Mild Steel vs Galvanized: Material Guide

Mild and galvanized steel are both popular types of steel, but their main difference lies in the zinc coating. Mild steel, also called low-carbon steel, is strong, malleable, and easy to weld. However, it is susceptible to rust when exposed to moisture. In contrast, galvanized steel is mild steel coated with a zinc layer, making it more resistant to rust and suitable for outdoor use. 

Understanding the importance of the zinc coating will help you choose the right material for your project. This article can help you know more about their features, differences, and applications in more detail.

The Differences Between Mild Steel and Galvanized Steel

Appearance

Carbon steel has a dark, smooth, and matte finish. It looks plain and can appear dull over time. Galvanized steel has a bright, shiny, and silvery look. 

Galvanized steel often shows a spangled pattern, with small, crystallized spots on the surface. This pattern appears mainly with hot-dip galvanizing, while other methods like electro-galvanizing give a smoother, uniform finish. In contrast, carbon steel usually has a uniform, smooth surface without any patterns.

Corrosion Resistance

Galvanized steel has much stronger corrosion resistance than mild steel. The key difference lies in the protective zinc coating on galvanized steel, which prevents rust, while mild steel is more susceptible to corrosion when exposed to moisture and air.

Why is Galvanized Steel More Resistant?

The zinc coating on galvanized steel protects the steel from moisture and oxygen. When the surface gets scratched, the zinc will continue to protect the steel underneath by a process called galvanic protection. 

Maintenance

Galvanized steel requires less maintenance than mild steel. The protection from zinc coating can reduce the need for regular upkeep. However, if the coating gets damaged, minor repairs, like applying zinc-rich paint, can restore its protection.

Mild steel, however, is more prone to rust, especially in moist conditions. To prevent corrosion, it needs regular maintenance, like painting or coating. Without these, it can weaken and require costly repairs over time.

Welding

Mild steel is easier to weld than galvanized steel. Since it does not have a coating, there are no extra steps needed before welding. This makes the process straightforward and efficient.

Galvanized steel has a zinc layer that can create challenges during welding. The zinc coating can release harmful fumes when heated, so it must be removed from the welding area or special precautions must be taken, such as proper ventilation. 

Cost

Mild steel is cheaper than galvanized steel. The main reason is that mild steel does not have an extra zinc coating, which makes production simpler and less expensive.

Galvanized steel costs more because of the added steps in the manufacturing process. Although this raises the price, the coating provides extra protection against rust, making it more cost-effective for long-term use in harsh environments.

Different Applications of Mild Steel and Galvanized Steel

Mild steel is widely used in general manufacturing and indoor projects. Galvanized steel, with its rust-resistant coating, is typically used for outdoor and moisture-prone environments.

Mild Steel

• Construction: Used in beams, frames, and reinforcements.
• Automotive: Car parts such as body panels, chassis, and engine components.
• Manufacturing: Common in the production of machinery, tools, and equipment.
• Furniture: Frames for tables, chairs, and shelving.

Galvanized Steel

• Outdoor Structures: Used for fencing, roofing, and building facades.
• Agriculture: Suitable for equipment like water tanks, irrigation systems, and fencing. 
• Electrical Infrastructure: Poles, cable trays, and outdoor electrical conduits. 
• Transportation: Guardrails, street signs, and highway barriers. 

Reliable Steel Partner

At Steel Pro Group, we offer high-quality mild steel and galvanized steel products that meet industry standards. We are committed to reliable, on-time delivery, ensuring your projects stay on track. Need a quote? Contact us today, and we can provide the steel solutions you need.