Hot-Dip Galvanizing Facility

Hot-dip galvanizing is a proven process of protecting iron and steel against corrosion by coating the surface with a layer of zinc. In this process, fabricated steel components are immersed in a bath of molten zinc maintained at approximately 860°F (460°C). When exposed to the atmosphere, the zinc coating reacts with oxygen to form zinc oxide, which further reacts with carbon dioxide to create a dense, stable layer of zinc carbonate. This dull grey, adherent layer provides long-term corrosion resistance and significantly extends the service life of steel. Galvanized steel can be readily identified by its characteristic spangled surface finish.

Indiana operates a state-of-the-art hot-dip galvanizing facility imported from Europe, designed to meet stringent international quality, safety, and environmental standards. The zinc bath measures 8.0 meters in length, 1.2 meters in width, and 2.5 meters in depth, enabling the galvanizing of large and complex fabricated components. The facility has a proven annual capacity of 36,000 MT.

The galvanizing furnace is equipped with energy-efficient pulse-fired burners, fully controlled through an advanced PLC-based automation system, ensuring precise temperature control, consistent coating quality, and optimized fuel consumption. Indiana follows a seven-tank galvanizing process, strictly adhering to all applicable Pollution Control Board regulations.

As part of its strong commitment to environmental sustainability, the galvanizing plant is supported by a complete Effluent Treatment Plant (ETP) incorporating Reverse Osmosis (RO) and evaporator systems. The facility operates as a Zero Liquid Discharge (ZLD) plant, ensuring that no liquid effluent is released outside the premises. Additionally, the plant is equipped with zinc and acid fume extraction systems, effectively controlling emissions and maintaining a safe and eco-friendly working environment.

Indiana’s galvanizing facility is ARAMCO-approved and is qualified to execute galvanizing works for all ARAMCO projects in India, reflecting the plant’s compliance with rigorous international quality and process standards. This approval underscores Indiana’s capability to deliver reliable, sustainable, and globally accepted galvanizing solutions for critical infrastructure and industrial applications.

Standards Followed

• Indian Standard: IS 2629
• American Standard: ASTM A123
• British Standard: EN ISO 1461:1999
• German Standard: DIN 50976
• AS/NZS Standard: 4680:2006