Galvanizing is a technology that allows for the creation of an exceptionally even, aesthetically pleasing, and stable zinc coating. At Strumet, we consider this process an integral part of ensuring the durability and safety of steel components. Although galvanizing differs from hot-dip galvanizing in the way the coating is applied, it can equally effectively protect steel from corrosion, especially where precision workmanship and a perfect surface are essential. We ensure that each step is carried out under repeatable conditions, ensuring the stability of the entire process. Only then can we guarantee an even zinc coating that retains its properties for many years.
Surface preparation for galvanizing
The process begins with very thorough surface preparation. This step is crucial, as electrolytically applied zinc requires perfectly pure metal. The best results are achieved with steel with a silicon content below 0,03% or in the compartment 0,15-0,25%. If there are any production residues on the surface, (oxides, transport traces or lubricant residues), The coating will be unstable and uneven. To avoid this, we increase our care from the very first minutes of working with a given element.
First we remove organic substances and all fats, that could interfere with the electrolytic reaction. Degreasing reveals the actual surface condition and allows for an assessment of whether corrections or additional processing are necessary. The steel is then sent to pickling bath, where we remove oxide layers and deposits formed during earlier stages of production and storage. After etching, we carry out rinsing and activation, which makes the surface homogeneous and properly prepared for contact with the electrolyte. The entire preparation process is performed with full awareness and attention to detail, as the quality and durability of the future coating depend on it.
The electroplating process at Strumet
Once the element is properly prepared, it goes to proper zinc bath. At this point, the electrolysis process begins – zinc is deposited on the steel surface under the influence of an electric current. Unlike hot-dip galvanizing, the coating is not formed by metal diffusion, but by the even deposition of zinc from a solution. This allows for precise control of its thickness and structure. This control makes galvanic coatings exceptionally smooth and aesthetically pleasing.
Our electroplating plant consists of two modern lines: suspension, intended for larger structures, and drum, designed with fine details and fasteners in mind. Both lines operate fully automatically. Elements are transported between stages autonomously, without human intervention, and process parameters are monitored by computer. suspension line We galvanize elements with dimensions up to 2.8 × 0.8 × 1.8 m and mass to 600 kg on the traverse. The structure must allow for suspension and free flow of the bath in all spaces. drum line we require a minimum input 20 kg, to ensure the process runs correctly. Each immersion lasts exactly as long as the technology requires, and the bath's stability is constantly monitored by our chemical laboratory. Laboratory staff examine the bath's composition daily and ensure proper proportions, pH and zinc ion concentration. This oversight allows us to maintain the process at the highest level.
Once the coating deposition is complete, the element passes through rinse sequence and passivation. Passivation protects the zinc from rapid oxidation and stabilizes its surface. Final drying solidifies the coating's structure and prepares the item for further use. The significance of these steps often remains invisible to the naked eye, yet they are crucial to the ultimate quality of the final product.
Quality control of galvanic coatings
Every electro-galvanized element at Strumet undergoes thorough quality control. uniformity of coating deposition, its thickness, adhesion and appearance. Aesthetics are crucial here, as electroplating is often used wherever the element is visible or must interact with other parts requiring high dimensional accuracy. Therefore, we carefully analyze flat surfaces, edges, and hard-to-reach areas.
We don't limit ourselves to the minimum values specified in standards. Standards establish acceptable levels, and we work to achieve a stable result that guarantees long-term durability. If any part of the coating raises concerns, the part is returned for further processing. We consider this a natural part of responsible work – we don't allow a product to be delivered that doesn't meet our standards.
Stability and predictability of the process in our electroplating plant
Galvanic zinc plating requires stable operating parameters. The electrolyte, temperature, current density, and surface cleanliness must remain within the same range, as even minor deviations affect the coating quality. Therefore, we conduct the process in constant, controlled conditions, which allow you to obtain an even and repeatable layer of zinc.
Stable baths, regular laboratory measurements, and an automated transport system allow us to maintain a process that ensures even, smooth, and resistant coatings. Coatings created under these conditions perform well both indoors and outdoors, where they are exposed to rain, temperature fluctuations, and periodic dampness. In these situations, they maintain their stability for a long time. Galvanically protected components require no subsequent maintenance, significantly reducing operating costs throughout their lifespan.
Lead times and efficiency of the galvanizing plant
Our electroplating shop is designed for continuous operation, with high efficiency and short turnaround times. We can process parts up to 100 kg within 24 hours, batches from 100 kg to 1 ton within 48 hours, and parts from 1 to 3 tons within 72 hours. Larger batches are negotiated individually. Daily throughput is 20,000 kg, allowing us to service both large production facilities and smaller batches tailored to specific needs.
How we perceive galvanizing in our work
We conduct galvanic galvanizing with complete control over every stage of the process. We ensure surface preparation, stable bath parameters, and precise evaluation of finished parts, as this determines the quality of the coating. Maintaining consistent operating conditions translates into an even, predictable, and durable zinc layer. When a component leaves the galvanizing plant with a coating meeting the correct parameters, we consider this a confirmation of a properly conducted process.
If you need electroplating performed in a stable and repeatable process, we're here to help you choose the right solution and prepare your components to achieve a coating that meets your operational requirements.
