Zinc electroplating is a technology that produces an exceptionally even, aesthetically pleasing and stable zinc coating. At Strumet, we treat this process as an integral part of our responsibility for the durability and safety of steel components. Although zinc electroplating differs from hot-dip galvanizing in the way the coating is formed, it can protect steel against corrosion just as well, especially where precision of execution and a perfect surface matter. We make sure that every stage is carried out under repeatable conditions and that the entire technology is stable. Only then can we guarantee an even layer of zinc that retains its properties for many  years.

Surface Preparation for Zinc Electroplating

The process begins with very thorough surface preparation. This stage is of fundamental importance, because electrolytically deposited zinc requires perfectly clean metal. We achieve the best results with steel with a silicon content below 0.03% or in the range of 0.15-0.25%. If there are production residues on the surface (oxides, transport marks or lubricant residues), the coating will be unstable and uneven. To avoid this, we increase our diligence from the very first minutes of working with a given component.

First we remove organic substances and all greases that could interfere with the electrolytic reaction. Degreasing reveals the actual condition of the surface and makes it possible to assess whether corrections or additional processing are necessary. Next, the steel goes into a pickling bath, where we remove oxide layers and films formed during earlier production and storage stages. After pickling we carry out rinsing and activation, which makes the surface uniform and properly prepared for contact with the electrolyte. We carry out the entire preparation process with full awareness and attention to detail, because the quality and durability of the future coating depend on it.

The Zinc Electroplating Process at Strumet

Once the component has been properly prepared, it goes into the actual zinc bath. At this point the electrolysis process begins: zinc is deposited on the steel surface under the influence of electric current. Unlike hot-dip galvanizing, the coating is not formed by diffusion of metals, but by even deposition of zinc from a solution. This allows its thickness and structure to be controlled precisely. It is this control that makes electroplated coatings exceptionally smooth and attractive.

Our electroplating shop consists of two modern lines: a rack line, intended for larger structures, and a barrel line, designed for small parts and fasteners. Both lines operate fully automatically. Components are transported between successive stages autonomously, without human intervention, and process parameters are monitored by computer. On the rack line we galvanize components with dimensions of up to 2.8 × 0.8 × 1.8 m and a weight of up to 600 kg per traverse. The design must allow for hanging and for free flow of the bath in all spaces. On the barrel line we require a minimum load of 20 kg for the process to run correctly. Each immersion lasts exactly as long as the technology requires, and the stability of the bath is continuously monitored by our chemical laboratory. Laboratory staff test the composition of the bath every day and ensure the correct proportions, pH and zinc ion concentration. This supervision allows us to keep the process at the highest level.

After coating deposition is complete, the component goes through a sequence of rinses and passivation. Passivation protects zinc from rapid oxidation and stabilizes its surface. Final drying fixes the structure of the coating and prepares the component for further use. The importance of these stages often remains invisible to the naked eye, yet they are essential to the final quality of the finished product.

Quality Control of Electroplated Coatings

Every component zinc electroplated at Strumet undergoes thorough quality control. We check coating deposition uniformity, thickness, adhesion and appearance. Aesthetics matter a great deal here, because electroplating is often used wherever a component is visible or has to work with other parts requiring high dimensional accuracy. That is why we analyze flat surfaces, edges and hard-to-reach areas very carefully.

We do not limit ourselves to the minimum values given in the standards. Standards set the acceptable level, and we work to achieve a stable result that guarantees durability for years. If any part of the coating raises doubts, the part goes back for further processing. We treat this as a natural element of responsible work - we do not allow a product that does not meet our standards to be released.

Process Stability and Predictability in Our Electroplating Shop

Zinc electroplating requires stable operating parameters. The electrolyte, temperature, current density and surface cleanliness must remain within the same range, because even minor deviations affect the quality of the coating. That is why we run the process under constant, controlled conditions, which make it possible to obtain an even and repeatable zinc layer.

Stable baths, regular laboratory measurements and an automatic transport system allow us to keep the process at a level that delivers even, smooth and resistant coatings.Coatings produced under such conditions perform well both where components work indoors with no contact with moisture, and outdoors, where they are exposed to rain, temperature changes or periodic dampness. In these situations they remain stable for a long time. Electroplated components do not require subsequent maintenance, which clearly reduces operating costs over the entire period of use.

Lead Times and Capacity of the Electroplating Shop

Our electroplating shop has been designed for continuous operation, with high capacity and short lead times. We process parts up to 100 kg within 24 hours. Batches from 100 kg to 1 ton in 48 hours. Components from 1 to 3 tons in 72 hours. Larger series are arranged individually. Daily throughput is 20,000 kg, which allows us to serve both large production plants and smaller series tailored to specific needs.

How We See Zinc Electroplating in Our Work

We carry out zinc electroplating with full control over every stage of the process. We take care of surface preparation, stable bath parameters and careful assessment of finished components, because the quality of the coating depends on it. Maintaining constant working conditions translates into an even, predictable and durable layer of zinc. When a component leaves the electroplating shop with a coating that has the right parameters, we treat it as confirmation of a properly executed process.

If you need zinc electroplating carried out in a stable and repeatable process, we are at your disposal. We will help you choose the right solution and prepare the components so as to obtain a coating that meets service requirements.