The continuous galvanizing process applies a zinc coating to the surface of a continuous ribbon of steel sheet as it passes through a zinc bath. The coated sheet coils are either directly roll formed or fed into stamping presses, or blanked/sheared and then formed into parts. The sheet thickness might be as thin as 0.010 inch [0.25 mm] or less, to as thick as 0.25 inch [6.3 mm]. The facilities in operation worldwide are typically “light-gauge”, “intermediate-gauge” or “heavy-gauge” coating lines. Product from light-gauge lines is used mostly for applications in the construction industry (roofing sheets, building sidewall panels, flashing, etc.) The largest application for product made on intermediate-gauge lines is automotive body panels. Product from heavy-gauge lines is used for culvert, automotive structural parts, grain bins, etc.

In this process, the steel sheet is passed through the molten zinc bath at speeds as high as 650 fpm [200] mpm. As the moving sheet exits the coating bath, it drags out molten zinc. The desired coating thickness is attained by the use of “gas knives”. These knives typically use air as the gas, and are directed at both sides of the sheet to remove excess zinc. The coated steel is then cooled and the zinc solidifies on the surface of the sheet.

  The value of the zinc coating process in combating corrosion of the steel surface has grown to be a product feature demanded in ever-increasing quantities. The steel's corrosion resistance makes it ideal for applications such as air conditioning units, air ducts, metal ties, studs, siding, decking, roofing and culvert.

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