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Need 20-year protection by electrogalvanizing

December 29, 2008

Myself Bikas working out metal forming & finishing product designing. I need a cheap coating process on steel sheet which can sustain 20 years against rust/ corrosion on outdoor extreme condition.
I tried using hot dip galvanising but during this process the flatness of sheet getting disturbed . My part needs flatness below 0.25 mm in sheet length 2.5 mtr.

Then I tried electro galvanizing , its comes good as far as flatness is concerned but not sure where it will sustain 20 years of rust free life in extreme outdoor application.

Please suggest what I should do ? is electro galvanizing will sustain 20 years corrosion-free life in extreme condition ? How much coating thickness I should do in electro galvanizing so that it could sustain 20 years rust free life?

None - India

December 31, 2008

Hi Bikas,

Zinc plating is not going to hold up outside for 20 years. You might want to look into a zinc alloy plate like zinc nickel or zinc iron properly passivated. 20 years is a tough one for plating. Paint or powder coating might be more effective.

Trent Kaufman
Trent Kaufman
electroplater - Galva, Illinois

January 15, 2009

Hi Bikas,

You might want to look at Zinc Aluminum Flake Coatings that are applied by dip-spin or sprayed on.

They should easily meet your 20 year requirement.

Khozem Vahaanwala
Khozem Vahaanwala
Saify Ind
supporting advertiser
Bengaluru, Karnataka, India
saify logo

January 18, 2009


I would like to know from Mr.Vahanwala whether a fat sheets can be coated with methods like Dacrotising or Zintek process where dip spin methods are used, would it be feasible technically, I think zinc alloy coating would be a good idea .

praveen kumar
Praveen Kumar
plating process supplier
Mumbai, India

January 26, 2009

Yes, Thick and large Sheet metal Parts can easily be coated by Zinc Aluminum Flake process without any problems.


Khozem Vahaanwala
Khozem Vahaanwala
Saify Ind
supporting advertiser
Bengaluru, Karnataka, India
saify logo

March 14, 2009

ZInc Aluminium flake is [another] solution for your application. Windmill industry also uses similar coating technology on their components to protect for 20-25 years span.

kalyan dhakane
Kalyan Dhakane
Mumbai, India

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