When to Use Each Type of Galvanized Wire Rope?

When to Use Each Type of Galvanized Wire Rope?

Summary

How the wire rope is galvanized affects its composition and strength, making each type suitable for a specific environment. So, which type of wire rope should you use and when? Below is a detailed introduction to the differences between the two.

Wire ropes are an essential part of industrial hardware equipment and serve multiple purposes for all types of projects. However, if you are looking for superior strength and durability, wire rope suppliers will let you know that galvanized wire rope is the best choice for you. 

Galvanizing is a process in which a metal is coated with zinc on iron or steel to prevent rust and corrosion. This helps extend the life of the metal, especially when exposed to weather elements or water. Galvanized metal is often used in steel structures, cables, and wire ropes to provide extra durability. 

Galvanized wire rope is more durable and rust-resistant than non-galvanized wire rope while being less expensive than stainless steel. This makes it an excellent choice for many applications and budgets. However, if you are looking for galvanized wire rope for sale, there are a few things you need to know. 

There are two methods of galvanizing steel wire rope: hot-dip galvanizing and electro-galvanizing. 

How the wire rope is galvanized affects its composition and strength, making each type suitable for a specific environment. 

So, which type of wire rope should you use and when? As a wire rope supplier, we understand the difference in galvanizing. The differences between the two are detailed below for you.

Electro-galvanized steel wire rope

Electro galvanizing (also known as electroplating) electrically attaches a zinc coating to the wire rope. First, the zinc powder is mixed into a saltwater solution with an electric current flowing through it. The wire rope is then carefully dipped into the zinc solution. The electric current causes electrons in the zinc to bond with the metal, creating an extremely thin protective coating.

Electro-galvanized wire rope is glossy and smooth - because the zinc coating is very thin and uniform. This makes it an excellent choice for applications where appearance is important and a glossy finish is required.

Hot-dip galvanized wire rope

Hot-dip galvanizing is another form of galvanizing. Zinc is heated in a vat until it melts at 860℉. The wires that will form the rope are then cleaned to ensure that there is no dust, metal shavings, or other contaminants on the cable before it is fully immersed in molten zinc. 

Once the wires are fully coated, they are removed and cooled before strands are formed to form the wire rope. 

The process produces a zinc coating that is 5 to 10 times thicker than an electro-galvanized coating. This provides the best protection against rust and wear, making the rope extremely wear-resistant and much harder and stronger.

Pros and cons

Each type of galvanized wire rope has advantages and disadvantages, and each type is designed for a different purpose. 

Cost

Hot-dip galvanized rope is 40% more expensive than electro-galvanized rope because it is heavier and stronger. However, one of the reasons electro-galvanized wire rope is less expensive is because it is lighter and smaller - which means it is also not as strong as hot-dip galvanized wire rope. 

Weight

Hot-dip galvanizing creates a thick coating that significantly increases the weight of the wire rope. Electro-galvanized wire ropes are lighter and thinner, so they can be used for more delicate applications. 

Durability

Because electro galvanizing produces an extremely thin coating, it does not provide as much protection as the thicker hot-dip galvanizing process. Electro-galvanized wire rope is much less durable. It is not suitable for applications that will be exposed to extreme elements or high friction. 

Flexibility

Electro-galvanized wire rope is much more flexible than hot-dip galvanized wire rope because the thin coating does not affect the movement of the rope much. Hot-dip galvanized rope is more rigid and stronger, which does make it more suitable for use where movement is not encouraged, such as in lifting and rigging. 

Appearance

Electro-galvanized steel wire rope is shiny and the galvanized layer is very uniform. Hot-dip galvanized wire rope has a dull appearance, and the galvanized coating may be uneven or streaked. Therefore, for design purposes, it is generally not used in construction applications - as it is not as attractive as electro-galvanized steel wire rope. 

When to use hot-dip galvanized rope?

This type of wire rope is best suited for applications where the cable is exposed to harsh weather conditions such as rain, heat, low temperatures, and wind. It is commonly used to set up fences and perimeters on construction sites - usually for hoisting and rigging cranes. You can also see hot-dip galvanized wire rope in parking lots and farms.

Hot-dip galvanized rope is also often used in applications where the rope must resist high friction, such as pulleys and ziplines. A thick zinc coating prevents rapid rope wear. 

Overall, hot-dip galvanized wire rope is best for projects that require the best strength and long-lasting robustness.

When to use electro-galvanized steel wire rope?

Electro-galvanized steel wire rope is rust-proof, but it is not the best choice for extreme environments where the rope is exposed to a lot of moisture. It is commonly used for wire mesh, fences, and perimeter cables. It can be used in architectural design, especially for fastening and binding. 

In conclusion

Galvanized wire rope is very strong and versatile - but the galvanizing process used can significantly affect the durability and use of the rope. Make sure the wire rope supplier you use has the right product for your application! If you have any other questions, or you are looking for a large selection of galvanized wire ropes for sale, you are welcome to contact us.

Terada hardware is a professional custom wire ropes and accessories manufacturer. Our role goes beyond designers and manufacturers. We treat our customers as part of the team and support them as partners. For non-standard hardware. We listen carefully to customers' requirements and provide some professional advice and technical support. Follow the new designs to make the most suitable hardware for your project