The word ‘galvanizing’ refers broadly to the electro-deposition procedure where any thin layer of any other material is inserted to any item that is made of steel. The core reason of the galvanizing process is to guard the base steel by avoiding the rusting. Though, one of the best galvanizing processes invented by the galvanizer companies does not utilize any kind of electrochemical deposition. This process is known as HDG or hot dip galvanizing.

This type of galvanizers has widely become very popular due to the effectiveness it offers while it comes to the corrosion protection. Actually, in the recent terms, the word ‘galvanizing’ or ‘galvanizers’ is popularly used to mention the process of hot dip galvanizing. In this process, a corrosion resistant four-layer surface or finish is produced on the steel base by using the zinc through the electrochemical procedure. As per the galvanizer consultant companies, commonly iron and steel are passed through any molten bath made of zinc at the temperature of 460˚C in order to protect the metals from corrosion. Among the four layers made up by the hot dip galvanizing consultant companies, the top layer is made of zinc and the underneath three layers are created of zinc-iron alloy. The galvanizer companies use this procedure for all the industrial applications which need the potency of steel while maintaining the resistance to the corrosion.

The method of hot dip galvanizing created by the hot dip galvanizing consultant companies has proved to be much more superior than the other methods like metalizing, paint, electroplate galvanizing or mechanical galvanizing. Besides, this method of galvanizing has come out as one of the most reliable as well as result oriented procedures which meets with all the galvanizing requirements of the clients. Unlike the electroplate method of galvanizing, the process of hot dip galvanizing creates a much durable and thicker coating that makes it very suitable also for the outdoor applications. On another side, the thin coating made by the electroplate galvanizers can be consumed quickly and it results in revealing the steel base of any item to the corrosion.

As mentioned by the galvanizer consultant companies, the hot dip galvanizing leads to the superior protection from any type of rusting or corrosion. The solid zinc-steel alloy layers of the hot dip galvanizing work as an effective barrier. If this barrier gets damaged, then the barrier of zinc works as a sacrificial anode and therefore prevents the corrosion. Additionally, the top most layer of this kind of galvanizing only comprises zinc. So, while it reacts with moisture, oxygen and carbon dioxide presented in the air, it creates a thin but strong film, which is known as zinc patina. It acts as the effective barrier over galvanized zinc coating and guards the item from possible corrosion.

Prashant Galvanizers is one of the reputable galvanizer consultant companies in India which offers manufacturing, installation and consultation services on various kinds of galvanizing procedures including the hot dip galvanizing to the galvanizing, manufacturing and engineering industries.

The manufacturing process of hot dip galvanizing may vary slightly from plant to plant. The fundamental steps in the galvanizing process in nutshell can be described as under:

The steel articles are dipped into a hot alkaline solution or caustic soda solution to remove dirt, oil, grease, shop oil, and soluble markings for decreasing and caustic cleaning. The article is dipped in rinsing tank containing clean water for cleaning.

Galvanizing-Process

Second pickling is performed in second pickling tank which contains dilute solution of either hydrochloric or sulfuric acid 10-32% to remove surface rust and mill scale to provide a chemically clean metallic surface. The same article is again washed in rinsing tank containing clean water.The article is then preserved in pickling tank containing dilute solution of either hydrochloric or sulfuric acid 10-12% for first pickling.

Next step is Flux heating system where the steel is dipped in fluxing tank containing usually a zinc ammonium chloride solution to remove oxides and to prevent oxidation prior to dipping into the bath of molten zinc. In the dry galvanizing process, the item is separately dipped in a liquid flux bath, removed, allowed to dry, and then galvanized. In the wet galvanizing process, the flux floats atop the molten zinc and the item passes through the flux immediately prior to galvanizing.

The article is immersed in a bath of molten zinc of 435 to 455 degree Celsius. During galvanizing, the zinc metallurgically bonds to the steel, creating a series of highly abrasion-resistant zinc-iron alloy layers, commonly topped by a layer of impact-resistant pure zinc.

After the steel is withdrawn from the galvanizing bath, excess zinc is removed by draining, vibrating. The galvanized item is then air-cooled or quenched in liquid.

The most important part of hot dip galvanizing shows the value of experience is flux heating system. An experienced and noted hot dip galvanizing consultant in Gujarat Prashant Galvanizers supply Online Flux Filter System that eliminates production downtime. It eliminates or reduces iron content to a minimum in the flux solution which reduces Dross formation in zinc bath. Using Flux Heating system and Online Flux Filter system, zinc consumption is reduced anywhere from 1-2 kg per metric.

The material is due for dispatch after “Passivation” and inspection formalities. Coating-thickness and surface-condition inspections complete the process of hot dip galvanizing.

Galvanization is the process of applying a protective zinc coating to steel, aluminum and iron, in order to prevent rusting. The term Galvanization is derived from the name of Italian scientist Luigi Galvani. Although galvanization can be done with electrochemical and electro-deposition processes but the most common and popular method in present time is Hot Dip galvanizing, in which steel parts are submerged in a solution of molten zinc.

Process of coating of thin layer of zinc on iron, steel and aluminum at a temperature of about 860 °F (460 °C) by a bath of molten zinc is called Hot Dip Galvanizing. It is a form of galvanization. Oxygen (O2) in the atmosphere reacts with the pure zinc (Zn) to form zinc oxide (ZnO), which forms zinc carbonate (ZnCO3) by reacting with carbon dioxide (CO2) of the atmosphere. Generally it looks dull gray and in many circumstances it stops further corrosion, protects the galvanized material from the effects of outside elements. Rust resistance is the main cause of widely use of steel, and can be recognized by spangles on the surface (The size of crystallites in galvanized coatings is a visual feature, known as spangle).

Hot Dip Galvanizing is a factory controlled metallurgical combination of zinc and steel that provides corrosion resistance in a wide variety of environments. Hot Dip Galvanizing protects steel from corrosion in two ways. It provides cathodic protection and barrier protection.

Cathodic protection is commonly applied to a coated structure to provide corrosion control to areas where the coating may be damaged.  It may be applied to existing structures to prolong their life.

Barrier protection is commonly applied to a Hot Dip Galvanizing done surface to protect structure from germs in air or water, which prolongs its life and sustainability.

Prashant Galvanizers expertise of nearly 15 years in galvanizing contractor, manufacturer and supplier of India have an experienced and proficient technicians working team for manufacturing Hot Dip Galvanizing plants. They undertake any kind of critical job like tower line angle, channel and pipe of Shipyard Company, fabrication of tower-line, etc.

Most important and notable fact for Prashant Galvanizers is their un-imaginable capability of manufacturing of automatic/manual galvanizing plant system or 2-in-1 hot dip galvanizing plant system. They have earned a name and fame in a short time among the Galvanizers Consultant in India.