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:


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.

8. Finishing

The galvanized steel is finished by removing any sharp edges, spikes and burrs which may have formed during galvanizing and any uncovered areas repaired and inspected for quality Benefits Of Galvanizing

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.

    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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