Hot-dip galvanization is a form of galvanization. It is the process of coating iron and steel with zinc, which alloys with the surface of the base metal when immersing the metal in a bath of molten zinc at a temperature of around 449 °C (840 °F).

When exposed to the atmosphere, the pure zinc (Zn) reacts with oxygen (O2) to form zinc oxide (ZnO), which further reacts with carbon dioxide (CO2) to form zinc carbonate (ZnCO3), a usually dull grey, fairly strong material that protects the steel underneath from further corrosion in many circumstances.

Building design and construction process — step by step

The process of hot-dip galvanizing results in a metallurgical bond between zinc and steel, with a series of distinct iron-zinc alloys. A typical hot-dip galvanizing line operates as follows:


1. Caustic cleaning

Steel is cleaned using a degreasing solution. This removes oil/grease, dirt, and paint.

2. Rinsing

The degreasing solution is rinsed off the steel in water (optional if acidic degreaser is used).

3. Pickling

The steel is pickled in an acidic solution to remove mill scale.

4. Rinsing

The pickling solution is rinsed off with water

5. Flux solution

A flux, often zinc ammonium chloride is applied to the steel to inhibit oxidation of the cleaned surface upon exposure to air. The flux is allowed to dry on the steel and aids in the process of the liquid zinc wetting and adhering to the steel.

6. Drying

The steel is dipped into the molten zinc bath and held there until the temperature of the steel equilibrates with that of the bath.

7. Zinc Bath

The steel is cooled in a quench tank to reduce its temperature and inhibit undesirable reactions of the newly formed coating with the atmosphere.

Benefits Of Galvanizing

Galvanized steel is widely used in applications where corrosion resistance is needed and is considered superior in terms of cost and life-cycle.

Like other corrosion protection systems, galvanizing protects steel by acting as a barrier between steel and the atmosphere. However, zinc is a more electropositive (active) metal in comparison to steel. This is a unique characteristic for galvanizing, which means that when a galvanized coating is damaged and steel is exposed to the atmosphere, zinc can continue to protect steel through galvanic corrosion, it self-repairs when damaged, sacrifices itself to protect the base metal.

Hot dip galvanizing offers coverage both externally and internally within hollow sections, is environmentally sustainable, has good impact and abrasion-resistance and a maintenance-free life of 50 years or more. Galvanized steel is widely used in applications where corrosion protection is needed

Applications of Galvanized Steel

Galvanized Steel has versatile applications. It can be installed outdoors and indoors, where ever higher service life of the steel is required and corrosion protection is needed to maintain functionality of the product.

Some of the major consumers of galvanized steel are the following industries


Wind energy




Power & Transmission




Solar energy


Roadways & Infrastructures




Railways & Metro projects




Large scale industrial plants

Our Plant Locations

Hylite Group has in all 3 galvanizing lines strategically located to cater to industries in the Mumbai- Pune region.


Bath size: 7.5 m long x 1.5 m deep x 0.9 m wide
Plant Capacity : 2000 MT/Month


Bath size : 3.25 m long x 1.2 m deep x 0.8 m wide
Plant Capacity : 300 MT / Month


Bath size : 1.0 m long x 1.0 m deep x 0.7 m wide
Plant Capacity : 100 MT / Month

Why Galvanize at HYLITE ?

The Hylite group is a one stop solution to all coating needs. Even when it comes to galvanizing we are the only sundry galvanizing company who has 3 baths of different sizes to cater to a variety of customers irrespective of job specifications, size and location.

75 years + of industry experience to benefit from

Client job is a priority since we do not have our own products and are focused on finishing client work.

Quickest lead times

Single source for any job size or specifications in galvanizing

Largest spare capacity available in the region (2000 MT)

Technically sound team who YOU can consult for any coating advice and queries

ISO certification and affiliation to major coating / galvanizing associations

In House testing lab and strong QC team


Knowledge Sharing

Design for Hot Dip Galvanising

Inspection of work before dispatch to the Galvaniser

Fabricated assemblies, casting and other components for hot dip galvanising should be inspected and any significant surfaces identified before dispatch to the galvaniser to ensure that the following points conform to design requirements. This may avoid costly rectification and delays at the galvinishing plant.

Call us and get it done

When you hire us, you know you’re getting highly qualified professionals who have the expertise and experience to make sure your project is done properly
and functions.

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