Hot Dipped Galvanized Wires FAQs for 2022


Hot Dipped Galvanized Wires FAQs for 2022

Posted on October 10, 2021

Hot dipped galvanized wires are used in a variety of ways. This article describes the features and specifications of hot dipped galvanized steel wire, its applications, and answers from frequently asked questions about the subject.

Features of Hot Dipped Galvanized Wire

hot dipped galvanized wire

Hot dipped galvanized steel wire is available in two types, namely mild steel and stainless steel. The mild steel hot dip galvanized wires are further divided into three kinds. They are the plain hot dipped galvanized wires (electrical armored), structural hot dipped galvanized (mechanical) armor wires, and non-armored hot dipped galvanized steel wire.

The stainless steel wires are divided into two types, namely bright annealed and hot dipped galvanized. The former is used to make food-grade products only. In contrast, the latter is applicable for automotive applications, pressure vessels, pipelines, etc., requiring high tensile strength and corrosion resistance.

Features of hot dipped galvanized wires include:

  • Corrosion resistance (hot dipped for longer service life)
  • High yield strength (provides high tensile strength and load-bearing capacity)
  • Low cost (cost-effective when compared to other materials in the market)
  • Lightweight (reduces total cost of the material because lightweight steel wires need less support, transportation means, etc.)
  • Low fatigue failure (resists metal fatigue during long-term use)
  • Easy installation (hot-dip galvanized steel wire is lightweight, which makes it easier to handle)

Hot Dip Galvanizing

hot dipped gi wire

Rapid deterioration of non-galvanized steel components such as iron poles, lamp posts, and signposts is a widely known drawback. Damaged steel is easily corroded by atmospheric conditions such as humidity, rainfall, etc. It speeds up the rusting process and leads to unsightly metal structures and increased replacement costs.

An alternative solution is a hot dip galvanizing applied on steel components that are to be exposed in outdoor conditions. The process involves immersing the base metal (usually mild steel) under an electrolytic charge of zinc ions in a molten bath of molten salt at elevated temperature (at least 30 degrees Celsius).

The hot dip galvanizing process provides better protection against atmospheric corrosion than other paints, powders, and cold-applied zinc methods.

Hot Dipped Galvanized Wire

  • Used in fencing (strands for woven wire fences)
  • For reinforced concrete (reinforced with steel mesh-like weave)
  • Chain link fences (hot dip galvanized wires are less expensive than wrought iron or steel fences)
  • Power transmission structures (applied for high load-bearing capacity applications)
  • Architectural structures (applied for ornamental purposes)
  • Aviation industry (for aircraft support systems, cabling, etc.)
  • Hydropower industry (used for underwater power cables, hydraulic tubes, etc.)
  • Landscape art (applied for metal railings, sculptures, etc.)
  • Telecommunication industry (for towers, masts, signages, etc.)
  • General construction uses
See also  Why is hot dipped Galvanised wire better than Electro Galvanised wire?

Other Uses of Hot Dip Galvanized Steel Wire

Metal buildings are made from hot dip galvanized steel wire. This is because the process provides resistance against corrosion and rusting. Hot dip galvanized steel wires are also used for other buildings such as gazebos, pavilions, and garden furniture where the frame needs to be strong and corrosion-resistant.


What is the difference between galvanized and hot dipped galvanized?

A: Galvanization, or galvanizing, is a process where a zinc alloy coating is applied to an iron base metal. It serves to protect the surface of the metal from rusting, although if enough force is applied, it will still scratch or be punctured. Galvanized wire is a very thin wire coated and does not have any electrical insulation properties.

Hot Dipped Galvanized Wire is giving another layer of zinc alloy coating for galvanizing the iron base metal that has already been produced from the galvanizing process. The additional layer protects against corrosion and wears along with the strength and insulation of the wire.

How long will hot dip galvanize last?

A: Hot-dip galvanizing is a permanent process. It cannot be repaired or scraped off like paint and other types of protection finishes, and it must be done again if another layer of zinc alloy coating is desired.

What are the disadvantages of Galvanising?

A: There are several, as it is a chemical process that uses the hazardous metal cadmium. It is also more expensive than applying other finishes such as paint and powder coating and does not produce as aesthetically pleasing results.

What is the process of hot dip galvanizing?

A: First, the iron base metal is cleaned by removing oil and grease with a solvent. The base metal will then be dipped in a molten zinc bath at a temperature of approximately 450°F. It must be shaken off periodically during this process to ensure that it is evenly coated. Afterward, the wire or other product will be dipped in a bath of hot water and then transferred to a cooling tank of air or oil, which is where it will be quenched.

Does galvanized steel need to be painted?

A: The zinc alloy coating does not produce any insulation properties, so if electrical purposes are necessary, the wire should be insulated after hot dip galvanizing.

See also  What is Galvanising?

Can hot dipped galvanized steel be painted?

A: Yes, as long as the coating of zinc has not been damaged too badly. It should be sandblasted and primed with silicon-based paint before applying any topcoats such as enamel or powder coating. Like other surfaces painted, the galvanized surface should be cleaned with a solvent before painting.

Can hot dipped galvanized wire steel be powder coated?

A: Yes, after cleaning and sandblasting, it can be treated the same way as any other metal that will receive this finishing treatment. It will probably need to be primed if it has been only hot-dip galvanized before applying a topcoat.

Can steel be hot dip galvanized?

A: Yes, steel can be galvanized with the same process as other metals such as iron and aluminum. The zinc alloy coating will not stick to stainless steel, so this metal type must have another coating applied before hot-dipping galvanizing.

Why is hot dipped galvanized wire more expensive than regular galvanized wire?

Hot-dip galvanizing is an operation that forms a strong and corrosion-resistant zinc coating on steel or iron. This process is applied to sheet or coil stock, as opposed to just applying paint.

Regular galvanizing is just coating steel with zinc. Any regular galvanized paint is just that – regular paint, not galvanizing.

Galvanizing coatings are designed to protect against corrosion. There are two kinds of galvanized coatings: electroplated and hot-dip. The primary distinguishing feature between the two types is their origin; one originates from electrolysis, and the other originates from molten metal.

Electroplated galvanizing is just coating steel with zinc and does not protect as well as hot-dip galvanizing. Zinc is a cathodic protection element; it is sacrificial, which means it corrodes first before the base metal (steel). If there is no zinc coating on the steel, then the steel will rust first. 

This galvanizing can be done by painting a base coat of paint onto the steel. It is just a temporary coating that eventually flakes off due to contact with moisture and other corrosives.

If there is going to be a coating over the electrolytic zinc coating, then hot-dip galvanizing is the preferred coating method because it forms a strong bond between the steel and zinc.

With hot-dip galvanizing, steel will not rust – it will remain in its current condition (will not rust) unless there is damage to the zinc coating itself where moisture can reach the steel.

Can hot dipped galvanized wire rust?

A: If the zinc coating is intact, then it will not rust. The only way the zinc coating would fail is if there are cracks or holes in the coating or if the steel underneath is exposed due to damage to the coating.

See also  Advantages and Benefits of Galvanized Iron Wire

If hot-dip galvanized steel rusts, is it more or less resistant to corrosion?

A: If the zinc coating is intact, then it will provide excellent protection against corrosion. There are no free ions of metal with an intact coating that would allow galvanic corrosion to occur. This means that hot-dip galvanized steel would be more resistant to corrosion than bare steel.

What happens if hot dipped galvanized steel rusts?

A: When zinc corrodes, it will form an insulating barrier that prevents further corrosion of the underlying material (steels). Steel rusts through a process called electrolytic oxidation; this is the same process that is used in hot-dip galvanizing.

Remember that if there’s bare steel, it will oxidize no matter what you do to it except hot-dip galvanize it or paint it. If there are holes in the coating, though, moisture can get under the coating due to rust damage and cause more rust.

Is it better to paint hot dipped galvanized wire or leave it as is?

A: The choice of painting should be based on whether there will be a need to modify the surface, either by mechanical means (grinding, drilling, etc.) or chemical means (paint stripper). If a mechanical modification is needed, the painting should be avoided, making the surface rough. This would make the process of mechanical modification more difficult to accomplish.

If chemical means are necessary, then paint must first be removed before hot-dip galvanizing. 

If there are any paints or other coatings on the steel, those must be removed before applying hot-dip galvanizing. This can be done by sandblasting or some other method depending on the application and the coatings present.


You have a lot of questions about hot-dipped galvanized wires. There are many benefits to using these high-quality, durable steel strands in your construction project. We hope our FAQ section has helped answer some of the most pressing concerns on your mind! If it hasn’t or anything else we can help with, please don’t hesitate to get in touch.

We would be happy to discuss any other aspects of this product and offer more information for you before making up your mind. All contact information is available at the bottom of each page, so feel free to take advantage anytime! Thanks again for visiting our website today!

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