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Tuesday, May 8, 2018 / Categories: Blog (https://www.mazzellacompanies.com/Resources/Blog/evl/0) Browse By Topic

Electro Galvanized vs. Hot Dip Galvanized Wire

Rigging Equipment 51
Rope & Steel Cable (https://www.mazzellacompanies.com/Resources/Blog/acat
A look at the differences in cost, corrosion-resistance, and suitable applications for equipment-1)
galvanized wire rope and steel cable.
Overhead Cranes 42
(https://www.mazzellacompanies.com/Resources/Blog/acat
cranes-5)

OSHA & ASME Compliance 35

(https://www.mazzellacompanies.com/Resources/Blog/acat
(/Portals/0/EasyGalleryImages/1/89/cable..jpg) asme-compliance-1)

Rigging Inspection 25
(https://www.mazzellacompanies.com/Resources/Blog/acat
inspection-2)

Steel strand can be used in the production of a variety of different products including wire rope Overhead Crane Service 11
(https://www.mazzellacompanies.com/Resources/Blog/acat
(https://www.mazzellacompanies.com/Resources/Blog/what-is-wire-rope-specifications-classifications-
crane-service-1)
construction), aircraft cable, and structural cable for bridge and building support. The construction of steel
Lifting And Rigging Training 11
cable consists of thin steel wires that are stranded together to give the cable the perfect blend of strength
(https://www.mazzellacompanies.com/Resources/Blog/acat
and flexibility. Different constructions allow steel cable to be used in a number of different industrial,
and-rigging-training-1)
commercial, recreational, and military applications.

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1/28/2020 Electro Galvanized vs. Hot Dip Galvanized Wire Rope & Steel Cable

Industry News 8
For extreme environments where exposure to moisture, salt water, or corrosive or caustic chemicals is (https://www.mazzellacompanies.com/Resources/Blog/acat
news-1)
possible, the correct type of stainless steel cable is the preferred choice. For most applications, a
galvanized zinc coating will offer some form of corrosion resistance and still provide the strength and Below-The-Hook Lifting Devices 8
flexibility characteristics desired by the end-user. (https://www.mazzellacompanies.com/Resources/Blog/acat
the-hook-lifting-devices-2)

However, the term “galvanized” can be confusing for the end-user as there are a number of options for Wire Rope 8

providing protection to the base metal. In this article, we’ll be reviewing two different galvanization (https://www.mazzellacompanies.com/Resources/Blog/acat
rope-1)
processes—electro galvanization and hot dip galvanization. There are a number of cable distributors who
carry one type of product and mark it as “galvanized,” but don’t specify whether it’s electro galvanized or a Fall Protection 7
(https://www.mazzellacompanies.com/Resources/Blog/acat
hot dip galvanized product. This can lead to confusion for the end-user when they’re comparing galvanized
protection-1)
cable quotes because the price and corrosion-resistance can vary between products of equal
specifications. Hoists And Hoist Parts 7
(https://www.mazzellacompanies.com/Resources/Blog/acat
and-hoist-parts-1)
At Mazzella Companies, we stock and distribute wire rope and cable in stainless, electro galvanized, and
Mazzella Companies News 4
hot dip galvanized coatings. Our goal for this article is to explain the differences between the two types of
(https://www.mazzellacompanies.com/Resources/Blog/acat
galvanized coatings, and identify the advantages, disadvantages, and proper applications for each product companies-news-1)
type.
Warehouse Solutions 3
(https://www.mazzellacompanies.com/Resources/Blog/acat
solutions-1)
What is Steel Cable Primarily Used For?
Lifting and Rigging – Steel cable can be made into wire rope slings
(https://www.mazzellacompanies.com/Resources/Blog/lifting-slings-wire-rope-slings-alloy-chain-
slings-synthetic-slings) or cable assemblies and used in conjunction with hoists or winches for lifting,
pulling, and hanging applications.
Vehicle and Load Securement – Securing military vehicles and aircraft and/or securing and tying
down cargo
Boats and Maritime – Securing boats in docking situations or hoisting boats in and out of the water
Overhead Doors – Used in conjunction with a strong pulley system to open and close garage or
overhead doors Welcome To Our Blog!
Perimeter Fencing – Used at construction sites or other locations as perimeter or security fencing
Fall Protection Barriers and Tie-Off Points – It can also be used as a line for workers to tie off to or Are you interested in OSHA compliance for overhead
a barrier to prevent falls for employees working at height cranes, slings, wire rope, hoists and rigging equipment?
Our blog is designed to help you learn more about
Guy-wire, Guy-line, or Guy-rope (also known simply as a Guy) – is a tensioned cable designed to lifting and rigging, and keep you up to date on industry
add stability to a free-standing structure. They are commonly used in ship masts, radio masts, wind best practices. Subscribe today!

turbines, utility poles, fire service extension ladders, and used in church raises and tents. First Name*
Zip Lines – Professional zip line courses utilize steel cable for its strength and durability

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What is Electro Galvanized Cable?

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1/28/2020 Electro Galvanized vs. Hot Dip Galvanized Wire Rope & Steel Cable

Electro galvanization is a form of zinc electro plating (https://www.youtube.com/watch?

v=OxhCU_jBiOA) where a thin layer of zinc is electrically and chemically bonded to steel in order to protect
against rust and corrosion.

During this process, bare steel wires are fully immersed in a saline/zinc bath and electricity is used to move
electrons from the zinc (anode) and bond them to the steel (cathode). In this case, the zinc acts as a barrier
(https://resources.mazzellacompanies.com/cs/c/?
layer on top of the steel to prevent corrosive substances from reaching the underlying steel or iron. The cta_guid=5297ad4d-13cf-40bf-bf73-
wires are then formed into strands and then the strands are helically formed into the finished cable or wire 0972b23da4b2&placement_guid=a2c6368e-1d64-
45c9-8762-
rope configuration. 5c2d5f3b6aeb&portal_id=3336966&canon=https%3A%2F%
galvanized-vs-hot-dip-galvanized-wire-rope-steel-
cable&redirect_url=APefjpG6Nrk-
When the process is complete, the finished coating is smooth, drip-free, and shiny—making it ideal for
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architectural applications or other applications where its aesthetic characteristics would be of value. Uy8tQ6GVOCeAbeXEwZi8ZXKqFzDjUGe4f3uQalTPdVWw
However, once it’s exposed to the elements, the finish can quickly deteriorate. xM5ecnGOOrHURkjapBV5JG7zNmfHl9ZCp6JT3mBfaalMo
hUruxYrJ9o8oA71y9waysSTDvHIvYuq0mZTAJzK_cBJfrFF
974c-411c-9f72-
45b5f8355a52&hsutk=b2d81736cb3d9bac446f291eaee74c

Advantages of Electro Galvanized Cable

Aesthetics - clean bright finish

Uniform zinc coating
Cost-effective solution

Disadvantages of Electro Galvanized Cable (https://resources.mazzellacompanies.com/cs/c/?

cta_guid=8eb31e3e-99ea-4b4a-b533-
Shorter service life – ranging from a few months to few years depending on exposure to caustic or 656aefeb1d9c&placement_guid=fa562007-f3cb-4d0e-
a8e4-
environmental elements
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Will corrode much faster than an identical product that’s been hot dip galvanized galvanized-vs-hot-dip-galvanized-wire-rope-steel-
Thinner zinc coating comparatively cable&redirect_url=APefjpGP78BPm777TaR_nj3pEdeArdvI
Q9eyzbUsh9B1Zmvoyt_A2RRvs_JN0b2VkJhZ7QlWwFGO
CaMM9_zqUjh8t6zLgLlFi6wgUwh53E-
3i6vjqVJj6CYP8SR-ys9FLQtiwv64UBirwsr2-elVIaXy0-
d9KVhBCMefHy6oF7GJXTwXUFUZ8WPvVN0tbyI8GOzUW
Applications 9I-I0Z7lVqx_fQZ0FTctxXl&click=133c20cd-fc41-43b4-
ab51-
Electro galvanized cable should be used in applications with limited exposure to harsh or extreme bc02f2402706&hsutk=b2d81736cb3d9bac446f291eaee74c
mBmzq1G3WDw&utm_referrer=https%3A%2F%2Fwww.ma
environments. It offers minimal corrosion protection, but in instances where it’s fully exposed to the
elements, it will begin to corrode much faster than hot dip galvanized.

The main advantage to electro galvanized cable is that it’s the most cost-effective solution. For construction
sites, it can be used as perimeter cable or as a barrier or tie-off cable for employees working at heights. For
applications where it may experience field use for a few weeks or a few months, it can then be safely
disposed of (https://www.mazzellacompanies.com/Resources/Blog/how-to-dispose-of-damaged-rigging-
gear-wire-rope-slings) once the project is complete.

If exposure to the elements is minimal, it can be used in architectural applications for aesthetic purposes
due to its naturally bright and shiny finish.

What is Hot Dip Galvanized Cable?

(https://resources.mazzellacompanies.com/cs/c/?
In hot dip galvanized cable, each uncoated steel wire is immersed in a molten zinc bath cta_guid=267ef7b1-90ca-4f09-8864-
115e5b760ddb&placement_guid=c73d8388-a920-4f48-
(https://youtu.be/kwCyq06aatA?t=1m7s). Prior to dipping, the wires are put through a rigorous 7-step
87cf-
caustic cleaning process and then dipped into the molten zinc at a temperature of around 860°F/460°C. As f1024009f744&portal_id=3336966&canon=https%3A%2F%
galvanized-vs-hot-dip-galvanized-wire-rope-steel-
it’s withdrawn from the molten bath, the material cools and forms a coating of zinc on the steel. The wires
cable&redirect_url=APefjpGOq13GnLIahv_czzxN5RTYEvh
are then formed into strands and then the strands are helically formed into the finished cable or wire rope VO4b23Xrh2CJkURdRZQ2f58X11ae7U22QV0a5U9PMV24

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1/28/2020 Electro Galvanized vs. Hot Dip Galvanized Wire Rope & Steel Cable

faef-488b-af3a-
e517a9b1637f&hsutk=b2d81736cb3d9bac446f291eaee74c

Lifting & Rigging Resources:

(/Portals/0/EasyGalleryImages/1/89/hot-dip-

galvanized.jpg)

configuration.
(https://resources.mazzellacompanies.com/cs
cta_guid=577a69fe-228a-
Hot dip galvanizing provides much better corrosion resistance than electro galvanization because the zinc 4445-a88e-
e3986196bc7c&placement_guid=155531d2-
coating is typically 5 to 10 times thicker. For outdoor or caustic applications where corrosion-resistance is
daf0-4afd-b027-
required, hot dip galvanized cable is the clear choice. e046cea55713&portal_id=3336966&canon=ht
galvanized-vs-hot-dip-
galvanized-wire-rope-steel-
cable&redirect_url=APefjpH_6JsiTz3NhKjorHc
Advantages of Hot Dip Galvanized Cable cme3lXIWwE235aPs86oXYOXhEFQhuIfpmBV
ZYJ8fuHdVzqH03h_WjzEdEHHSSw2l6f11UX
Longer service life than electro galvanized iI1Jjlfhs69kbF-
ECmmmfWjJSJQmGK65QDw0EWi1GEQy114
Process creates an iron-zinc alloy layer on the steel surface and a pure zinc coating on the outer
430f-4ad1-981b-
surface. The alloy is very hard and resistant to typical abrasions. c370a9483b61&hsutk=b2d81736cb3d9bac446
Normal coating thickness can be up to 10 times thicker than electro galvanized coating GsiSFctQiv0yp6A&utm_referrer=https%3A%2

Disadvantages of Hot Dip Galvanized Cable

Dull finish can be streaky, contain drips, and is typically not applicable in architectural or aesthetic
applications
(https://resources.mazzellacompanies.com/cs
Significantly more expensive than electro galvanized cable (approximately 40% more expensive for cta_guid=2ee3ec9a-3459-
comparable products) 4fc6-a1b4-
561c1b969cc9&placement_guid=d0b422fc-
Galvanic thickness can be inconsistent across the product
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79eb64bdde26&portal_id=3336966&canon=ht
galvanized-vs-hot-dip-
galvanized-wire-rope-steel-
Applications cable&redirect_url=APefjpHyzlfJ0nKVF-
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Because it offers superior corrosion resistance compared to electro galvanized cable, hot dip galvanized BHP7buoTdP-
LEJ4FUgmeYrzedEHmrxSM0S_S8OWuBoEP
cable can be used for any application where the cable will be exposed to the natural elements or a caustic vzpoKW5PUjnONS_DO_zywqQQs4ghT-
environment. Hot dip galvanized cable can be used for fencing or perimeters for construction sites, parking iYLkT5KHd3kNHBA7vsCn9uKktrZPIF8V8zAE
_-
garages, farm and livestock facilities, and much more.
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96be-4a2d-800f-
Hot dip galvanized wire rope can also be used for lifting and rigging in crane application and with outdoor 09ff3d6068e9&hsutk=b2d81736cb3d9bac446f

winches or pulley systems. Professional zip lines are also another popular use as the cable can withstand
corrosion in moist and humid environments.

Wrapping it up
The term “galvanized” only tells the end-user that some type of corrosion-resistant coating has been
applied to the steel material. However, suppliers don’t always specify whether the cable they’re selling is an
electro galvanized or a hot dip galvanized product.

Hot dip galvanized will always be more expensive than electro galvanized product because of a more labor
intensive galvanizing process and because it offers greater resistance to rust and corrosion.

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1/28/2020 Electro Galvanized vs. Hot Dip Galvanized Wire Rope & Steel Cable

(/Portals/0/EasyGalleryImages/1/89/wire-rope-

(https://resources.mazzellacompanies.com/cs
cta_guid=4a8e5c49-f930-
436a-9870-
cable-stock.jpg) 65d80028b182&placement_guid=c06aa20a-
39e1-43b6-95e7-
If you’re looking for a cost-effective option for a short-term project, or need a cable that won’t be exposed to 3134fb9d753b&portal_id=3336966&canon=htt
galvanized-vs-hot-dip-
the elements, then electro galvanized cable or wire rope would be the best choice for you.
galvanized-wire-rope-steel-
cable&redirect_url=APefjpEJnefxfmvyc5BEQD
V8vjp21kbSRDHPy-C-
In order to specify the right type of cable for your next project, do your research and work with a reputable
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and knowledgeable distributor. This will help ensure that the correct and most appropriate products are Reeg&click=2c2d8349-
purchased for your budgetary and performance requirements. 4231-44d4-b755-
022b10558012&hsutk=b2d81736cb3d9bac44
Fw&utm_referrer=https%3A%2F%2Fwww.ma
At Mazzella Companies, we sell all different types of wire rope, aircraft cable, and structural cables. We
carry stainless, electro galvanized, and hot dip galvanized products and our highly-trained Lifting
Specialists can help you determine the right type of steel cable or wire rope for your application. If you’re
interested in learning more about the different cable products we carry, or need a quote for your next
project, contact us (https://www.mazzellacompanies.com/Contact) today.

(https://resources.mazzellacompanies.com/cs
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