Wire ropes are a staple in rigging and lifting applications across industries. Whether mechanical power transmission or lifting and hoisting in cranes and elevators, you will see wire ropes everywhere. They offer safety and strength for lifting and rigging applications.
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As a galvanized wire rope supplier, we often come across the question – of electro galvanized vs hot dipped galvanized, which one is better?
For many business owners, considering hot-dipped galvanized vs electro galvanized can be daunting. But you will have to make this choice often, which is why you must understand what electro-galvanized and hot dipped mean, their advantages and disadvantages, and which one is a better choice.
Galvanizing or galvanization involves applying zinc coating to steel or iron objects. The primary goal of galvanization is to prevent rusting. Galvanization can prevent rusting in different ways, including:
As a wire rope distributor, we recommend galvanized wire ropes because they last longer. It offers you a better return on your investment. But it also provides additional benefits, like:
Unlike paint coating, galvanizing is highly reliable. The galvanized coating becomes a part of the steel itself. It’s more than just a chemical or mechanical bond.
Most importantly, galvanizing offers complete protection. That’s why your galvanized wire rope supplier is also likely to recommend only galvanized wire ropes. And when it comes to electro-galvanized vs hot dipped galvanized, the difference lies in the process. Let’s understand both these processes and their advantages and disadvantages.
Electro galvanization, as the name suggests, is the process of zinc electroplating. This is an electrochemical process where zinc gets electrically and chemically bonded to the steel or iron wire ropes.
This process involves immersing steel wire ropes in a saline or zinc bath. The electricity gets passed through the bath. The electrochemical reaction occurs as the electricity passes through the zinc bath. It moves electrons from the zinc (anode) and bonds them to the steel wire ropes (cathode). This builds a layer of zinc over the steel wire ropes.
Once the process is over, the steel wire rope will have a uniform coat of zinc. This drip-free and shiny layer is not only aesthetically appealing but also uniform. That’s what makes electro-galvanized wire ropes more popular.
Although the aim of hot dip galvanizing is the same, the process is different. In this process, steel wire ropes get immersed in a bath of molten zinc. That is the fundamental difference between electro galvanized vs hot dipped galvanized wire ropes.
It’s a three-step process.
Surface Preparation: In this step, the wire ropes get thoroughly cleaned. This includes degreasing, pickling, and fluxing. In the process of degreasing, steel wire ropes get cleaned to remove dirt, oil, and organic residues. The acid pickling bath removes mill scale and iron oxide, while fluxing will coat the wire ropes with a protective layer.
Galvanizing: Once the surface is ready, the wire ropes get immersed in a bath of at least 98% molten zinc. Hence they are called hot dip galvanized wire ropes. The metallurgic reaction between the steel rope surface and the zinc solution creates a durable protective layer.
Inspection: In this step, a visual inspection checks the quality of the overall zinc coating. Depending on the requirements, manufacturers may also use a magnetic thickness gauge to measure the thickness of the zinc coating.
Although both galvanization processes aim to provide protection, they offer different benefits and disadvantages. It’s no surprise business owners or site managers often have to compare hot-dipped galvanized vs electro-galvanized wire ropes.
The short answer is neither is better than the other. Using hot dip galvanized steel wire rope makes sense when you need better protection, long service life, and appearance is not a concern. As your wire rope distributor, we recommend you use these cables for applications in corrosive environments.
On the other hand, you should use electro-galvanized cables where harsh environmental elements are less likely to be present. In short, you can use these cables for indoor applications. However, despite the risk of faster corrosion, many people use these for outdoor applications because they are less expensive.
Choosing the right type of steel wire ropes can be a daunting task. The most common dilemma you will face is hot-dipped galvanized wire ropes vs electro galvanized wire ropes. Hopefully, this post will help you understand the difference between the two and their benefits and drawbacks. This will help you make an informed decision.
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.
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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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