Hot-Dip Galvanising

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Hot-dip Galvanization: Best Solution Against Rusting and Corrosion

Hot-dip galvanization  has been extensively used to prevent corrosion for 100 years. Hot-dip galvanized steel has a great lifespan. This effective form of galvanization provides 2 levels of protection :

– Barrier protection

– Cathodic protection

In Cathodic protection, Zinc protects the underlying material. If any part is scratched, Zinc will prolong its protection. Zinc can also function as a barrier slow down the corrosion rate.

There are 3 steps in hot-dip galvanization:

  • Surface set-up
  • Galvanization
  • Inspection

Preparing the surface for galvanization is important. Zinc will cease to react with unclean steel; so this process is significant.In case of unclean surface, the coating will not be even and quick remedial measures will be required.

Removal of contaminants will be required through acid bath or such degreasing processes. Pickling processes been an effective solution that involves diluted sulfuric acid usage on the surface. Fluxing is another process done with Zinc Ammonium Chloride solution that eliminates all oxides and prevents oxide formation.


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.

Why Hot Dip Galvanizing?

Talk to anyone in the hardware and construction industries, and ask them about what is that one concern that drives them to the wall – (not literally of course!) In all likelihood, the answer will be “the quality, longevity, and performance of the metals in use.  

Hot-dip galvanizing has come a long way since it was first invented 150 years ago. The popularity of the process is because of the many qualities and traits it endows steel with. Above all, hot-dip galvanizing is termed as steel’s “best friend” for it endows it with anti-corrosion properties.

At Hylite, we receive numerous inquiries and requests for improving the quality of their steel objects and structures, and we recommend our best-selling solution – hot-dip galvanizing. One of the foremost reasons why hot-dip galvanizing continues to receive increasing endorsement is because it is the only process that facilitates metallurgical bonding between two metals. The amalgamation ensures enhanced anti-corrosion and durability. In other words, hot-dip galvanizing is the secret behind steel’s agility, quality, function, and performance. If these are qualities that you’d like to infuse in your steelworks, then why not opt for hot-dip galvanizing, and let us do it for you? 

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:

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.

Our hot-dip galvanizing services are a bestseller because there are a lot of individual clients and companies that want to prolong the lifespan of their steel appliances and applications. Hot-dip galvanizing has earned a reputation and popularity because it helps steel to last up to 20 years. What’s more, the performance and quality stay intact throughout, and very little maintenance is required. 

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.
Our hot-dip galvanizing services are a bestseller because there are a lot of individual clients and companies that want to prolong the lifespan of their steel appliances and applications. Hot-dip galvanizing has earned a reputation and popularity because it helps steel to last up to 20 years. What’s more, the performance and quality stay intact throughout, and very little maintenance is required.
  • The uniqueness of the hot-dip galvanizing process makes it an attractive go-to service. Metals not only get coated but also get subjected to metallurgical-binding which helps them to develop improved resistance and durability thereby making steelworks easy-to-ship, handle, and handle.
  • With hot-dip galvanizing you do not have to worry about the coating uniformity or toughness. When steel objects and applications get dipped into the molten liquid, every awkward and unreachable nook and corner will get coated. Rest assured, when the process ends, the coating will be uniform, there will be complete coverage, and the coating will be tough.
  • Galvanized coatings take (almost) forever to reveal any wear and tear. In other words, galvanized steel has “long life and low maintenance” written all over it.
  • Hot-dip galvanizing is a cost-effective option. As opposed to painting which is an expensive process, galvanizing is more affordable, and the results last longer. What’s more, the process is automated, does not demand much more, and is not time-consuming thus.
  • The main reason why most engineers and architects readily recommend hot-dip galvanizing for steel is that the maintenance costs are very low, and because the process is heavily-regulated, the margin was error is very slim, and the process gets completed within a few hours.
  • Steel that has undergone hot-dip galvanizing is easy-to-construct and easy-to-inspect.

Corrosion protection

Good protection against rusting and corrosion.Multiple layer of Zinc-Iron alloy is coated on the metal confirming its corrosion-resistance.


Hot-Dip galvanization provides great durability with resistance to abrasion, sound protection against rusting for the entire product. The complete coverage of the products rules out all chances of corrosion.


Hot-dipped galvanized products require zero maintenance for a long period. Surrounding environment can be a decisive factor determining the corrosion of the product. This form of galvanization can be most useful to protect steel buried in the soil or immersed in water. Hot-dipped galvanized steel can be stored outdoors  without spoiling its coatings.

Versatility and durability

Wide variety of steels and steel structures can be hot-dip galvanized.

Environmental advantages

Galvanized steel is renewable and environment-friendly.

Applications of Galvanized Steel

Galvanized Steel has versatile applications. It can be installed outdoors and indoors, wherever higher service life of the steel is required and corrosion protection is needed to maintain functionality of the product.
The galvanization process occurs through an electrochemical action, where the surface of a metal is coated with a highly corrosion resistant material such as zinc on steel or iron products. An alternate method is known as hot dip galvanizing. Where articles are submerged and then coated with hot zinc, this method is used to usually galvanize steel sheets.
We at Hylite Group offer our clients premium service as a recognized brand that provides hot dip galvanizing in Mumbai . Our staff work to ensure the quality of our products is top notch and we are a well-known name amongst galvanizers in Mumbai and also galvanizers in pune.
The list of items that can be galvanized varies and according to your requirements, items that belong in the household category such as buckets, tubs and other types of containers can be put through the galvanization process, thereby ensuring a long corrosion free life!
In the constructional and engineering fields, machine part, tools, tanks, ships, and even wires can be galvanized to ensure long term use. 

There are several different methods in which the galvanization process can occur. Zinc is widely used to prevent corrosion and that too has multiple different types of zinc coating, each with its own set of unique characteristics.

Steel metal is a rather popular and common material that is utilized in various industry, to ensure that steel can be durable and long lasting, manufactures, and the constructional industry therefore, opt for galvanized products.

Most common methods are:

  • Thermal Spray (Metallizing)
Semi -molten zinc (or an alloy containing zinc) is sprayed on to the steel or iron item, using a wire or powder heated by a flame, or an arc spray or even a plasma heat source. This method allows a thick layer of coating to be applied on the item during the process, up to 1500 g/m2. This galvanization process can be done manually or mechanically and it is most often processed in a factory. Items are always prepped before undergoing the galvanization process. They are subjected to a grit blast, in which the surface is cleared of sand and other materials that could prevent a smooth finish.
  • Hot dip galvanization
Widely and a popular method of galvanizing, immersion of products in hot zinc allows for a fool proof method of covering every inch of the product, both inside and outside, with a protective coating. After the items are removed from the bath, the drying process occurs which leads to the zinc to cool and leaves the final zinc galvanized layer.
  • Sheet galvanizing (Continuous Sheet Galvanizing)

A coil-to-coil process that is used to bond zinc on layers of steel sheets, wires, or strips. The continuously moving ribbon applies a fine thickness of zinc on the sheets, and the thickness of the coating can reach up 1.70 inches to 72 inches, depending on your requirements. To prepare for this process, the material is annealed, a treatment process where metals are heated until they are glowing and then allowed to cool at room temperature, this is done to ensure that no foreign particles are attached to the articles in the process to undergo galvanization.

Sheets that have been galvanized using this process are used in the automobile industry for in car bodies, roofing for residential projects and piping.

  • Electroplating
This process isn’t meant for large scale items, but rather everyday use items. Electroplating galvanization coats the item with a fairly thin layer of zinc by passing a constant stream of electric current through the electrolyte solution. With a complex process, and various equipment this method provides just the right amount of coating necessary for items such as fasteners and what not.
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.


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.

At Hylite, we deliver advanced hot-dip galvanization services. Acquired good expertise, we are leaders in hot dip galvanizing in Mumbai. We will make the galvanizing process simple and offer you long-term safeguard against corrosion. Reach us with your industrial requirements and our team will deliver best services…

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