Industry Overview
Galvanization is the process of applying a protective zinc coating to steel or iron to prevent corrosion and extend the service life of metal components. The term is derived from the name of the Italian scientist Luigi Galvani. Galvanized iron (GI) sheets are steel sheets coated with zinc through processes such as hot-dip galvanizing and electro-galvanizing, providing durable protection against rust and environmental exposure.
Zinc weathers at a relatively slow rate, enabling the coating to provide long-lasting protection. Since zinc is more electrochemically active than iron, it offers cathodic, or sacrificial, protection by corroding in preference to the underlying steel if the coating becomes chipped or damaged. This mechanism helps preserve the structural integrity of the base metal even when the protective layer is locally compromised.
In addition to corrosion resistance, the zinc coating retains the original strength of the steel, improves surface appearance, and enhances the performance and lifespan of compatible organic finishing systems applied over it. Acting as a continuous protective barrier between steel and the surrounding atmosphere, galvanized steel is widely used where durability, longevity, and reliable corrosion protection are essential. These characteristics make galvanization an effective and economical solution for extending the operational life of steel products across a broad range of industrial and infrastructure applications.
Cost Estimation
| Particular | Value |
|---|---|
| Plant Capacity | 10 MT/Day |
| Land & Building (2000 sq.mt.) | Rs. 1.24 Cr |
| Plant & Machinery | Rs. 1.10 Cr |
| Working Capital for 2 Months | Rs. 1.37 Cr |
| Total Capital Investment | Rs. 3.94 Cr |
| Rate of Return | 38% |
| Break Even Point | 63% |
Content Index
- INTRODUCTION
- ADVANTAGES OF GALVANISING
- THE USE OF GI SHEETS GIVES THE FOLLOWING ADVANTAGES
- USES AND APPLICATION OF GALVANISING
- MARKET SURVEY OF HOT DIP GALVANIZING
- KEY PLAYER IN THE HOT DIP GALVANIZING MARKET
- BENEFITS OF GALVANIZING
- CORROSION PROTECTION
- DURABILITY
- LONGEVITY
- VERSATILITY AND DURABILITY
- ENVIRONMENTAL ADVANTAGES
- STEPS IN HOT DIP GALVANIZING
- THE EFFECTIVE FORM OF GALVANIZATION PROVIDES 2 LEVELS OF PROTECTION:
- THERE ARE 3 STEPS IN HOT-DIP GALVANIZATION:
- SURFACE PREPARATION FOR HOT DIP GALVANIZING
- CLEANING STEEL TO PREPARE FOR THE HOT-DIP GALVANIZED COATING CONSISTS OF THREE STEPS:
- DEGREASING
- PICKLING
- FLUXING
- PROCESS FLOW CHART
- GALVANISING PROCESS
- THE GALVANIZING PROCESS CAN BE GROUPED TOGETHER UNDER THREE CATEGORIES, NAMELY
- SOME OF THE COMMON TERMINOLOGY USED IN GALVANIZING PROCESS IS AS FOLLOWING:
- ASH –
- DROSS –
- FLUX –
- OVER-PICKLING –
- INHIBITOR –
- GALVANIZING BATH –
- ALUMINUM ADDITIONS –
- COATING THICKNESS
- DETAILS OF HOT DIP GALVANIZING PROCESS
- ALL GALVANIZING CONSISTS OF FOUR FUNDAMENTAL STEPS:
- SURFACE PREPARATION:
- DEGREASING:
- CLEANING:
- PICKLING:
- AGITATION:
- RINSING:
- FLUXING:
- GALVANIZING:
- IMMERSION:
- WITHDRAWAL:
- WATER QUENCHING:
- CENTRIFUGING:
- THREAD BRUSHING:
- POST TREATMENT:
- STACKING:
- 5. INSPECTION
- CHARACTERISTICS OF GALVANIZED SURFACES
- 6. QUALITY CONTROL
- INSPECTION & TESTING
- GALVANIZING PLANT SAFETY AND STANDARD
- GALVANIZING STANDARDS
- ASTM STANDARDS
- THE THREE GOVERNING ASTM SPECIFICATIONS FOR HOT-DIP GALVANIZING ARE:
- OTHER GALVANIZING STANDARDS
- THERE ARE ALSO A FEW INTERNATIONAL GOVERNING STANDARDS TO BE AWARE OF:
- PRE-GALVANIZING
- POST-GALVANIZING
- SUPPLIERS OF RAW MATERIALS
- SUPPLIERS OF ZINC INGOT
- SUPPLIERS OF CASTIC SODA
- SUPPLIERS OF HYDROCLORIC ACID
- ADDRESSES OF PLANT AND MACHINERY SUPPLIERS
- SUPPLIERS OF DG SETS
- SUPPLIERS OF EOT CRANES
- SUPPLIERS OF POWER TRANSFORMERS
- SUPPLIERS OF ELECTRICAL PANEL
- SUPPLIERS OF ELECTRIC MOTOR
- SUPPLIERS OF COOLING TOWER
- SUPPLIERS OF EFFLUENT TREATMENT PLANT (ETP PLANT)
- SUPPLIERS OF AIR POLLUTION CONTROL EQUIPMENTS
- SUPPLIERS OF AIR CONDITIONING EQUIPMENTS
- SUPPLIERS OF AIR COMPRESSORS
- SUPPLIERS OF PLATFORM WEIGHING MACHINE
- SUPPLIERS OF MATERIAL HANDLING EQUIPMENTS
- SUPPLIERS OF FIRE FIGHTING EQUIPMENTS
- SUPPLIERS OF SHOT BLASTING MACHINE
- SUPPLIERS OF JIGS AND FIXTURE
- SUPPLIERS OF SUBMERSIBLE WATER PUMP
Appendix
- 01. PLANT ECONOMICS
- 02. LAND & BUILDING
- 03. PLANT AND MACHINERY
- 04. OTHER FIXED ASSESTS
- 05. FIXED CAPITAL
- 06. RAW MATERIAL
- 07. SALARY AND WAGES
- 08. UTILITIES AND OVERHEADS
- 09. TOTAL WORKING CAPITAL
- 10. TOTAL CAPITAL INVESTMENT
- 11. COST OF PRODUCTION
- 12. TURN OVER/ANNUM
- 13. BREAK EVEN POINT
- 14. RESOURCES FOR FINANCE
- 15. INSTALMENT PAYABLE IN 5 YEARS
- 16. DEPRECIATION CHART FOR 5 YEARS
- 17. PROFIT ANALYSIS FOR 5 YEARS
- 18. PROJECTED BALANCE SHEET FOR (5 YEARS)
Frequently Asked Questions
Galvanization is the process of coating steel or iron with zinc to protect it from corrosion.
The zinc coating acts as both a physical barrier and a sacrificial layer, reducing rust formation even if the surface is scratched. This process significantly increases the service life of steel products while reducing maintenance requirements, making galvanized steel suitable for construction, infrastructure, industrial equipment, and general engineering applications.
Zinc protects steel by acting as a sacrificial metal.
Because zinc is more electrochemically active than iron, it corrodes before the underlying steel. Even if the coating is damaged, the surrounding zinc continues to provide cathodic protection, helping to prevent rust from spreading and extending the useful life of the steel component.
Hot-dip galvanizing involves surface preparation, galvanizing, and post-treatment.
Surface preparation generally includes degreasing, pickling, rinsing, and fluxing to remove contaminants. The cleaned steel is then immersed in molten zinc, withdrawn, cooled, and inspected. Additional finishing and quality control procedures help ensure the coating meets the required performance standards.
GI sheets provide long-lasting corrosion protection and improved durability.
In addition to protecting steel from rust, the zinc coating enhances appearance, helps maintain the original strength of the steel, and improves the performance of compatible paint or finishing systems. These benefits make GI sheets suitable for a wide variety of industrial and commercial applications.
Proper surface preparation is essential for achieving a high-quality zinc coating.
Removing grease, rust, scale, and other contaminants allows the molten zinc to bond effectively with the steel surface. Inadequate cleaning can lead to poor coating adhesion, uneven coverage, and reduced corrosion resistance, affecting the long-term performance of the galvanized product.
Hot-dip galvanized steel is widely used in construction, infrastructure, manufacturing, and utility sectors.
Its excellent corrosion resistance makes it suitable for structural steel, roofing materials, transmission towers, industrial equipment, fencing, agricultural structures, transportation components, and other applications where long service life and reduced maintenance are important.
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