Galvanising is putting a layer of zinc 'barrier' onto iron or steel, and is used to enhance properties against corrosion from environmental conditions, and in turn enhances the functional life of structural steel. Galvanising is key for many industries under the scope of Build and Infrastructure, Transport, Farming and Agriculture, Manufacturing where steel components are surrounded by or come into direct contact with frequent moisture, chemicals and other corrosive factors.Galvanising protects everything from load-bearing steel frames and road and pedestrian safety barrier components to industrial machinery, heavy machinery and components. When you have galvanised steel or iron, it is the best solution for maximum protection against corrosion and to protect the surface itself. The galvanised zinc is the final step, and once it is tested as galvanised surface, you have a permanent and uniform coating to the entire surface.
How Does the Galvanising Process Work?
The most popular method is hot-dip galvanising, a process of multiple steps to provide complete and uniform protection:
1. Surface Preparation
Steel components are degreased using a combination of caustic solutions, acid pickling, and fluxing to strip away dirt, oil, rust, and mill scale.
2. Galvanising (Zinc Bath)
The cleaned steel is immersed in a bath of molten zinc at a temperature of about 450°C. A metallurgical reaction occurs, producing a series of zinc-iron alloy layers closely adherent to the base metal.
3. Cooling and Inspection
The steel is cooled in water or air after galvanising. An appropriate inspection is then carried out to ascertain coating thickness, adhesion, and surface flatness.This galvanising technique encompasses all, including hollow structure internal cavities, and is therefore better than most other types of protective coating.
Advantages of the Galvanising Process
The galvanising process is full of performance and economic advantages, particularly in the tropics like Malaysia:
Improved Corrosion Resistance
Zinc forms a sacrificial coating, protecting steel from corrosion even if the coating is scratched.
Long Life
Galvanized steel can have a lifespan of 50-plus years indoors or outdoors in a commercial situation.
Minimal Maintenance
Once steel is galvanized, minimal or no maintenance is required. This eliminates any ongoing repainting or surface treatment.
Cost-Effective
Although the upfront cost of galvanizing may be more than other coatings, the long-term costs of replacement and maintenance provided by galvanizing are substantially lower.
100% Recyclable
Zinc and steel are 100% recyclable and the galvanizing process supports global sustainability efforts to reduce the environmental impact.
Uses of the Galvanising Process
The galvanising process is of key importance to several industries where steel needs to perform in harsh environments. Typical uses include:
Highway guardrails and crash barriers
Structural steel for bridges and buildings
Agricultural fencing and equipment
Roofing systems and metal framing
Marine and offshore components
Industrial and commercial steel fabrications
Our cutting-edge galvanising facilities at VG Steel Industries Sdn Bhd are equipped with one of the world's largest volume galvanising kettles. This allows us to uniformly and efficiently galvanise steel parts of all sizes.
Why VG Steel is Malaysia's Trusted Name in Galvanising
Since 2012, VG Steel Industries Sdn Bhd has been the leader in the galvanising services market in Malaysia. Strategically located in Shah Alam with satellite facilities in Kapar, Subang, and Nilai, we cater to a vast group of clients with efficient, speedy, and reliable solutions.Our strengths are:
Large capacity (20,000 metric tonnes per year)
Compliance to International Standards (BS729 / EN ISO 1461)
Advanced equipment and qualified labour
Competitive pricing and quick turnaround
Green and eco-friendly
VG Steel is competitive cost and reliable quality, no matter if you galvanize for distribution, structural or industrial use.
Environmental Impact and Sustainability
Since galvanising protects products, it is also good at fulfilling environmental and sustainability objectives: in these regards, galvanising can, for example, extend structural steel by 60 years, serve as an enduring barrier to further industrial reaction or play a part in reducing waste on a daily basis in comparison to standard manufacturing processes.
Zinc Recyclability
Zinc used in the galvanising process is fully recyclable without degradation of properties. This reduces virgin material demand.
No VOCs (Volatile Organic Compounds)
Hot dip galvanising is not a VOC-emitting process and is a much cleaner and hence safer process than solvent or paint coating work.
Energy Efficiency
The extended lifecycle of galvanised steel translates to low maintenance and replacement demand that minimises energy usage throughout the lifetime of the infrastructure
Life Cycle Analysis (LCA)
There are several studies that suggest the galvanised steel system is better suited for long-term environmental effects compared to other protection systems. Being recyclable with minimal maintenance needs and longevity is an excellent choice in green construction and production.
Maintenance of Galvanised Steel
As low-maintenance, there are some simple practices that can help ensure optimum performance:
Do's and Don'ts
Do clean galvanised surfaces periodically with a mild detergent
Avoid using strong cleaners or scrubbing agents that will destroy the zinc coat
Do inspect for evidence of mechanical damage or abnormal wear in manufacturing plant and fabrication plant environments
When Should You Repaint or Recoat?
Touch-up maintenance is usually not necessary for the first 20-30 years. Maintenance touch-ups may be needed for zinc-rich coatings if the zinc coating is beginning to wear down or is undergoing highly corrosive exposures such as marine environments.
Inspection Practice
Yearly visual inspections of safety-critical items of corrosion, surface condition, and coating thickness must be conducted in year one on the following safety-critical items (e.g., bridges & guard rails).
Challenges and Issues of Galvanising
Even though galvanising is highly effective, a few challenges exist and need to be considered for manufacturers and designers:
Thin Steel Warping
If you apply thin or asymmetrical pieces of steel to hot dip galvanising at high temperatures, they will warp. Good design and good preparation can avoid this outcome.
Surface Finish
Galvanised coatings may produce irregularities or flat finishes that may not be acceptable for aesthetic-based applications and can be compared to paint or powder coating. Irregularities and dissimilar finishes do not affect performance but may affect the appearance of the project.
Compatibility with Welding or Fabrication
Galvanised steel can be welded, with ventilation and subsequent treatment necessary to ensure safety and maintain corrosion resistance.
Call to Action
If you're looking for a dependable partner for galvanizing in Malaysia, VG Steel Industries Sdn Bhd has the experience, capability and dependability to provide you with high value.
Request a Free Consultation
Our engineering team is always available for your project requirements, engineering specifications and reduced costs.
Speak To VG Steel About Special Galvanizing Projects
Whether you are embarking on a new infrastructure project or replacement of industrial parts or looking for a supplier to deal with long term, we've got you covered.Contact us today at 014-3624 014 or send us an email at vgironsales9@gmail.com to start the conversation.VG Steel Industries – Strength and Steel.
