Mild Steel vs Galvanized Steel: Differences, Uses, and Price Insights

Every contractor and fabricator knows what's at stake when the wrong steel is chosen: premature corrosion, mounting maintenance costs, and avoidable project delays. A single material mismatch can significantly compromise the structural integrity. That's why understanding the difference between mild steel and galvanized steel is a strategic decision that determines durability, cost efficiency, and project success.

Across South India's construction and fabrication projects, this choice influences how well a structure performs under real-world conditions. While mild steel offers flexibility and affordability, galvanized steel features a protective zinc coating that resists corrosion.

This blog compares the two types in terms of price, durability, and usage parameters. By clearly understanding these differences, you can make more informed material choices across your projects.

Key Takeaways

• Mild steel offers flexibility, weldability, and cost-effectiveness. It is ideal for indoor, low-exposure, or short-turnaround projects, such as framing, truss work, and fabrication.

• Galvanized steel features a zinc coating that provides superior corrosion resistance. That coating makes it the preferred choice for outdoor, coastal, or industrial structures that demand durability and minimal maintenance.

• Price-wise, mild steel typically ranges between ₹44,000 and ₹72,000 per ton. However, galvanized steel products start around ₹64,000 and can exceed ₹1,00,000 per ton (exclusive of GST), reflecting the added protection and processing costs.

• Although galvanized steel costs more upfront, it delivers better lifecycle value by reducing maintenance, repainting, and replacement costs over time. That's a crucial benefit for projects in humid, coastal areas, and metro cities.

• Choosing the right material depends on exposure, longevity goals, and budget: mild steel for adaptable, economical builds; galvanized steel for long-term, high-performance applications.

What is Mild Steel?

Mild steel, also known as low-carbon steel, contains approximately 0.05% to 0.35% carbon content, making it ductile, malleable, and easy to fabricate. Its low carbon content gives it flexibility and weldability. These two traits make it indispensable across the fabrication industry.

Mild steel is produced primarily through two methods: the blast furnace process, where iron ore is combined with coke and limestone, and the electric arc furnace (EAF) method, which melts recycled scrap steel using electricity. In both cases, the carbon content is precisely controlled to achieve a balance between strength and workability.

Although mild steel is less resistant to corrosion compared to coated steels, its affordability, versatility, and easy availability make it a preferred material for indoor and non-exposed applications. When properly coated or painted, it performs well even in moderately humid conditions.

Applications of Mild Steel

• Residential and commercial structures: Commonly used in columns, beams, and roof trusses where strength and weldability are key. For instance, many small to mid-scale residential projects in Hyderabad and Bengaluru prefer mild steel channels and plates for cost-effective frameworks.

• Fabrication and manufacturing: Ideal for making MS pipes, flats, and angles used in industrial sheds, machinery frames, and enclosures.

• Automotive and appliance industries: Widely used for vehicle body panels, brackets, and casings where easy forming and cutting are needed.

• Workshops and light engineering: Favored for custom fabrication in small-scale industries, thanks to its easy availability and low machining cost.

Key Insight: Mild steel remains the dominant choice in areas where cost efficiency and flexibility outweigh the need for corrosion resistance. This makes it the backbone material for general-purpose steel applications across South India.

Also Read: Mild Steel Applications in Fabrication: Uses, Advantages & Processes

What is Galvanized Steel?

Galvanized steel refers to the steel that's coated with a thin layer of zinc. This layer gives protection from rust and corrosion. This process, known as hot-dip galvanization, involves immersing steel in molten zinc at a temperature of around 445 to 460 °C, which forms a metallurgical coating. That shields it from moisture, oxygen, and other environmental elements.

The zinc coating also acts as a sacrificial barrier, meaning it continues to protect the underlying steel even if the surface is scratched. This makes galvanized steel a top choice for outdoor and coastal applications, where durability and long-term performance are essential.

Applications of Galvanized Steel

• Roofing and cladding: Extensively used in industrial sheds, godowns, and warehouses across coastal areas, such as Chennai, Visakhapatnam, and Mangaluru, where humidity and salt exposure demand corrosion resistance.

• Infrastructure projects: Used for street light poles, guard rails, and structural supports that face constant exposure to the elements.

• Agricultural and rural constructions: Common in fencing, irrigation structures, and storage sheds that need a long service life with minimal maintenance.

• Fabrication and utilities: Used for ducting, cable trays, and panels, especially in factories and utilities that require high safety and longevity.

Why It Matters: In South India's humid and coastal conditions, galvanized steel significantly reduces long-term maintenance costs and extends structural lifespan. This way, it offers clear value where exposure to moisture is unavoidable.

Understanding how mild steel and galvanized steel are produced, and where they excel, sets the stage for a practical comparison.

Mild Steel vs Galvanized Steel: How They Differ in Performance and Use

Both types play vital roles across construction and fabrication, but their suitability depends on exposure and project demands. The table below highlights their core differences to help you select the right material for long-term performance and value.

Factor	Mild Steel	Galvanized Steel
Production Process	Produced via blast furnace or EAF process using iron and 0.05%–0.35% carbon for strength and flexibility. No protective coating unless applied later.	Made by coating steel with zinc through hot-dip or electro-galvanizing, forming a bonded layer.
Corrosion Resistance	Low; prone to rust unless painted or coated.	Excellent; the zinc coating protects against moisture and oxidation.
Durability	Moderate; performs well indoors but needs regular upkeep outdoors.	Highly durable; the zinc layer withstands weather and saline conditions.
Weldability	Excellent; easy to cut, bend, weld, and shape, making it ideal for fabrication and general construction.	Slightly reduced due to the zinc coating; requires controlled welding and ventilation, but still suitable for prefabricated assemblies.
Applications	Preferred for indoor or low-exposure projects:   Trusses Enclosures Fixtures Decorative frameworks Machinery parts Light structures	Used in outdoor, coastal, and industrial projects that need corrosion protection   Roofing sheets Purlins in roof construction Cladding Guard rails Exterior frameworks and industrial sheds
Cost	Lower initial cost but higher maintenance if exposed to weathering or moisture.	Higher upfront costs but lower lifetime expenses due to minimal maintenance and a longer lifespan.
Appearance	Plain, smooth finish, and can be polished or painted as needed for aesthetic purposes.	Features a spangled or matte silver finish from zinc coating, often used without additional finishing.

With a clear understanding of how mild steel and galvanized steel differ across key performance factors, we can now examine how these differences reflect in procurement costs.

Mild Steel vs Galvanized Steel Price Comparison

Material costs often guide procurement decisions as much as performance does. While both types of steel are widely available across South India, their prices vary depending on coating, grade, and application. Let's examine the price comparison between mild steel and galvanized steel, focusing on actual regional data before placing your next bulk order.

Product	Typical Price Range (per MT)
MS Rounds	₹ 44,000 – ₹ 53,061
MS Angles	₹ 44,500 – ₹ 76,700
MS Squares	₹ 44,000 – ₹ 47,700
MS Channels	₹ 46,500 – ₹ 54,000
MS Plates	₹ 47,500 – ₹ 72,100
MS Flats	₹ 44,000 – ₹ 57,511
MS Square Pipes	₹ 53,250 – ₹ 68,000
MS Rectangular Pipes	₹ 47,300 – ₹ 68,000
MS Round Pipes	₹ 53,250 – ₹ 68,000
Galvanized Plain (GP) Sheets	₹ 72,000 – ₹ 1,00,890
GP Square Pipe	₹ 64,500 – ₹ 83,000
GP Rectangular Pipe	₹ 67,000 – ₹ 70,800

Note: All prices are exclusive of GST and are based on current listings in Andhra Pradesh, Telangana, and Karnataka.

In short, the average prices for MS products typically range between ₹44,000 and ₹72,000 per ton (excluding GST), depending on the section and specification. For galvanized steel materials, prices start significantly higher around ₹64,000 and can reach ₹1,00,000 per ton, reflecting the added zinc protection and processing costs.

Is the Price Difference Justified?

Though galvanized steel costs more upfront, its longer lifespan and lower maintenance can offset the price gap over time. For instance, a lower initial price (for mild steel) may look attractive, but if the structure is exposed to moisture or salt-laden air, the total cost over 5–10 years may far exceed the difference.

That's because mild steel requires painting or coating to prevent rust, especially in humid or coastal environments, which adds recurring maintenance expenses. In contrast, galvanized steel's zinc coating offers built-in corrosion resistance, minimizing future repainting or replacement costs.

Knowing how mild and galvanized steel compare in cost and other parameters is only half the picture. Choosing the right one depends on where and how it will be used. Next, let's examine how to select the appropriate steel for your project.

Choosing Between Mild Steel and Galvanized Steel for Your Project

Selecting between mild steel and galvanized steel depends on your project's environment, performance requirements, and maintenance expectations. Each serves a distinct purpose: one offers flexibility and economy, while the other ensures durability and long-term protection. Here's a quick guide to help you make an informed choice.

Choose Mild Steel If:

• You need a solution for indoor or low-exposure projects: Suitable for interior frameworks, trusses, partitions, and decorative elements that don't face harsh weather conditions.

• Flexibility and ease of fabrication are top priorities: Mild steel's excellent weldability and formability make it ideal for fabrication workshops, machinery frames, and light construction with frequent on-site adjustments.

• You're working on short-turnaround or budget-sensitive builds: Its wide availability and lower cost per ton make it practical for large commercial or residential projects with tight schedules.

• You plan to apply your own surface protection: When paired with painting or powder coating, mild steel performs reliably even in semi-exposed environments, offering a balance between cost and performance.

Choose Galvanized Steel If:

• Your project is highly susceptible to moisture or corrosion: It is ideal for coastal, industrial, or outdoor applications such as roofing, purlins, streetlight poles, and safety barriers, where humidity and pollutants are constant challenges.

• You want long-term durability with minimal upkeep: The zinc coating prevents rust and eliminates the need for frequent painting or replacement, saving both time and lifecycle costs.

• You're building for longevity and structural reliability: Perfect for infrastructure projects, warehouses, or utility frameworks where extended service life and performance stability are priorities.

• You aim to reduce maintenance-related downtime: This is especially relevant for large fabrication units or public infrastructure in tier 1 cities like Hyderabad and Bengaluru, where maintenance cycles are costly and disruptive.

Pro Tip: Request coating specifications for galvanized products. Verify the zinc thickness and quality certifications to ensure consistency.

Also Read: Choosing Between Galvalume and Galvanized Steel for Your Next Project

Once the right material is clear, the next question is where to source it, and SteelonCall makes that decision simple.

Why Buy Mild Steel and Galvanized Steel from SteelonCall?

Sourcing steel for large projects shouldn't mean chasing multiple dealers or worrying about inconsistent supply. SteelonCall eliminates the inefficiencies of traditional steel procurement, bringing verified suppliers onto a single digital marketplace. Here's how it helps contractors, fabricators, and project managers solve the most common sourcing challenges:

• Verified Supplier Network: All manufacturers and distributors are pre-vetted, ensuring authentic, certified material and eliminating risks of counterfeit or substandard steel.

• Direct Manufacturer Access: Buyers connect directly with authorized brands like Vizag Steel, Tata Tiscon, and more. This way, we help eliminate intermediaries, avoid markups, and reduce sourcing delays.

• Transparent, Competitive Pricing: Using SteelonCall's live TMT bar prices feature provides you with a clear picture of regional market rates. These insights support smarter cost planning for mild and galvanized steel as well.

• Reliable, On-Time Delivery: Integrated logistics ensure safe, timely dispatches, minimizing site downtime and project delays.

• Bulk and Custom Orders: From MS sections to GP sheets, SteelonCall efficiently handles high-volume and specification-based requirements through its extensive network.

• Quality Assurance: Every batch undergoes rigorous grade and quality checks to ensure consistency across all deliveries.

• Expert Guidance: Industry specialists help you select the right material based on exposure, strength, and cost factors, ensuring each purchase aligns with your project goals.

SteelonCall brings together quality, transparency, and reliability, giving modern fabrication teams a smarter way to source mild and galvanized steel.

Final Thoughts

Both mild steel and galvanized steel have their place. The right choice depends on where your structure will stand and how long it needs to last.

Mild steel remains the practical choice for builders and fabricators who need a material that's easy to weld, shape, and install. Galvanized steel, on the other hand, is engineered for exposure. Its zinc coating offers lasting protection against humidity, salt, and pollutants, making it indispensable for roofing and outdoor infrastructure.

For region-specific pricing and availability, explore mild and galvanized steel listings on SteelonCall. Compare dimensions, types, and delivery options, or consult with an expert to match the right material to your project's environment and performance goals.

FAQs

1. What are the disadvantages of galvanized steel?

Galvanized steel can lose its corrosion resistance if the zinc coating is scratched or damaged. Over time, mishandling or wear exposes the underlying metal, leading to rust formation, especially in harsh or abrasive environments without proper maintenance.

2. Can you weld galvanized steel?

Yes, but it requires special precautions, such as adequate ventilation and controlled temperature. That's because welding releases zinc fumes that can be hazardous if not handled properly.

3. Are galvanized steel coatings uniform across all suppliers?

No. Coating thickness and quality vary depending on the manufacturing process and supplier standards. Always check for IS or ASTM certifications and zinc coating thickness (typically measured in microns) before making a purchase.

4. How does each respond to painting or coating?

Mild steel accepts paint readily. However, galvanized steel must be cleaned and primed with zinc-compatible coatings for adhesion. Nevertheless, it doesn't require paint often due to its natural finish.

5. How do these materials differ in availability across South India?

Mild steel is widely stocked across fabrication markets, while galvanized steel's supply depends on coating capacity and mill output. However, both are easily accessible through SteelonCall's verified supplier network, which lists region-specific availability across Hyderabad, Bengaluru, and Visakhapatnam, for faster and reliable sourcing.