When to Use Each Type of Galvanized Wire Rope

Wire ropes are an essential piece of industrial hardware equipment that serves numerous purposes for all types of projects. But if you are looking for exceptional strength and durability, a galvanized wire rope supplier will let you know that galvanized wire rope is the way to go. And there are different types of galvanized wire ropes, each one suitable for a specific set of operations.

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Galvanization is a process where a metal is coated in zinc over iron or steel to prevent it from rusting and corrosion. This helps to extend the life of the metal, particularly if it is exposed to weather elements or water. Galvanized metal is often used in steel structures, cables, and wire ropes to provide additional durability. 

Any types of galvanized wire rope are more durable and rust-resistant compared to non-galvanized wire ropes (also known as bright) while being less expensive than stainless steel. This makes it a great option for many applications and budgets. But there are some things that you need to know if you are in search of galvanized wire rope for sale. 

There are two ways that wire ropes can be galvanized: hot dip and electro galvanization. 

The way a wire rope is galvanized has an impact on its composition and strength, making each type optimal for specific circumstances. 

So, which type of wire rope should you use and when? As a leading galvanized wire rope supplier, we know a thing or two about the differences in galvanization.

Let&#;s discuss this.

Electro Galvanized Wire Rope

Electro galvanization (also known as electroplating) attaches the zinc coating to a wire rope by electricity. First, zinc powder is mixed into a saline solution that has an electric current running through it. Wire rope is then carefully dipped into the zinc solution. The electricity causes the electrons from the zinc to bond to the metal, creating an extremely thin protective coating.

Electro galvanized wire rope is shiny and smooth &#; as the zinc coating layer is extremely thin and even. This makes it a great option for applications where appearances matter and a shiny finish is desired.

Hot Dip Galvanized Wire Rope

Hot-dip galvanization is the other form of galvanizing. Zinc is heated up in a large vat until it becomes molten at 860 F°. The wires, which will form the rope, are then cleaned to ensure that there are no particles of dust, metal shavings, or other contaminants on the cable before it is completely immersed in the molten zinc. 

Once the wires are completely coated, they are removed and cooled before they are formed into strands to create the hot dip galvanized wire rope. 

The process creates a thicker zinc coating that is 5 to 10 times thicker than electro-galvanized coating. This provides optimal protection against rust and wear, making the hot dip galvanized wire rope extremely resistant to abrasions &#; as well as stiffer and stronger.

Galvanized Wire Rope Pros and Cons

Different types of galvanized wire rope offer different benefits and downsides, and each is designed to be used for different purposes.

Costs

Hot dip galvanized wire rope is up to 40% more expensive than electro-galvanized rope because it is heavier and stronger. However, one of the reasons why electro-galvanized wire rope is less expensive is because it is lighter and smaller &#; which means that it is also not as strong as hot dipped galvanized rope. 

Weight

Hot-dip galvanization creates a thick coating, which increases the weight of the wire rope significantly. Electro-galvanized wire rope is much lighter and thinner, so it can be used for more delicate applications.

Durability

Since electro-galvanization creates an extremely thin coating, it does not offer as much protection as the thicker hot-dipped galvanization process. Electro-galvanized wire rope is far less durable. It is not made to be used in applications where it will be exposed to extreme elements or high levels of friction.

Flexibility

Electro galvanized wire rope is far more flexible than hot dip galvanized wire rope because the thin coating does not compromise the rope&#;s movement as much. The hot dipped galvanized rope is much stiffer and sturdier, which does make it better for use where movement is discouraged, like in lifting and rigging. 

Appearance

Electro galvanized wire rope is shiny and has a very even zinc coating. Hot dip galvanized wire rope has a dull appearance, and the zinc coating can be uneven or streaky. Therefore, it is often not used in architectural applications for design purposes &#; since it is not as appealing as electro-galvanized wire rope.

When to Use Hot Dipped Galvanized Rope

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These types of galvanized wire ropes are best for applications where the cables will be exposed to harsh weather elements, such as rain, heat, cold temperatures, and wind. They are commonly used on construction sites for setting fences and perimeters &#; and are generally used in lifting and rigging cranes. You may also see hot dip galvanized wire rope in parking garages and farms.

Hot-dipped galvanized ropes are also often used in applications where the rope must resist high levels of friction, like pulleys and zip lines. The thick zinc coating prevents the rope from wearing down quickly. 

Overall, it is best to use hot dip galvanized wire rope for projects which require optimal strength and long-lasting sturdiness.

When to Use Electro Galvanized Wire Rope

Electro galvanized wire rope is rust-resistant, but it is not optimal for extreme environments where the rope gets exposed to lots of moisture. The anti-corrosion and anti-oxidation are good enough to provide protection under normal circumstances. As a result, this galvanized wire rope gets used in routine applications. They include the following.

The most common applications include wire mesh, fencing, and perimeter cables.

Wire Mesh: This is probably the most typical use of electro-galvanized wire rope. Usually, digitally controlled automatic welding equipment is used to make these wire meshes. This mesh comes in precut rolls and panels. It frequently gets used in light construction and fencing. In the construction industry, you will see this wire mesh in concrete floors, reinforcement walls, retaining walls, and reinforcement mesh, among others.

It may be found in architectural design, particularly for fastening and binding. The most common fencing applications include fences for livestock, flowering plants, trees, windows, doors, pathways, and poultry cages.

This galvanized wire rope also gets used as mesh fencing but with a larger diameter. You can also find this wire rope as shields on machinery, equipment, and even cargo.

Call a Trusted Galvanized Wire Rope Supplier Now

Whether construction, fencing, or any other use, galvanized wire ropes are often a better and less expensive alternative. They provide superior corrosion resistance compared to low-grade carbon steel wire ropes. However, they cost considerably less than steel wire ropes.

Moreover, galvanized wire ropes are incredibly strong and versatile &#; but the galvanization process that is used can significantly impact the durability and use of the rope. Be sure that you are using the correct one from your galvanized wire rope supplier for your application! Most suppliers will be more than happy to help you pick the one best suited for your application and budget.

If you have any further questions or you are looking for a great deal on different types of galvanized wire ropes for sale, reach out to our sales team at Elite Sales. We are more than just a wire rope supplier &#; we carry many other hardware supplies including industrial strands, hooks, shackles, and chains for nearly any type of project. Make Elite Sales your one-stop shop for all of your industrial hardware needs.

Some baling wire undergoes a galvanization process that involves coating the wire in a layer of zinc. The zinc coating acts as a sacrificial outer layer, protecting the wire from rust, corrosion, and abrasion.

Zinc-coated steel wires are exceptionally resilient to weather conditions, making them a primary choice for baling recyclable materials that will be stored outside, farm fencing, and vineyard trellising.

Different classes of galvanized steel

Baling Wire Direct offers both Class 1 and Class 3 galvanization on all wire products. Class 3 galvanization offers significantly higher corrosion resistance than the standard Class 1 galvanization.

• Class 1 galvanized wire features a thinner zinc coating of 0.28 ounces per square foot and provides basic protection, but it tends to rust after 2&#;12 years depending on the environment. In coastal areas, Class 1 coating fails even sooner due to saltwater corrosion. It is often used for barbed wire fencing.
• Class 3 galvanized wire offers a premium zinc coating (nearly three times as thick as Class 1) that uses 0.80 ounces of zinc per square foot. This wire coating offers a higher degree of protection, providing a lifespan of 13&#;30 years. Class 3 galvanized wire is more expensive up front, but it is much more long-lasting. Class 3 galvanization is our most rust resistant wire coating, the ideal choice for harsh environments.

Galvanized steel properties

Compared to regular baling wire, galvanized wire has many advantages. The benefits of galvanized wire include:

• Versatility. Galvanized steel wire is suitable for a variety of industries, including recycling, agriculture, and construction, due to its high tensile strength, formability, and corrosion resistance.
• Corrosion resistance. Galvanized iron wire resists rust up to 100 times better than uncoated steel, making it highly durable and long-lasting.
• Durability. The zinc coating is extremely durable and resistant to scratches from abrasion.
• Recyclability. Hot-dip galvanized wire is as recyclable as other types of steel, making it an environmentally friendly wire material.
• Surface appearance. All zinc-coated steel wires have a matte-gray appearance. The zinc coating applied by electro-galvanizing is smoother than galvanized steel made with hot-dip galvanization.
• Formability. The zinc coating on galvanized steel is resistant to cracking and loss of adhesion, making it highly formable.
• Long life. Hot-dip galvanized steel has a long life, requiring less maintenance and offering a low long-term cost.

Different types of galvanization

Metal can be galvanized through several different processes, including:

• Hot-dip galvanizing. This involves immersing the base wire material into a bath of molten zinc, providing a complete zinc coating. It is the most popular and trusted method of galvanization due to its thorough coverage and durability.
• Pre-galvanizing. Similar to hot-dip galvanizing, but performed at a steel mill, where the steel is coated with a layer of zinc before it is formed into the final wire product.
• Galvannealing. A process that combines hot-dip galvanizing and the annealing process, resulting in a zinc-iron alloy product with a dull matte surface appearance. It is conducive to welding and provides an excellent surface for paint adhesion.
• Electro galvanizing. This method does not use a molten zinc bath. Instead, it involves applying zinc in a thin coating to the base metal, typically through an electroplating process. The zinc coating applied by electro-galvanizing is smoother than that of hot-dip galvanized products.

Our hot-dip galvanizing process

Our hot-dip galvanization process involves the following steps:

1. Surface preparation. First, the wire undergoes a cleaning process to eliminate any impurities from the exterior of the metal. This purification ensures the adhesion of the zinc coating.
2. Pickling. We then submerge the wire in an acidic solution to strip off any remaining oxides and residue. This process primes the surface for galvanizing by generating a pristine foundation.
3. Fluxing. We soak the wire in a flux solution (zinc ammonium chloride) that hinders oxidation and enables a uniform coating of zinc.
4. Molten bath. We then plunge the wire into a bath of zinc heated to around 450°C (850°F).
5. Alloy formation. While immersed in the pool of zinc, a strong bond occurs between the iron in the wire and the zinc, forming a sheet of distinct iron-zinc alloys.
6. Extraction. We then gradually extract the wire from the zinc bath. We control the extraction rate to enable excess zinc to drain off and ensure an even coating on the final product.
7. Quenching. We then quickly cool the coated wire in water or a cooling solution to solidify the protective zinc coating and complete the galvanizing process.

Our technique generates galvanic protection that safeguards against the elements.

We sell galvanized bale ties and galvanized wire by the stem.