NUMBER

21
MARCH
2013

In-

IN D US TR IA L

GALVA NIZE RS
CO RP O RAT IO N

Tech Tips

How much does hot dip galvanizing

cost?
The fixed costs of a structural galvanizing
plant are high. The furnace (kettle) must
operate on a 24-7 basis and for this
reason, large tonnages of structural steel
can be processed at a much lower cost
than smaller, 3-D items such as trailers.

W H Y G A L V AN IZ E ?
Hot dip galvanized coatings
are applied to steel to
improve the anti-corrosion
performance of the steel to
ensure that it lasts as long as
possible with a minimum of
maintenance

C O A T IN G S D IF F E R
Only hot-dip galvanizing
gives a coating that can
reach the 50 year life
required of structural building
products.

A complex fabrication is easily galvanized. Galvanizing

provides excellent value for money as well as long life and
low maintenance.

The cost of hot dip galvanizing is

determined by a number of factors. These
include:

The cost of zinc;

The type of item being galvanized:

T H IC KN E SS C O U N TS

light, medium, heavy, 1, 2, or 3dimensional, hollow or solid section.

Compared to other zinc-rich

The size of the item;

coatings, hot-dipped

The current cost of labour, chemicals,

galvanizing is:-

THICKER
HARDER
FULLER

H O T - D IP G A L V A N IZ E D
P R O D UC T S L AS T
L O N G E R ...

waste disposal and recycling, power

and gas

Sustainable

margins to support
reinvestment in the business.

The cost of zinc has a major impact and

can make up 40% of the total processing
cost. Zinc is a globally traded commodity
and its price is set by the London Metals
Exchange (LME). The zinc price is can be
volatile depending on world supply and
demand as well as local availability.

As a result, the cost of hot dip galvanizing

steel can range from several hundred
dollars per tonne for large, on-going
tonnages of structural steel, to several
thousand per tonne for small cash-sale
items.
It is long-standing industry practice to
charge hot dip galvanized coatings on the
basis of white weight. This is based on
the weight of the steel after it has been
galvanized. This weight is recorded by the
galvanizer using certified weighbridge
scales and the customer will be charged
at a rate per kg or rate per tonne, based
on that weight.
In some cases, a unit rate may be
negotiated
where
repetitious
manufactured products such as fence
panels, star pickets or building products
are processed on a regular basis. The
tonnage of steel that can be processed
through the galvanizing bath in a given
time will have a big impact on how it is
costed. All the fixed overhead costs of the
galvanizing business are allocated to the
galvanizing bath. Steel fabrications that
can be processed at 6 tonnes per hour will
incur a lower bath cost component than
those than can only be processed at 2
tonnes per hour.

Industrial Galvanizers and its representatives have made reasonable efforts to ensure the accuracy of the information provided in this publication,
but it does not constitute product advice. The information is of a general nature only and does not take into account your individual situation or
needs. It should not be used, relied upon, or treated as a substitute for specific professional advice. Industrial Galvanizer s recommend that you
obtain your own independent professional advice before making any decision in relation to your particular requirements or circumstances.

Information Technology Solutions

How much does hot dip galvanizing

cost?
T R IE D & P R O V EN
Over 40 years of field testing
shows that galvanized
coatings perform well even in
harsh environments.

C O S T O F G A L V A N IZ IN G
Hot-dip galvanizing provides
significant value for money.
No other coating for steel
matches galvanizings unique
combination of properties and
advantages. For most
steelwork, galvanizing
provides the lowest long-term
cost. In many cases it also
provides lowest initial cost.

W H Y G A L V AN IZ E W IT H
IN D U ST R IA L
G A L V A N IZ ER S ?
For steel users requiring fast,
proven corrosion
protection for local or
national projects Industrial
Galvanizers is the
established hot dip
galvanizer with nationwide
coverage.

A.C.N. 000 545 415

Registered Office:
11 Talavera Road,
Macquarie Park, NSW 2113

This means that attention to detail design

can significantly reduce galvanizing costs.
A fabrication that can be assembled from
2-dimensional sections will be less costly
to process than if it was a 3-dimensional
fabrication, as more fabricated sections
can be loaded onto the galvanizing jigs in
2-d form. Fabrications that have
dimensions within those of the galvanizing
bath will avoid the additional cost
associated with double-end dipping that is
required with items that are longer or
deeper than the bath dimensions.
While the costs of galvanizing lighter steel
sections appears to be significantly higher
than heavier sections, there is a
significant cost saving when compared on
a surface area basis. Hot dip galvanized
coatings are the most cost effective heavy
-duty coatings when compared on this
basis.
For example:Medium structural steel (12mm section
thickness) could be galvanized for say,
$800/tonne.
Steel of this thickness has a surface area
of about 20 m2/tonne, so the cost of
galvanizing per square metre is $40.
Light steelwork, commonly associated
with box trailers, or light hollow section
that averages 3 mm in thickness may cost
$1500/tonne to galvanize. Its surface area
is 85 m2/tonne so the cost of hot dip
galvanizing is then less than $18/m 2.

Hot-dip galvanizing provides significant

value for money. No other coating for steel
matches galvanizings unique combination
of properties and advantages:
1. For most steelwork, galvanizing provides
the lowest long-term cost. In many cases
it also provides lowest initial cost.
2. The galvanized coating is part of the
steel surface it protects. It has
outstanding toughness and resistance to
mechanical damage in transport,
erection and service.
3. Galvanizings cathodic protection for
steel ensures that small areas of the
base steel exposed through impacts or
abrasion are protected from corrosion.
4. During galvanizing the work is
completely immersed in molten zinc and
the entire surface is coated, even
recesses and returns which often cannot
be coated using other processes.
5. Galvanizing is versatile process. Items
ranging from small fasteners and
threaded components, up to massive
structural members can be coated.
6. Galvanizing
provides
outstanding
corrosion performance in a wide range
of environments.
7. Duplex coatings of galvanizing-pluspaint are often the most economic
solution to the problem of protecting
steel in highly corrosive environments.
The life of the combined coatings
exceeds the total life of the two coatings
if they were used alone.

INDUSTRIAL GALVANIZERS (AUSTRALIA)

Townsville | Brisbane | Newcastle | Sydney | Port Kembla | Melbourne | Launceston | Perth

www.ingal.com.au

www.valmont.com