Barbed Wires are extensively used for fencing of farm, houses, ground, garden etc. The wire forming or barbing operation involves the manufacturing of single wire and then Zinc coating it through galvanization. The zinc coating is done to enhance life through sacrificial protection (Zinc corrodes preferentially to steel), thereby protecting the steel wire.
While making Barbed wire, 2 GI wires are formed into a strand and at every 3 - 4 inch, another two wires are tightly twisted and cut into sharp barb as depicted in this video. These barbs prevent intrusion of animals or humans through the fence. The diameter of the barb wires varies from 2 mm to 2.5 mm. The barbing operation takes place at line speed varying from 12 to 25 metres/min. The outer diameter of the barbed wire coils varies from 380 to 400 mm and weigh approx. 26 kg.
In the process of barbing, the barbed wire is severely twisted and cut, which exposes the steel surface. Therefore, these Barb are found to be the initiation point or source of the rust, which gradually spreads over line wire and thereby reduces the overall life of the barbed wire. Normally, the barb tips start appearing rusty within 1-3 months, depending on the season. After installation of a fence, the spread of corrosion across the barbed wire fence is observed from these barb points. As a result of this, there is internal rejection, diversion and customer complaints causing customer dissatisfaction.
This is a universal issue due to the way the barbed wire is designed and manufactured, which cannot be changed or altered. Globally, this issue is addressed with heavy zinc coating or painting, but that is a costly process. Customers seek bright shiny barbed wire bundles with higher service life. Thus, we are looking for an economical method of enhancing the corrosion life of barbed wires.