Protection against the elements

Steelguard manufactures and installs a full range of steel windows and doors; fire-rated, security, curtain wall and stainless steel. We know that the finish of the final frame isn't just a pretty colour, the system used need to be selected to provide the best protection against the elements and protect your investment over the long term. We have been bringing many of these processes 'in-house' so that we have better control over quality.


Galvanizing is a process of applying a protective zinc coating to steel or iron to prevent rusting and corrosion. This method is widely used in various industries, especially in construction, automotive, and infrastructure, to enhance the durability and longevity of metal structures and components.

There are two primary methods of galvanising:

Hot-Dip Galvanising

  • In the hot-dip galvanising process, steel or iron articles are immersed in a bath of molten zinc at a temperature typically around 450°C (850°F).
  • The chemical reaction between the iron or steel substrate and the molten zinc forms a series of zinc-iron alloy layers on the surface of the metal. This creates a metallurgical bond, providing a robust and durable coating.
  • The coated articles are then removed from the zinc bath, and the zinc coating solidifies to form a protective layer.

Advantages of Hot-Dip Galvanising

  • Excellent corrosion protection: The thick zinc coating provides long-lasting protection against rust and corrosion.
  • Uniform coverage: The immersion process ensures complete coverage, even on complex shapes.
  • Self-healing properties: If the coating is scratched or damaged, the surrounding zinc sacrifices itself to protect the exposed steel.

Electro-galvanising (Electroplating)

  • Electro-galvanising is a process where a thin layer of zinc is electrochemically deposited onto the steel or iron surface.
  • The metal articles serve as the cathode, and a zinc anode is dissolved in an electrolyte solution.
  • The zinc ions in the solution are then attracted to the steel or iron substrate, forming a zinc coating on the surface.

Advantages of Electro-galvanising

  • Smoother finish: Electro-galvanised coatings are generally smoother and thinner compared to hot-dip galvanised coatings.
  • Precise thickness control: The thickness of the zinc coating can be controlled more precisely.

Key Benefits of Galvanising

  • Corrosion Resistance – The zinc coating acts as a barrier, protecting the underlying steel or iron from exposure to corrosive elements like moisture and oxygen.
  • Longevity – Galvanised coatings are known for their durability and longevity, providing extended protection against rust and corrosion.
  • Low Maintenance – Galvanised surfaces require minimal maintenance over their lifespan, reducing the need for frequent recoating or repairs.
  • Versatility – Galvanising can be applied to a wide range of steel and iron products, from small components to large structural elements.
  • Environmental Sustainability – Zinc is a naturally occurring element, and the galvanising process produces a durable and recyclable coating. The long lifespan of galvanized products contributes to sustainability by reducing the need for replacements.

Galvanising is a popular and effective method for preserving steel and iron structures in various applications, offering robust protection against the damaging effects of corrosion. The choice between hot-dip galvanising and electro-galvanising depends on factors such as the specific requirements of the application and the desired characteristics of the coating. Talk to Steelguard to find out the most suitable solution for your project.

Hot Wire Zinc Spray

Hot zinc wire spray, also known as thermal sprayed zinc, is a surface coating process used to protect metal substrates, primarily steel, from corrosion. This method involves the application of molten zinc onto the surface of the substrate, creating a protective layer that acts as a barrier against environmental factors. Here’s a more detailed explanation of the process:

Process Steps:

  • Surface Preparation: The metal substrate (often steel) is cleaned thoroughly to remove any rust, scale, or contaminants. Proper surface preparation is crucial for the effectiveness of the coating.
  • Wire Feeding: In the hot zinc wire spray process, zinc is typically used in the form of wire. The zinc wire is fed into a specialized spray gun.
  • Melting: The spray gun incorporates a heat source, which can be an oxy-fuel flame or an electric arc. As the zinc wire passes through the flame or arc, it is heated and melted.
  • Spraying: The molten zinc is propelled onto the prepared surface of the metal substrate using compressed air or another suitable gas. The high velocity of the sprayed zinc ensures even distribution and good adhesion to the substrate.
  • Solidification: Upon contact with the substrate, the molten zinc rapidly solidifies, forming a protective coating on the surface.

Key Characteristics and Benefits:

  • Corrosion Protection: The primary purpose of hot zinc wire spray is to provide corrosion protection. Zinc, through a sacrificial corrosion process, corrodes preferentially to the base metal, thus protecting the substrate from rust and corrosion.
  • Uniform Coating: The spraying process allows for the creation of a uniform and consistent coating, even on complex or irregularly shaped surfaces.
  • Adhesion: The high velocity of the molten zinc particles aids in achieving strong adhesion to the substrate, creating a metallurgical bond.
  • Durability: The resulting zinc coating is durable and provides long-lasting protection against environmental elements.
  • Versatility: Hot zinc wire spray can be applied to various metal substrates, making it suitable for a range of applications in industries such as construction, infrastructure, and marine.
  • Efficiency: The process is relatively fast and can be more efficient for large-scale projects compared to some other coating methods.


  • Surface Preparation: Proper surface preparation is critical for the success of the coating. Any contaminants or corrosion on the substrate should be removed to ensure optimal adhesion.
  • Environmental Impact: The process may generate fumes, and consideration should be given to the environmental impact. Adequate ventilation and safety measures are often implemented.

Hot zinc wire spray is widely used in industries where corrosion protection is essential, especially for steel structures exposed to harsh environmental conditions. It’s an effective and economical method to extend the lifespan of metal components and structures.

Finish Coat

Epoxy paint and powder coating are both popular finishes used for a variety of applications, but they have distinct characteristics and benefits. Here’s a comparison of the two:

Epoxy Paint

Application Flexibility

  •  Epoxy paint can be applied to various surfaces, including metals, concrete, and wood.
  • It is suitable for both indoor and outdoor use.

Ease of Application

  • Epoxy paint is typically easier to apply than powder coating. It can be brushed, rolled, or sprayed onto surfaces.


  • Epoxy paint is relatively easier to repair. If it gets damaged, it can be touched up or recoated without the need for extensive surface preparation.


  • Epoxy paint is often more expensive than powder coating, making it a cost-effective choice for certain applications.

Color Options

  • Epoxy paint offers a wide range of color options and can be easily customized to achieve specific shades.

Powder Coating


  • Powder coating is known for its durability and resistance to chipping, scratching, and fading when used internally Epoxy paint provides a more robust and long-lasting finish compared to powder coating when used externally.

Environmental Considerations

  • Powder coating is considered more environmentally friendly than traditional liquid coatings because it produces fewer volatile organic compounds (VOCs) during application.

Uniform Finish

  • Powder coating provides a more uniform and consistent finish than liquid coatings, with no drips or sags.

Thinner Coating

  • Powder coating generally results in a thinner coating compared to epoxy paint. Epoxy paint allows us to prepare the surface by using fillers to provide a better finish, powder coating typically sits on the surface as it.

Efficiency in Large-Scale Production

  • Powder coating is often preferred for large-scale production processes as it can be more efficient and cost-effective in these scenarios. Sizes and pre-finish requirements can limit the overall size of the unitised frame.

Resistance to Chemicals

  • Powder coating is more resistant to chemicals and harsh environmental conditions than epoxy paint.


Application Method

  • The choice between epoxy paint and powder coating may depend on the specific application method and the equipment available.

Surface Preparation

  • Both epoxy paint and powder coating require proper surface preparation for optimal adhesion and performance. This may include galvanising or hot wire zinc spraying.

Cost and Budget

  • Consideration of the overall project budget may influence the choice between epoxy paint and powder coating.

In summary, the choice between epoxy paint and powder coating depends on factors such as the application, desired finish, durability requirements, and budget constraints. Each has its advantages, and the selection should be based on the specific needs of the project.