The benefits of Steel Wire in Industrial Applications

Wire made from carbon steel is one of the most versatile and widely used materials in the world, particularly in the construction sector. However, its use extends to the manufacturing of many products, whether for everyday use, such as hangers, or much more specialized, such as for parts of automobiles and other machines.

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Industrial wire comes in many presentations, from Bright Basic Wire to Plating Quality Wire or Wire Forms, that in turn are suitable for many various applications.

What are some of the benefits of using Steel Wire in industrial applications?

• There are several types of wires offered by WMC: Bright Basic Wire, Plating Quality Wire, Bright Basic Deformed Negative Wire, Hard Drawn Wire, Black Annealed Wire, Spooled Box Wire, Straight & Cut Wire, and Wire Forms, each with unique qualities that make them ideal solutions to produce a very wide range of products.
• In any of its presentations, Steel Wire stands out for being durable, resistant and versatile.
• Its presentations can range from rolls and bars to even custom shapes and cuts, depending on the characteristics of each type of wire.
• Steel Wire is suitable for dozens of industries including construction, automotive, recycling, and agricultural. 
• For added protection against corrosion and to make it more durable, Steel Wire can also be galvanized. Find out about the applications of Galvanized Steel Wire in this article on our blog: (LINK)

Industrial Wire: a Flexible and Versatile Solution

Steel Wire is such a versatile material that it can be found in everyday items that we see all around, from nails or shopping carts to very different uses such as reinforcement in bridges, landing strips, and underground concrete pipes.

Its diverse uses and applications make it a profitable option for the manufacturing of products, being at the same time sustainable, given that the steel industry largely depends on using scrap metal for the reprocessing of new raw material.

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Galvanized steel wire offers enhanced corrosion resistance compared to regular baling wire. According to the American Galvanizers Association, galvanized steel corrodes at a rate of 1/30 that of unprotected steel, and it lasts roughly 70 years in average conditions.

The galvanization process involves coating the wire in a protective layer of zinc, which improves the wire’s resistance to corrosion and abrasion and makes it suitable for outdoor applications.

What are the properties of galvanized wire?

Galvanized wire is known for its:

• Rust and corrosion protection.
• Strength and durability.
• Long lifespan.
• Versatility.
• Affordability.

Rust and corrosion protection

The main advantage of galvanization is enhanced protection against rust and corrosion. The protective zinc coating makes galvanized wire ideal for use in wet conditions and outdoor environments. Since zinc is anodic, it must be entirely corroded before the underlying steel wire starts to rust.

Strength and durability

Galvanization increases the wire’s resistance to abrasion, making galvanized wire an excellent choice for harsh conditions and exposure to the elements. Through a process called cathodic protection, even when small areas of the steel wire are exposed, the remaining zinc coat protects the exposed section from rusting. The process of galvanization increases the hardness of the zinc layer beyond that of the steel, providing extra durability.

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Galvanization has a negligible effect on tensile strength. In fact, depending on the galvanization process, the wire might lose up to 10% of its strength. Hot-dip galvanization (our method) is sometimes correlated to a minor increase in tensile strength.

Long lifespan

Galvanization dramatically increases the wire’s lifespan. In maritime and aquatic environments, galvanized wire can typically last up to 12 years, while in moderate conditions, it can remain functional for up to 150 years. Longevity has made galvanized wire a go-to choice for farm fencing.

Versatility

 Superior corrosion resistance, abrasion resistance, strength, and long lifespan make galvanized wire extremely versatile. It is used in the recycling, agricultural, construction, and even telecommunication industries for jobs that demand long-lasting durability.

Affordability

The durability and longevity of galvanized wire make it a cost-effective solution. It is often cheaper than stainless steel wire, and eliminates frequent maintenance and replacement costs to offer a wise long-term investment.

What is galvanized wire used for?

Galvanized wire comes in regular and high-tensile varieties. It is used for a wide range of industrial applications, these include:

• Fencing. Galvanized steel wire is commonly used to create chain-link fencing, welded wire mesh, and other protective enclosures.
• Baling. Galvanized wire is used for securing recyclables such as aluminum, textiles, and plastic. It is also used for bundling hay, branches, and other agricultural materials.
• Construction. Galvanized wire is used for binding or baling materials on construction sites, as well as for supporting structures.
• Vineyards and orchards. Galvanized wire is used for running trellises and supporting the growth of crops such as grapes or tomatoes. High-tensile wire is often preferred because of its rigidity and superior load strength.

• Telecommunication industry. High-tensile galvanized wire is used in the manufacture of reinforcement for overhead aluminum and steel conductors.

Our galvanizing process

We use a hot-dip galvanization process, here’s how it works:

1. Surface preparation. First, the wire is cleaned to remove any surface impurities. This is important for ensuring proper adhesion of the zinc coating.
2. Pickling. The wire is then immersed in an acid solution to remove any remaining oxides and scale.
3. Fluxing. The wire is then immersed in a flux solution (zinc ammonium chloride), which helps to prevent oxidation and promotes a uniform application of the zinc coating.
4. Galvanizing bath. Next, the wire is dipped into a molten zinc bath at a temperature of around 450°C (850°F).
5. Alloy formation. While immersed in the molten zinc, a metallurgical reaction occurs between the iron in the wire and the zinc, resulting in the formation of a series of zinc-iron alloy layers. These provide excellent adhesion and corrosion resistance.
6. Withdrawal. The wire is then slowly withdrawn from the zinc bath, ensuring the final product has an even coating.
7. Quenching. The coated wire is then quenched in water or a quenching solution to cool it rapidly. This process solidifies the zinc coating and completes the galvanizing process.

This multifaceted process creates a durable and corrosion-resistant coating that protects against the elements.

Our galvanized wire is available in stems and also as bale ties. 

Class 3 galvanization

We offer two classes of galvanization. Class 3 galvanization offers excellent corrosion resistance compared to the standard Class 1 galvanization. Here are some of the differences between the two classes:

• Class 1 galvanization. Our Class 1 galvanized metal wire offers a basic zinc coating that uses 0.28 ounces of zinc per square foot. Class 1 galvanized wire is more cost-effective, but will typically rust after anywhere from 2–11 years, depending on the environment. In coastal areas, Class 1 coating fails even sooner due to saltwater corrosion.
• Class 3 galvanization. With 0.80 ounces of zinc per square foot, this premium galvanization is nearly 3 times thicker than Class 1. The robust coating offers a higher degree of protection, providing a lifespan of 13–30 years. While it involves a higher initial cost, Class 3 galvanization is the ideal choice for harsh environments.

Does galvanized wire rust?

Galvanized wire will eventually rust after the zinc coating completely corrodes, however, it lasts much longer than untreated steel wire. The zinc coating offers enhanced resistance to rust and corrosion, even in wet and humid environmental conditions. It acts as a barrier between the steel wire and moisture in the environment, providing corrosion protection.

Even though galvanized bale wire has good rust resistance, it can eventually wear down over time, especially in highly corrosive environments. The zinc coating will start to corrode before the steel underneath, protecting the steel itself for some time. However, once the zinc layer is fully worn away, the steel itself will begin to rust.

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