Galvanized Wire vs. Annealed — Which Works for Your Application?

What Is Galvanized Wire?

To make galvanized wire, the manufacturer must put the wire through the hot-dip process. First, the manufacturer fabricates the steel wire to the specified gauge and thickness. Then, they must clean it in an acid bath to eliminate surface oxides. After rinsing and drying the wire, the manufacturer dips it into a bath of molten zinc, completely coating it in a thin layer of the metal. The manufacturer controls the zinc's thickness. A sequence of water cascades cools the wire and its coating. 

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Galvanized zinc coating provides some unique benefits.

• Rust prevention: Does galvanized wire rust? Galvanized wire is highly resistant to rust because of the protective zinc coating that keeps moisture away from the steel beneath. 
• Damage resistance: A galvanized coating is solid and robust, protecting the wire from chipping, scratching and cutting. 
• Fire resistance: The zinc coating's melting point is exceptionally high, making galvanized wire resistant to melting in a fire. 

While a zinc coating increases the wire's durability in several ways, zinc alone is sometimes insufficient for specific applications. At Bekaert, we also use an enhanced process called Bezinal® to galvanize steel wires. Bezinal® combines zinc with aluminum, fortifying the wire even more against corrosion. This mixture of metals offers superior durability to zinc alone. 

Enhanced Galvanization

Bekaert offers a range of steel wire coating solutions that provide corrosion resistance and strength. Our Class A, Class B and Class C galvanized zinc coatings are the most commonly used across applications and environments. We also provide enhanced galvanized wire coated with Bezinal®, our line of zinc aluminum coatings. Of all the galvanized wire coating available, Bezinal® offers the best durability, heat and corrosion resistance and processability. 

Bezinal® is a eutectic coating offering cathodic protection of the steel wire's uncoated areas. The coating produces an electric current that counteracts corrosion on scratched or cut areas due to the addition of aluminum, which is more corrosion-resistant than zinc. We have thoroughly tested Bezinal®-coated wires and proven they can resist corrosion two to six times longer than hot-dip galvanized wires. Wires coated with Bezinal® last up to eight times longer in heavily polluted areas.

Another benefit of Bezinal® is its heat resistance. Often, galvanized wires that undergo the hot-dip process experience growth of the alloy layers after exposure to high temperatures. In contrast, Bezinal® is immune to alloy growth and exhibits no cracks in the zinc aluminum layer. Bekaert's engineered wire coating solution ultimately provides better performance than galvanized wires. 

Bright baling wire(also known as uncoated wire) has a shiny, bright finish and lacks any additional protective coating. Primarily chosen for its cost effectiveness, it has its advantages and disadvantages. The following table summarizes the pros and cons of bright baling wire.

Pros of bright baling wire

Cost-effective

Bright baling wire is highly cost effective. Compared to coated wire options such as galvanized wire or annealed wire, bright baling wire is cheaper. The absence of additional coatings or treatments during manufacturing reduces costs. The lower price point of bright baling wire makes it an attractive option for applications where corrosion resistance is unnecessary, such as indoor or short-term baling.

Aesthetically pleasing

Bright baling wire is aesthetically pleasing. The wire’s bright finish gives it a clean, attractive look, making it perfect for retail settings and other client-facing applications In situations where the appearance of the bales matters, such as in stores or showrooms, bright baling wire can enhance the visual appeal of the packaged products.

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High tensile strength

Bright baling wire offers impressive tensile strength. Our 9 gauge bright double loop bale ties are one of the strongest wire options in our product lineup, featuring a tensile strength of 220,000 PSI. High tensile strength ensures our bale ties safely and securely bind bales of heavy recyclables, such as e-waste, glass, and rubber tires. The inherent strength of steel maintains bale integrity against exceptional weight and pressure.

Cons of bright baling wire

No corrosion resistance

Bright baling wire lacks the corrosion resistance that other types of baling wire provide. When we compare bright wire to annealed wire and galvanized wire, corrosion resistance is a differentiator that stands out. The galvanization process coats wire in a protective layer of molten zinc, and the annealing process produces a thin oxide layer that resists corrosion.

Bright baling wire is more susceptible to rust and deterioration when exposed to moisture, humidity, and corrosive environments. Over time, the wire may weaken and lose its strength, compromising the integrity of the bales.

Not suitable for outdoor use

Bright baling wire is untreated and not recommended for outdoor environments. Moisture, rain, and other environmental factors accelerate the rusting process, leading to premature deterioration.

For applications that involve outdoor storage or exposure to wet or humid conditions, galvanized wire or stainless steel wire are the best options, as they offer superior corrosion protection and can withstand the elements.

Lacks versatility

Bright baling wire lacks versatility compared to galvanized wire and annealed wire. Galvanized wire offers enhanced resistance to corrosion and can be used in harsher environmental conditions.

Annealed wire excels in applications that require elongation or twisting, having undergone a heat treatment process that improves its flexibility and formability.

Bright baling wire is best suited for short-term waste and recyclables baling or baling and storage in climate-controlled environments.

Our bright wire products

We offer high-quality bright wire products. Our bright bale ties(tie wires) are manufactured from 100% US steel and undergo a meticulous quality control process to ensure you get the best wire products.

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