application technique and consequent coating thickness are the primary differences: galvanizing offers a cost-effective and protective balance in less severe situations, while hot-dipped galvanizing offers strong protection in tough environments.
Table 1 below highlights the properties of hot-dipped galvanized steel and galvanized steel:
The parameters:
Using the AGA Life-Cycle Cost Calculator, a quantitative analysis was conducted comparing hot-dip galvanizing to four paint systems, as well as a duplex system and metallizing with defined maintenance schedules.
Including materials (paint, metallizing, etc.), the number of coats, the surface prep cleaning method (painted systems: SP-10; duplex: SP-16/ASTM D; metallizing: standard near white metal), where the application was performed, and labor costs versus galvanizing&#;s all-inclusive price:
Coating System$/ft2TotalHot-Dip Galvanizing$1.76$ 88,000Epoxy/Epoxy$2.92$ 146,150Epoxy/Polyurethane$3.35$ 167,650Inorganic Zinc/Epoxy$3.17$ 158,650Inorganic Zinc/Epoxy/Polyurethane$4.53$ 226,300Galvanizing/Epoxy/Polyurethane (Duplex)$5.28$ 263,950Metallizing$8.37$ 418,550These findings indicate that when all the costs are considered, galvanizing is often less expensive and at the very least, exceedingly competitive with other coating systems.
Utilizing a practical maintenance cycle over the prescribed 75-year lifetime of the project based on Net Future Value (NFV) and Net Present Value (NPV) calculations at 3% inflation and 2% interest, and accounting for a very unlikely needed maintenance paint with an inorganic zinc at year 70 for the galvanized steel:
Coating System$/ft2TotalHot-Dip Galvanizing$ 4.29$ 214,500Galvanizing/Epoxy/Polyurethane (Duplex)$22.84$1,142,000Inorganic Zinc/Epoxy$39.92$1,996,000Inorganic Zinc/Epoxy/Polyurethane$41.53$2,076,500Epoxy/Epoxy$51.91$2,595,500Epoxy/Polyurethane$61.63$3,031,500Metallizing$62.80$3,140,000Even with the one maintenance cycle near the end of the life of the project, hot-dip galvanizing was proven to have a significantly more economical lifecycle than that of the other coating systems.
To maximize return on investment, it&#;s critical that buyers ensure the longevity of their purchase. Enhanced over 200 years, galvanizing is a process that best protects steel for long-lasting, corrosion-free performance. In fact, galvanized components can potentially last up to a century without the need for costly maintenance, delivering a significantly lower lifecycle cost, especially when compared to alternatives like stainless steel, aluminum, and epoxy coating. And research suggests that non-galvanized structures incur indirect costs as much as 11 times higher than those that utilize galvanized products. In an economy where steel prices are expected only to rise, buyers are wise to protect their investment and achieve cost savings by galvanizing.
AZZ&#;s GalvXtra four-step, hot-dip galvanizing process uses a proprietary formulation of molten metals to deliver consistent, high-quality zinc coatings on ferrous materials. At the preparation stage, steel arrives at AZZ&#;s galvanizing plant and is inspected to ensure that drainage and venting requirements are met. Then, the metal is cleaned by immersion in a hot alkali solution, acid pickled to remove rust or scale, and fluxed to eliminate surface oxides. Next, the steel is hot-dip galvanized&#;submerged in a bath of molten zinc to form a shield of zinc/iron intermetallic layers on all surfaces. Finally, the newly galvanized steel is cleaned, weighed, and carefully inspected with calibrated instrumentation to ensure quality standards.
AZZ performs hot-dip galvanizing for steel components used in a wide range of applications, including agriculture, bridge & highway, construction, electrical utility, industrial, original equipment manufacturers, petrochemical, recreational, and transportation. Backed by 60 years of experience in the materials industry, AZZ offers exceptional galvanizing service at over 40 locations across the U.S. and Canada. Click to learn more about protecting your steel investment.
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