People often get tangled in the nuances when considering the myriad factors for the right wire gauge sizes. One aspect that stands out and requires special attention is the wire gauge. It’s not just about thickness but understanding its relevance in various applications.
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Wire gauge size, at its core, is the measurement of a wire’s thickness. The concept traces back to a unique method where steel was drawn through a set of dies that decreased in diameter.
If we took a 14-gauge wire as an example, it would be pulled through 14 progressively smaller dies to achieve its thickness. However, the modern era sees precision instruments ensuring strict gauge standards, maintaining the consistency of the measurement.
Galvanization – a process where a protective zinc coating is applied to the wire to prevent rusting – is also used and ensures the wire’s longevity, especially in outdoor applications, making galvanized wire a favored choice for projects exposed to harsh weather elements.
It’s easy to get confused here. Wire gauge sizes follow the following pattern: A larger gauge number implies a thinner wire. Why? It’s all about the number of times a wire was drawn through dies during its manufacture. A 20-gauge wire, thinner than its 9-gauge counterpart, has undergone more “draws” or passes through the dies.
This inverse relationship is crucial to remember when choosing the appropriate wire for your needs.
Choosing the wrong wire gauge can have ramifications, from reduced efficiency to safety concerns. The gauge directly impacts a wire’s strength and conductivity. For instance:
A thicker wire (lower gauges) will generally withstand more physical stress. So, for robust applications like fencing for larger animals, a 9 to 12.5-gauge wire would be more apt, while more delicate tasks might employ a 16-gauge wire.
The gauge also influences electrical conductivity. A thinner wire tends to have more resistance and can heat up faster than a thicker wire when electricity flows through it.
Galvanized wire doesn’t escape the gauge conundrum. Remember our friends Brown and Sharpe? Their standardized formula from still stands today, primarily in North America, guiding the wire gauge sizes from 1 to 40.
The carbon content in a wire has a direct impact on its flexibility and strength. With approximately 0.10% carbon, low-carbon wire is more malleable but more prone to stretching. In contrast, high tensile wire, with a carbon content of about 0.28%, offers more strength and resistance to stretching, though it can be a tad trickier to work with.
There are a many uses for wires of various gauges with applications that run vast and wide. The recycling industry is a big user of baling wire for its strength.
After diving deep into the intricacies of wire gauge and its historical, technical, and practical applications, it becomes evident that understanding wire gauge is paramount in choosing the right wire for a specific purpose.
The thickness or gauge of a wire plays a pivotal role in determining its strength, conductivity, and suitability for a task.
So, what gauge should you generally opt for? While specific needs can vary, here’s a guideline:
Lastly, always prioritize quality and longevity. Galvanized wire, for instance, due to its protective zinc coating, is excellent for outdoor applications as it resists rusting.
Galvanized wire is a form of wire that has been coated with a zinc layer to protect it from corrosion. Galvanization involves immersing the wire in molten zinc or adding a zinc-rich coating using various procedures such as electroplating or hot-dip galvanizing. The zinc coating functions as a barrier between the wire and its surroundings, limiting direct contact with moisture, oxygen, and other corrosive factors that can cause rust and degradation.
When in doubt, trust the experts. For over 40 years, Vulcan Wire has epitomized excellence in the steel industry, providing unmatched product quality, expertise, and Red Carpet Service. As one of North America’s largest distributors of baling wire products, we pride ourselves on timely deliveries facilitated by our expansive carrier network.
Steel strand can be used in the production of a variety of different products including wire rope, aircraft cable, and structural cable for bridge and building support. The construction of steel cable consists of thin steel wires that are stranded together to give the cable the perfect blend of strength and flexibility. Different constructions allow steel cable to be used in a number of different industrial, commercial, recreational, and military applications.
Are you interested in learning more about electro galvanized wire? Contact us today to secure an expert consultation!
For extreme environments where exposure to moisture, salt water, or corrosive or caustic chemicals is possible, the correct type of stainless steel cable is the preferred choice. For most applications, a galvanized zinc coating will offer some form of corrosion resistance and still provide the strength and flexibility characteristics desired by the end-user.
However, the term “galvanized” can be confusing for the end-user as there are a number of options for providing protection to the base metal. In this article, we’ll be reviewing two different galvanization processes—electro galvanization and hot dip galvanization.
There are a number of cable distributors who carry one type of product and mark it as “galvanized,” but don’t specify whether it’s electro galvanized or a hot dip galvanized product. This can lead to confusion for the end-user when they’re comparing galvanized cable quotes because the price and corrosion-resistance can vary between products of equal specifications.
At Mazzella, we stock and distribute wire rope and cable in stainless, electro galvanized, and hot dip galvanized coatings. Our goal for this article is to explain the differences between the two types of galvanized coatings, and identify the advantages, disadvantages, and proper applications for each product type.
Electro galvanization is a form of zinc electro plating where a thin layer of zinc is electrically and chemically bonded to steel in order to protect against rust and corrosion.
During this process, bare steel wires are fully immersed in a saline/zinc bath and electricity is used to move electrons from the zinc (anode) and bond them to the steel (cathode). In this case, the zinc acts as a barrier layer on top of the steel to prevent corrosive substances from reaching the underlying steel or iron. The wires are then formed into strands and then the strands are helically formed into the finished cable or wire rope configuration.
When the process is complete, the finished coating is smooth, drip-free, and shiny—making it ideal for architectural applications or other applications where its aesthetic characteristics would be of value. However, once it’s exposed to the elements, the finish can quickly deteriorate.
Electro galvanized cable should be used in applications with limited exposure to harsh or extreme environments. It offers minimal corrosion protection, but in instances where it’s fully exposed to the elements, it will begin to corrode much faster than hot dip galvanized.
The main advantage to electro galvanized cable is that it’s the most cost-effective solution. For construction sites, it can be used as perimeter cable or as a barrier or tie-off cable for employees working at heights. For applications where it may experience field use for a few weeks or a few months, it can then be safely disposed of once the project is complete.
If exposure to the elements is minimal, it can be used in architectural applications for aesthetic purposes due to its naturally bright and shiny finish.
In hot dip galvanized cable, each uncoated steel wire is immersed in a molten zinc bath. Prior to dipping, the wires are put through a rigorous 7-step caustic cleaning process and then dipped into the molten zinc at a temperature of around 860°F/460°C. As it’s withdrawn from the molten bath, the material cools and forms a coating of zinc on the steel. The wires are then formed into strands and then the strands are helically formed into the finished cable or wire rope configuration.
Hot dip galvanizing provides much better corrosion resistance than electro galvanization because the zinc coating is typically 5 to 10 times thicker. For outdoor or caustic applications where corrosion-resistance is required, hot dip galvanized cable is the clear choice.
Because it offers superior corrosion resistance compared to electro galvanized cable, hot dip galvanized cable can be used for any application where the cable will be exposed to the natural elements or a caustic environment. Hot dip galvanized cable can be used for fencing or perimeters for construction sites, parking garages, farm and livestock facilities, and much more.
Hot dip galvanized wire rope can also be used for lifting and rigging in crane application and with outdoor winches or pulley systems. Professional zip lines are also another popular use as the cable can withstand corrosion in moist and humid environments.
The term “galvanized” only tells the end-user that some type of corrosion-resistant coating has been applied to the steel material. However, suppliers don’t always specify whether the cable they’re selling is an electro galvanized or a hot dip galvanized product.
Hot dip galvanized will always be more expensive than electro galvanized product because of a more labor intensive galvanizing process and because it offers greater resistance to rust and corrosion.
If you’re looking for a cost-effective option for a short-term project, or need a cable that won’t be exposed to the elements, then electro galvanized cable or wire rope would be the best choice for you.
In order to specify the right type of cable for your next project, do your research and work with a reputable and knowledgeable distributor. This will help ensure that the correct and most appropriate products are purchased for your budgetary and performance requirements.
At Mazzella, we sell all different types of wire rope, aircraft cable, and structural cables. We carry stainless, electro galvanized, and hot dip galvanized products and our highly-trained Lifting Specialists can help you determine the right type of steel cable or wire rope for your application. If you’re interested in learning more about the different cable products we carry, or need a quote for your next project, contact us today.
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