Coated Wires — Galvanised and Zn-Al Coated
Zinc-aluminum coated for outdoor and high-humidity service. Supplied for mattress, fencing and agricultural spring production — with roughly twice the salt-spray life of an equivalent-weight galvanized coating.
Pick a diameter. Everything else follows.
Coating weight, minimum salt-spray life, dimensional tolerance and the governing standard all move with the wire diameter. Drag the slider to see the combination you would actually be quoted on.
Note. Minimum SST hours are indicative for 5% dark brown rust formation. Values between the tabulated diameters are interpolated for illustration and must be confirmed against the mill test certificate.
| Diameter (mm) | Coating weight (gm/m²) | Salt spray test (hrs, min.) |
|---|
Galstar™-type coating, 95% Zn + 5% Al. Two coating weights are offered at 3.00 mm; the heavier class is specified where exposure hours are contractual.
| Element | Range | Role |
|---|---|---|
| Carbon (C) | 0.45 – 0.85% | Sets attainable tensile and spring temper |
| Manganese (Mn) | 0.30 – 1.00% | Hardenability and hot-working behaviour |
| Silicon (Si) | 0.10 – 0.35% | Deoxidation, elastic-limit contribution |
| Sulphur (S) | 0.025% max | Held low — controls hot shortness |
| Phosphorus (P) | 0.025% max | Held low — controls cold brittleness |
Standard.As per EN 10264-2, or to the customer's own chemistry where a specific spring temper or coating class is contracted.
The higher coating weight class. Specified where exposure hours are contractual — geohazard fencing, rockfall arrestors, permanently exposed hardware.
The general-service class. Automotive springs and components, mattress and furniture springs, agricultural equipment.
| Property | Specification |
|---|---|
| Finish | Zinc-aluminum coated, hot-dip (95% Zn + 5% Al) |
| Grade | On request — matched to temper and coating class |
| Coating standard | EN 10264-2 · EN 10270-1 |
| Base wire | Carbon spring steel, patented and drawn |
| Hydrogen embrittlement | Not applicable — hot-dip process, not electroplated |
| Diameter band | Tolerance | As a % of Ø |
|---|---|---|
| 0.80 – 1.60 mm | ±0.02 mm | 2.5% at 0.80 mm · 1.3% at 1.60 mm |
| 1.60 – 3.00 mm | ±0.03 mm | 1.9% at 1.60 mm · 1.0% at 3.00 mm |
Bars are a qualitative read of test coverage, not measured values.
Twice the life, at the same coating weight.
Comparison of SST hours, indicative for 5% dark brown rust formation. The zinc-aluminum alloy gives sacrificial protection from the zinc and passivation from the aluminium — the two together outrun a plain galvanized coating of the same weight by roughly a factor of two. The difference is not just a bigger number. Plain galvanising corrodes at a steady rate; a zinc-aluminium coating passivates as its surface weathers, so the rate slows year on year instead of holding constant. Over a long service life that gap widens rather than closes.
Hours vs. coating weight
IndicativeMinimum hours to 5% dark brown rust, plotted against applied coating weight in gm/m².
Minimum SST by diameter
HrsTabulated minimums for the five supplied diameter / coating-weight combinations. Hover a bar for its coating weight.
Note.Minimum SST hours are indicative for 5% dark brown rust formation. Figures follow the reference brochure data for Zn95/Al5 coated spring wire and are pending confirmation against Manisha's own supply.
Why specify zinc-aluminum.
Corrosion protection
Sacrificial protection from the zinc plus passivation from the aluminium. Exposure tests indicate roughly double the salt-spray life of an equivalent-weight galvanized coating.
Mechanical properties
Core mechanical properties stay unchanged after completing the minimum required exposure hours in the salt spray chamber — the coating carries the corrosion duty, not the steel.
Formability
Withstands more severe bending with virtually no cracking or flaking, compared with galvanized wire of the same diameter and coating weight. Coiling does not strip the coating.
Automotive-grade
Electroplated coatings on auto components carry a hydrogen-embrittlement failure mode. The hot-dip process used here is inherently safer and eliminates that risk.
What we supply, and to which standard.
Fencing and rockfall arrestor
Geohazard
Springs and components
Automotive
Mattress, furniture and agricultural springs
General engineering
Protected in transit, ready at the pay-off.
Packaging is designed to safeguard the product from damage, contamination and environmental exposure during transit — and to hand off cleanly into your line. Select a coil type to see it drawn to true relative scale.
From incoming rod to despatch.
Send the spec. We confirm before you commit.
Give us the diameter, coating class and quantity. We come back with availability, price and delivery — and the mill test certificate that goes with the lot. For a live requirement, the phone is faster than the form.
