How GI Pipes Are Made — The Complete Manufacturing Process

Galvanized Iron (GI) Pipes are steel pipes coated with a layer of zinc to protect them from rust and corrosion.
At Hi-Tech Pipes Limited, we manufacture GI pipes using a state-of-the-art hot-dip galvanizing process, ensuring strength, safety, and long service life for every pipe we produce.

1️⃣ Raw Material Selection

The process begins with high-quality mild steel (MS) coils or strips.
These are carefully inspected for surface finish, thickness, and mechanical properties to ensure they meet IS:1239 and IS:3589 standards.

2️⃣ Pipe Forming (ERW Process)

The steel coil is slit into strips and fed into a tube-forming mill, where it is shaped into a circular tube.
The edges are welded together using the Electric Resistance Welding (ERW) method, forming a strong and continuous seam.
The welded joint is then heat-treated to restore uniform strength throughout the pipe.

3️⃣ Surface Cleaning & Preparation

Before galvanizing, the pipes undergo a series of cleaning processes:

  • Degreasing – removes oil, dirt, and grease

  • Pickling – removes rust and mill scale using acid solution

  • Rinsing & Fluxing – prepares the surface for even zinc adhesion

A perfectly clean surface ensures a uniform zinc coating during galvanization.

4️⃣ Hot-Dip Galvanizing

The cleaned pipes are dipped into a molten zinc bath (around 450°C).
As the steel reacts with zinc, a metallurgical bond forms, creating multiple protective layers that resist rust, moisture, and chemical corrosion.
This is what makes GI pipes durable and ideal for outdoor and underground applications.

5️⃣ Cooling & Finishing

After galvanization, the pipes are slowly withdrawn, cooled in water or air, and inspected for coating thickness, uniformity, and finish.
Ends are trimmed, threads may be cut (for threaded pipes), and surfaces are wiped clean for a smooth final appearance.

6️⃣ Testing & Quality Assurance

Every pipe is tested for:
✅ Zinc coating thickness
✅ Leakage and pressure resistance
✅ Dimensional accuracy
✅ Bend and flattening strength

Only pipes that pass all tests are stamped with the Hi-Tech Jal Shakti quality mark and dispatched for distribution.

7️⃣ Final Product — Built to Last

The result is a corrosion-resistant, high-strength GI Pipe ready for use in agricultural irrigation, borewells, water supply, fencing, and infrastructure projects.

Each Hi-Tech GI Pipe reflects our promise of trusted strength since 1988 — powering India’s growth with quality that endures.


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