Industry Overview
Galvanization is the process of applying a protective zinc coating to steel or iron to prevent corrosion and extend service life. Galvanized iron (GI) sheets comprise steel sheets coated with zinc through hot-dip or electro-galvanizing processes. Zinc provides sacrificial protection because it corrodes preferentially to exposed steel when the coating is damaged, while also providing a durable barrier against atmospheric corrosion, improving appearance, and supporting the performance of suitable organic finishing systems.
The galvanizing process was developed simultaneously in France and England in 1837, with both methods using hot dipping to coat steel sheets with zinc. Modern galvanizing is primarily carried out on cold-rolled sheets or strips. Hot-dip galvanizing involves immersing prepared steel in molten zinc and is suited to heavier coating weights, while electro-galvanizing uses an electrolyte to deposit a controlled layer of pure zinc and is generally suited to lighter coatings.
Galvanized steel is also used to produce corrugated sheets through automated roll forming. Further treatment through galvannealing can improve surface properties such as paint adhesion and weldability. GI sheets are produced in both annealed and full-hard conditions for applications requiring different mechanical properties.
Cost Estimation
| Particulars | Value |
|---|---|
| Plant Capacity | 4 MT/Day |
| Land & Building (2000 sq.mt.) | Rs. 1.47 Cr |
| Plant & Machinery | Rs. 2.48 Cr |
| Working Capital for 1 Month | Rs. 17.73 Lac |
| Total Capital Investment | Rs. 4.37 Cr |
| Rate of Return | 22% |
| Break Even Point | 64% |
Content Index
- INTRODUCTION
- PROCESS OF GALVANIZING
- GI SHEETS SPECIFICATION
- ADVANTAGES OF GALVANISING
- USES AND APPLICATION OF GALVANISING
- B.I.S. SPECIFICATION
- PROCESS FLOW CHART
- GALVANISING PROCESS
- MANUFACTURING PROCESS OVERVIEW
- THE GALVANIZING PROCESS CAN BE GROUPED TOGETHER UNDER THREE CATEGORIES, NAMELY
- SOME OF THE COMMON TERMINOLOGIES USED IN GALVANIZING PROCESS ARE AS FOLLOWING:
- ASH –
- DROSS –
- FLUX –
- OVER-PICKLING –
- INHIBITOR –
- GALVANIZING BATH-
- ALUMINUM ADDITIONS –
- COATING THICKNESS
- THE METALLURGICAL BOND
- HOT DIP GALVANIZING PROCESS
- ALL GALVANIZING CONSISTS OF FOUR FUNDAMENTAL STEPS:
- 1. SURFACE PREPARATION:
- A. DEGREASING
- B. CLEANING
- C. PICKLING
- D. AGITATION
- E. RINSING
- F. FLUXING
- 2. GALVANIZING:
- A. IMMERSION
- B. WITHDRAWAL
- C. WATER QUENCHING
- D. CENTRIFUGING
- E. THREAD BRUSHING
- 3. POST TREATMENT:
- 4. STACKING:
- 5. INSPECTION:
- CHARACTERISTICS OF GALVANIZED SURFACES
- 6. QUALITY CONTROL:
- INSPECTION & TESTING
- MARKET POSITION
- CONSTRUCTION INDUSTRY TO LEAD THE GLOBAL GALVANIZED STEEL MARKET
- GALVANISED STEEL MARKET
- COASTAL INFRASTRUCTURE
- AUTO SECTOR
- THE RAILWAYS
- ENERGY SECTOR
- GALVANIZED STRUCTURE STEEL MARKET
- GLOBAL GALVANIZED STRUCTURE STEEL MARKET COMPETITION BY TOP MANUFACTURERS
- PRINCIPLES OF PLANT LAYOUT
- PLANT LOCATION FACTORS
- EXPLANATION OF TERMS USED IN THE PROJECT REPORT
- PROJECT IMPLEMENTATION SCHEDULES
- PLANT LAYOUT
- MANUFACTURERS/SUPPLIERS OF GALVANISING SERVICES
- SUPPLIERS OF RAW MATERIALS
- SUPPLIERS OF ZINC INGOT
- SUPPLIERS OF CASTIC SODA
- SUPPLIERS OF HYDROCHLORIC ACID
- SUPPLIERS OF PLANT AND MACHINERY
- SUPPLIERS OF HOT DIP GALVANISING PLANT
- SUPPLIERS OF DG SETS
- SUPPLIERS OF EOT CRANE
- SUPPLIERS OF POWER TRANSFORMERS
- SUPPLIERS OF ELECTRICAL PANEL
- SUPPLIERS OF ELECTRIC MOTOR
- SUPPLIERS OF COOLING TOWER
- SUPPLIERS OF EFFULENT 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 applying a protective zinc coating to steel or iron to prevent corrosion. The zinc coating acts as a physical barrier against the atmosphere and also provides sacrificial protection when the steel is exposed through damage to the coating. Galvanized products are therefore used where improved corrosion resistance and extended service life are important. The process can be carried out using hot-dip galvanizing or electro-galvanizing, depending on the required coating characteristics and application.
Hot-dip galvanizing coats steel by immersing it in molten zinc, while electro-galvanizing deposits zinc electrolytically from a zinc-containing electrolyte. Hot-dip galvanizing is generally more suitable when heavier zinc coating weights and strong corrosion protection are required. Electro-galvanizing provides more precise control over coating thickness but generally does not produce the same heavy coatings possible with hot-dip galvanizing. The choice depends on product requirements, coating specifications, surface characteristics, and intended application.
The main steps include surface preparation, galvanizing, post-treatment, stacking, and inspection. Surface preparation can involve degreasing, cleaning, pickling, agitation, rinsing, and fluxing to prepare the steel surface. During galvanizing, the prepared material is immersed in molten zinc and withdrawn under controlled conditions. Depending on the product, operations such as water quenching, centrifuging, or thread brushing may follow. Post-treatment and quality inspection help ensure that the finished galvanized surface meets the required characteristics.
Zinc protects steel through both barrier and sacrificial action. It forms a continuous coating that separates the steel surface from corrosive atmospheric conditions. When the coating is chipped or damaged and the underlying steel becomes exposed, zinc preferentially corrodes and provides cathodic or sacrificial protection to the steel. This property helps maintain the integrity of the steel and can significantly extend its useful service life in suitable environments.
Galvanized steel sheets are used in applications where corrosion resistance and durable steel performance are required. The report identifies sectors and applications including construction, coastal infrastructure, automotive, railways, and energy. A portion of galvanized steel production can also be corrugated to manufacture corrugated sheets. The zinc coating provides protection against atmospheric corrosion, while the underlying steel provides the required structural and mechanical characteristics for the intended application.
Galvannealing is a treatment in which a zinc-coated steel strip is heated to form an iron-zinc alloy layer within the coating. It is used to improve properties such as paint adhesion and weldability, which may not be optimal on a conventional zinc surface. In a galvannealing line, the zinc-coated strip passes through a galvannealing furnace, followed by equipment such as a skin pass mill, tension leveler, and chemical treatment equipment. The resulting surface contains iron within the zinc coating layer.
Corrugation converts galvanized steel sheets into profiled sheets with improved structural characteristics for applications such as roofing and construction. Modern corrugation commonly uses automated roll forming, in which sheets are drawn from large rolls and passed through forming dies that create the required profile. The material can then be automatically cut to the desired length. The report notes that the commonly used profile is a round wavy shape, although different shapes and sizes can be produced by changing the forming dies.
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