What Are Mobile Towers and Why They Need Galvanizing
Purpose of Telecommunication Towers
Mobile communication towers are steel structures that serve as supports for antennas, repeaters, data transmission equipment, and other telecommunication infrastructure. They are installed in cities, villages, mountainous areas, and even remote locations to provide stable cellular and internet signals.
Depending on the type of facility, mobile towers can be:
- lattice (tall sectional masts);
- tubular (monopole or mast-like structures);
- frame (with additional reinforcements for equipment);
- special (for base stations on building roofs, containers, etc.).
The main requirements for them are stability and safe operation for many years, despite constant exposure to external factors. Here, corrosion protection is a critically important necessity.
Operating Conditions — Why Metal Is Vulnerable
Mobile towers are installed in open areas where they are exposed daily to:
- ultraviolet radiation;
- atmospheric precipitation (rain, snow, fog);
- temperature fluctuations — from heat to severe frost;
- aggressive chemicals from air and soil;
- high humidity in coastal and marshy areas.
Even high-quality metal without protection will start to rust just a few months after installation. This not only results in loss of appearance but also weakens load-bearing capacity. For such strategically important facilities as telecommunication towers, this is unacceptable.
Hot-dip galvanizing is the most reliable and long-lasting method of protecting towers from destructive environmental influences. Thanks to the zinc layer, the structure is resistant to rain, snow, aggressive chemicals, and maintains its strength for decades.
How Hot-Dip Galvanizing Differs from Other Methods
There are various methods of treating metal to protect it from corrosion: painting, spraying with zinc powder, electro-galvanizing, etc. But only hot-dip galvanizing by immersion forms a monolithic layer tightly bonded to the metal.
In the hot-dip galvanizing process, the structure is fully immersed in molten zinc, where at a temperature above 440°C a chemical reaction occurs between zinc and iron. This creates several diffusion layers that not only coat the surface but merge with it. As a result:
- the coating becomes resistant to moisture, chemicals, ultraviolet;
- it does not crack or peel over time;
- it protects even in the case of mechanical damage — thanks to the cathodic effect.
Unlike paint or electroplating, hot-dip galvanizing does not require annual maintenance and lasts 5–10 times longer compared to alternatives.
How Corrosion Resistance Is Achieved
The key feature of hot-dip galvanizing is the formation of a multilayer diffusion coating consisting of several microstructures:
- FeZn7 layer — the base that ensures adhesion;
- FeZn12 middle layer — the main anti-corrosion barrier;
- Zn outer layer — which additionally provides cathodic protection.
All these layers form naturally during the reaction between zinc and metal in the bath. This coating withstands even marine climates, which are among the most aggressive environments for metal structures.
That is why hot-dip galvanizing is the choice of telecommunication companies that aim to build infrastructure for years to come without the risk of annual repairs or tower replacements.
Galvanizing Mobile Communication Towers at the First Ukrainian Galvanizing Plant
Technological Capabilities of Our Equipment
The First Ukrainian Galvanizing Plant has one of the most powerful hot-dip galvanizing lines in the region. We can process large-sized structures, including sections of telecommunication towers up to 14 meters high and weighing several tons. The production equipment is automated, which allows us to achieve consistent coating quality on any parts — from main masts to mounting units and brackets.
We work with all types of towers made of steel: raw structures, galvanized according to GOST, European telecom standards, as well as towers built according to custom drawings. Our specialists advise clients even at the project preparation stage so that the structure meets the technical requirements for galvanizing.
Thanks to this, we can guarantee reliable protection of your infrastructure for decades.
Types of Towers We Process
We have experience in processing a wide variety of telecommunication structures, including:
- lattice guyed towers;
- self-supporting masts (triangular, square);
- tubular monopole masts;
- supports for communication antenna systems, including 5G;
- frame towers for rooftop installation;
- load-bearing structures for mobile portable stations.
Each type has its specifics, but our approach to processing always remains the same: maximum precision, compliance with standards, and consistent results.
Requirements for Structures: What Should Be in Place Before Processing
Preparation Features for Telecommunication Towers
To ensure the hot-dip galvanizing process is effective, tower structures must be designed and manufactured with technological requirements in mind. The most important thing is to ensure free access of molten zinc to all parts of the structure. This means that pipes, cavities, and channel connections must have:
- Drainage and ventilation holes (at least two per cavity);
- No paint, sealants, or oil stains;
- High-quality welds without flux residue;
- A safe design that eliminates the formation of explosive “traps.”
We recommend that customers agree on drawings with our engineers before manufacturing the sections. This will help avoid unnecessary costs for rework, modifications, or additional cleaning before processing.
The Most Common Mistakes
Among the typical mistakes we see when accepting structures for galvanizing:
- sealed welded joints without ventilation;
- paint residues, foil, or plastic elements on parts;
- incorrectly placed holes — resulting in zinc not draining and runs forming;
- unaccounted deformation under thermal load.
To avoid this, we advise considering the preparation requirements for galvanizing already at the project stage and contacting us for consultation.
Stages of Hot-Dip Galvanizing Mobile Towers
Abrasive Blasting
Before starting the hot-dip galvanizing process, each tower section undergoes abrasive blasting preparation. This is an important technological stage during which the following are removed from the metal surface:
- rust, scale, dust, greasy spots;
- residues of welding materials or contaminants;
- microscopic films that prevent adhesion with zinc.
We use automated equipment that allows for uniform cleaning of parts from all sides. The abrasive is selected depending on the material of the structure, its thickness, and the degree of contamination. The result is a rough, clean, slightly matte surface — ideal for deep adhesion with molten zinc.
This stage ensures that the zinc layer will not simply “sit” on top, but will bond into the metal structure.
Immersion, Cooling, Quality Control
After abrasive preparation, the structure undergoes chemical activation (fluxing), then drying, and immersion in a bath of molten zinc.
After removal from the bath, the structure is cooled, during which a dense coating forms. Then mandatory inspection is carried out:
- measurement of zinc layer thickness;
- visual inspection for the absence of runs, cracks, gaps;
- adhesion and integrity testing.
All measurements are recorded in the documentation we provide to the client along with the finished products.
Advantages of Hot-Dip Galvanized Telecommunication Towers
Protection in Any Climate
Galvanizing provides absolute protection for structures in all climatic conditions: from Arctic frost to maritime humidity or heat. The zinc layer is resistant to acids, salts, wind, and ultraviolet light. It does not crack from temperature fluctuations and does not allow moisture to penetrate, even into microcracks.
This makes it possible to install telecom towers on mountain slopes, seashores, and industrial sites without worrying about their durability. A tower with quality hot-dip galvanizing will last several times longer than a painted or electro-galvanized equivalent.
Minimal Maintenance
Thanks to the physical and chemical properties of zinc, the coating does not require painting, renewal, or repair for decades. This layer “self-heals” — the cathodic effect compensates for minor damage.
For telecom operators, this means a significant reduction in maintenance costs for towers, especially in hard-to-reach areas. There is no need for frequent crew trips, climbing, dismantling, or repainting — everything works for years without intervention.
Long Service Life
Hot-dip galvanizing extends the service life of mobile communication towers from 25 years or more — without loss of functionality or strength. This is the most cost-effective investment in long-term telecom infrastructure. You get a stable, safe structure ready for any conditions.
In combination with a reliable foundation, quality installation, and modern equipment, a galvanized mast will be the backbone of uninterrupted communication for years to come.
Hot-Dip Galvanizing Plant for Metal Structures: Quality Standards
ISO 1461:2022 and ISO 9001:2015
All work at the First Ukrainian Galvanizing Plant is carried out in accordance with international quality standards:
- ISO 1461:2022 — regulates coating parameters, thickness requirements, uniformity, layer integrity, and process conditions;
- ISO 9001:2015 — confirms the quality of technological process management at the enterprise.
These standards are not just certificates. They are a guarantee that galvanizing will be carried out at the highest professional level.
Zinc Thickness Check
At the First Ukrainian Galvanizing Plant, we strictly adhere to the requirements of the EN ISO 1461 standard regarding zinc coating thickness. The thickness depends on the parameters of the steel from which the structure is made — from 60 to 100 μm.
We check the thickness using special calibrated devices for each batch, after which we prepare a technical report. You receive not only quality galvanizing but also official confirmation of its compliance with international standards.
Our Clients and Completed Projects
Who We Work With
The First Ukrainian Galvanizing Plant actively cooperates with telecom operators, infrastructure solution manufacturers, installation companies, and developers. Our clients include enterprises building base stations, deploying 4G/5G networks, servicing national-level operators, or implementing IoT solutions in challenging environments.
We work both directly with customers and through contractors — always with the same responsibility and attention to quality. Even a small order is considered in the context of long-term partnership.
Example Projects
Among our completed projects:
- mobile communication towers in the mountainous regions of the Carpathians (high humidity and temperature fluctuations);
- masts for base stations in urban environments (intensive use and pollution);
- towers for private telecom operators in rural areas (limited access for maintenance);
- corrosion protection for structures for industrial IoT systems.
We are proud that our solutions operate reliably in the most diverse conditions and help maintain stable communication across Ukraine.
Logistics and Supply Geography
Where Structures Are Delivered From
Our hot-dip galvanizing plant is located in Stryi, Lviv region, but we accept orders from all regions of Ukraine. Most often, structures are delivered to us from Kyiv, Dnipro, Kharkiv, Vinnytsia, Odesa, as well as from border areas for projects with international coverage.
We work with both large batches (national-level base stations) and local private operators. We have no distance limits — we are always ready to adapt logistics to the client’s needs.
How to Deliver a Tower to the Galvanizing Plant
You can deliver the sections yourself or use trusted carriers. If needed, we will recommend logistics partners experienced in transporting telecommunication structures. The main thing is to agree on the delivery date in advance to avoid downtime and speed up processing.
How to Order Galvanizing for Mobile Communication Towers
Step by Step:
- Prepare technical documentation (drawing, sketch, or description of the structures).
- Send it to email sales@zink.com.ua or call: +38 (050) 430 38 38.
- We will promptly process the request, clarify conditions, and calculate the cost.
- After approval — deliver the structures to our production site.
- Receive high-quality galvanized towers with all accompanying documents within the agreed time.
Contacts:
- 📧 Email: sales@zink.com.ua
- 📞 Phones: +38 (050) 430 38 38, +38 (050) 370 88 57
Why the First Ukrainian Galvanizing Plant Is the Right Choice
Reputation and Experience
We are a modern Ukrainian plant specializing exclusively in hot-dip galvanizing. Our processes are streamlined, our staff is qualified, and our equipment is certified and up to date. We do not experiment — we provide a proven solution that already works on hundreds of sites across the country.
Advantages of Cooperation
- Flexible terms and fast order processing;
- High precision and control at every stage;
- Transparent pricing with no hidden costs;
- Openness to consultations, technical support even before production;
- Constant communication with the client at all stages of cooperation.
A mobile communication tower is not just a metal structure. It must withstand years of operation in a harsh environment, be safe, and remain stable. Hot-dip galvanizing provides exactly this level of protection. The First Ukrainian Galvanizing Plant is your reliable partner in building a resilient telecommunications infrastructure.
Frequently Asked Questions (FAQ)
What Is the Service Life of Hot-Dip Galvanized Towers?
On average — from 25 to 60 years, depending on operating conditions.
Can an Already Installed Tower Be Galvanized?
No, structures must be galvanized before installation. This is a technological requirement due to the immersion method.
What Is the Optimal Zinc Thickness for Such Structures?
According to EN ISO 1461 — from 60 to 100 microns, depending on the chemical composition and thickness of the steel elements.
Is There a Warranty on the Coating?
Yes, we provide official documents with measurement results and confirmation of compliance with standards.