Galvanized Steel vs. Stainless Steel: What to Use?

The selection of what type of steel to work with in your application can be a performance-enhancer for your life, lifespan, and being cost-effective. Two of the most commonly used materials to work with are stainless steel and galvanized steel. Although both look and feel the same regarding their application and power, they each possess their own nature that makes them appropriate for application under other conditions and use. In this article, we elucidate the benefits and drawbacks of each to allow you to make an informed decision for your project.

Galvanized steel is bare carbon steel with a coating of zinc to prevent it from corroding and rusting. Hot-dip galvanizing is the most common method of galvanizing, where the steel is submerged in hot zinc to form a protective barrier. The zinc coating is a sacrificial coating—it's the first to rust away, shielding the underlying steel.

Galvanized steel is generally applied in structural applications, fencing, plumbing, roofing, and power reinforcement. Gi channel is one of the most common applications of galvanized steel in construction as a long-lasting and anti-rust material in comparatively harsh conditions.

Galvanised iron sheets, being a popular type of galvanized material, are steel sheets that are zinc-coated to avoid rust. The sheets are used widely in construction, roofing and cladding, residential and farm houses, and industrial applications. The sheets are light, low-priced, and easy to fix, and hence become the first choice for most semi-outdoor and outdoor applications.

But whereas galvanized sheets work perfectly well in suburban and rural conditions, they are unlikely to last long in industrially corrosive or coastal areas, where the zinc covering readily wears off continuously upon exposure to sea or chemical fumes.

Stainless steel, as the name indicates, is an iron-based metal with a minimum of 10.5% chromium content. The chromium forms a passive layer of chromium oxide on the surface of the metal that is highly rust- and corrosion-resistant, even in its bare state.

Stainless steel exists in different grades, i.e., 304 and 316, with different corrosion resistance, strength, and price. They are greatly admired for their looks, durability, and corrosion resistance. Uses are kitchen appliances, medical devices, marine hardware, and high-rise buildings.

Now let's proceed with the intrinsic differences between stainless steel and galvanized steel so that you are able to make the optimal choice in your application:

Enhanced long-term corrosion resistance is due to stainless steel due to its chromium-based damaged surface. Stainless steel is appropriate in the case of exposure to acidic, salty, and wet conditions.

Galvanized steel, being originally rust-proof, has a layer of zinc to serve as armour. When that is rubbed off or scratched, the metal underneath will be exposed to rust.

Utilize stainless steel in beach, chemical, or highly corrosive environments.

Utilize galvanized steel for milder conditions such as rural buildings, HVAC ducts, or fences.

Stainless steel is more resistant and usually longer-lasting, particularly in harsh conditions. It's scratch-resistant, non-absorbent, and will remain functional for decades with very little maintenance.

Galvanized steel lasts long, but only makes it through 15–20 years in poor conditions. It's best to utilize in temporary buildings or uses where long-lasting is not so important.

One of the reasons that galvanized steel is used so extensively is that it's cheaper. It is simpler to produce and procure than stainless steel.

Stainless steel is more costly to purchase initially, but gives long-term savings with fewer maintenance needs, additional durability, and better corrosion resistance.

Stainless steel is shiny, high-quality, and white and is best suited for outdoor use, such as railings, façades, and designer furniture.

Galvanized steel, being rough and flat in its zinc plating, is best suited for applications where aesthetics do not count.

Stainless steel is cleaner and safer to weld due to the homogeneous nature of its construction. It will also not deteriorate under exposure to high heat.

Galvanized steel is challenging to weld since the zinc coating emits poisonous fumes and will be weakened unless steps are taken to ensure it is not.

Below is a brief guide to help with your choice:

Where chemicals, water exposure, or excessive temperatures are at play in your endeavour, the stainless steel will give the most performance. If you have a budget limitation or are designing for typical conditions, the galvanized steel can be a cost-effective and smart option.

Both galvanized steel and stainless steel have extensive uses in many industries. It is your budget, your location, and your requirement. Venus Wires manufactures precise and accurate stainless steel products to the utmost standards of the industry. You select the material for your design based on whether you are designing for aesthetics, durability, or corrosion resistance.

Want to go for stainless steel or require a spec comparison? Get in touch with us today.