21 FEB 2020  |  --> CLOSED ON: 22 MAY 2020  |  REWARD: INR 2,00,000
Reward money is paid in exchange of legally acquiring the solution, implementing it to solve the problem and meeting the success criteria. Milestones for paying the reward money would depend upon the complexity of challenge and maturity of the proposed solution, which would be discussed with the solver as soon as the proposed solution is selected by us.

22 NOV 2020

22 NOV 2020

We are looking for low-cost solutions to prevent early rusting of barbed wire tips.

Challenge Details

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 (called GI wires). 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 barbs. The diameter of the barb wires varies from 2 mm to 2.5 mm. The barbing operation takes place at a line speed of up to 25 meters/min. The barbed wires are coiled in a diameter of about 400 mm and each coil weighs approx. 26 kg.

In the process of barbing, the barbed wire is severely twisted and cut, which exposes the steel surface. These surfaces (barb tips) are found to be the starting point of rust, which gradually spreads over the wire. The barb tips start appearing rusty within 1-3 months, depending on the season. Globally, this issue is addressed with heavy zinc coating or painting, but that is a costly process. We are looking for an economical method of enhancing the life of barbed wires by avoiding corrosion.

Options Tried:

  • During manufacturing of the GI wires, the secondary coating was tried in addition to zinc coating. However, this coating gets damaged during the barbing operation and thereby could not stop rusting of barb tips.
  • Organic colour coatings were not feasible.


  • The solution should not degrade the appearance of the barb wires.
  • The proposed solution should preferably avoid any additional coating or painting step after the barbed wires are coiled.
  • The cost of the solution should be less than INR 1000/MT of Barbed wire produced.

Constraints: The process of barb wire manufacturing cannot be altered

Have any query or need more clarification about this challenge?