Galvanized Wire vs. Annealed — Which Works for Your Application?

What Is Galvanized Wire?

To make galvanized wire, the manufacturer must put the wire through the hot-dip process. First, the manufacturer fabricates the steel wire to the specified gauge and thickness. Then, they must clean it in an acid bath to eliminate surface oxides. After rinsing and drying the wire, the manufacturer dips it into a bath of molten zinc, completely coating it in a thin layer of the metal. The manufacturer controls the zinc's thickness. A sequence of water cascades cools the wire and its coating. 

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Galvanized zinc coating provides some unique benefits.

• Rust prevention: Does galvanized wire rust? Galvanized wire is highly resistant to rust because of the protective zinc coating that keeps moisture away from the steel beneath. 
• Damage resistance: A galvanized coating is solid and robust, protecting the wire from chipping, scratching and cutting. 
• Fire resistance: The zinc coating's melting point is exceptionally high, making galvanized wire resistant to melting in a fire. 

While a zinc coating increases the wire's durability in several ways, zinc alone is sometimes insufficient for specific applications. At Bekaert, we also use an enhanced process called Bezinal® to galvanize steel wires. Bezinal® combines zinc with aluminum, fortifying the wire even more against corrosion. This mixture of metals offers superior durability to zinc alone. 

Enhanced Galvanization

Bekaert offers a range of steel wire coating solutions that provide corrosion resistance and strength. Our Class A, Class B and Class C galvanized zinc coatings are the most commonly used across applications and environments. We also provide enhanced galvanized wire coated with Bezinal®, our line of zinc aluminum coatings. Of all the galvanized wire coating available, Bezinal® offers the best durability, heat and corrosion resistance and processability. 

Bezinal® is a eutectic coating offering cathodic protection of the steel wire's uncoated areas. The coating produces an electric current that counteracts corrosion on scratched or cut areas due to the addition of aluminum, which is more corrosion-resistant than zinc. We have thoroughly tested Bezinal®-coated wires and proven they can resist corrosion two to six times longer than hot-dip galvanized wires. Wires coated with Bezinal® last up to eight times longer in heavily polluted areas.

Another benefit of Bezinal® is its heat resistance. Often, galvanized wires that undergo the hot-dip process experience growth of the alloy layers after exposure to high temperatures. In contrast, Bezinal® is immune to alloy growth and exhibits no cracks in the zinc aluminum layer. Bekaert's engineered wire coating solution ultimately provides better performance than galvanized wires. 

Long Lasting

Galvanized wire dipped in zinc is resistant to rust and corrosion. In this way, the service life of galvanized wire is long. Although the corrosion resistance life for galvanized wire varies depending on the zinc coating thickness, according to EN norms, Class A coated wire has a corrosion resistance of 20-25 years in urban areas and over 50 years in rural areas.

Different Solutions for Different Needs

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The hot-dip method used to galvanize wires is the most economical and efficient method against rust. Different galvanized steel wires can be produced for every need by changing the amount of zinc coating. In this way, savings are achieved in production. Different solutions can be produced for different needs.

Corrosion Resistant

Galvanized wire is coated with a physical barrier that is resistant to moisture and corrosion. It is therefore resistant to corrosion and rust. The zinc layer on the surface of the wire acts as a barrier between steel and air.

Low Cost

Galvanized wire can be produced more cost-effectively than other coated wires. In addition, since it does not require surface preparation, coating, inspection and painting, it is produced ready for use on delivery. This will save customers additional preparation costs when they buy galvanized wire.

Easy to Use

Unlike other materials, galvanized wire is ready for use as soon as it is delivered. It does not require any additional preparation, painting and coating.

Hard Coating

The zinc coating on galvanized wire makes it resistant to rust and corrosion. The zinc coating acts as a protective buffer, shielding the wire from oxygen and moisture.