Galvanising or Galvanization is commonly known as a process or technique to safeguard materials like steel from corrosion by application of a protective film or layer of zinc coating. In galvanising, a layer of zinc is coated on the base metal by a variety of processes. Earlier, steel wire was coated with zinc either by electro galvanising or by hot-dipped galvanising process. Electro galvanising results in a lower coating of zinc, in the range of 5 to 10 grams per square metre and corrosion resistance of such wires is lower. In hot-dipped galvanising, after cleaning the surface, the steel wire is passed through molten zinc and coated thoroughly.

After years of research and comparison between the two techniques, hot-dipped galvanising was found much better but also more expensive.

For a period of time, with improvement in surface cleaning of wires and better wiping, varieties like light coating (@90 GSM minimum), medium coating (@120 GSM) and heavy coating (@260 GSM) were also developed. The higher the coating, the better the corrosion resistance of wires. However, costing differs depending on the coating range. Certain applications like farming wires (vineyards), fencing products used in coastal areas, products used in highly corrosive environments and marine applications require heavily coated wires. The lifecycle cost of heavily coated wires in such an environment is lower compared to wires with lower coating. e.g. For instance, if heavily coated wires are used in vineyards or poultry cages, the expected lifespan is around 10–12 years compared to a life of around 3 years with lightly coated wires.

Recent trends suggest that the name of the manufacturer and coating range are also printed on wires to educate the end users. Wires are also branded by many manufacturers and today, consumers are better aware of the product quality.

The future trend is to use newly invented coatings of alloys. Coating of 90% zinc and 10% Aluminium, commonly known as Galfan is showing 3 times higher corrosion resistance compared to galvanized wires. In the near future, we will see ZAM (zinc – aluminium – magnesium) coated wires which have shown 2 times better corrosion resistance compared to galvanized wires.

The buyers should always look for the amount of coating, BIS-certification of the manufacturer and insist on a test certificate from the supplier. H D Wire Pvt Ltd is leading manufacturer of Galvanized Wires in the size range of 1.40 MM – 6.00 MM and in all ranges of zinc coating as per the need of the customer. Material is always supplied with a test certificate and the company has the BIS licence required for zinc-coated wire.