Why Some Zinc-Plated Casters Last Longer
Caster Surface Treatment Why Some Zinc-Plated Casters Last LongerZinc plating is one of the most common surface treatments for steel caster brackets. It improves appearance, but its more important purpose is to protect the steel from corrosion. Two brackets may look almost identical while having very different coating thickness, salt spray resistance, and service life. |
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Zinc Plating Is Available in Different Colors
Depending on the passivation process and appearance requirements, caster brackets may be finished in blue zinc, white zinc, blue-white zinc, color zinc, black, gold, and other customized colors.
Color is the most visible difference, but it does not tell the whole story. Brackets with a similar appearance may have different coating thicknesses, surface preparation, uniformity, passivation, and sealing quality.
The real durability of a zinc-plated caster is determined by the complete coating process—not by color alone.
Barrel Plating vs. Rack Plating
3–6 μm + Sealing
Barrel PlatingMultiple parts are placed inside a rotating barrel for plating. The process is efficient and economical, but the parts contact and collide with one another during production. Minor scratches may occur, and coating thickness and uniformity can be more difficult to control. Typical salt spray resistance: approximately 48 hours |
7–10 μm + Sealing
Rack PlatingEach bracket is fixed separately to a rack during plating. This reduces collisions between parts and helps prevent scratches. Rack plating generally provides a more uniform coating and is suitable when appearance and corrosion resistance are more important. Typical salt spray resistance: approximately 96 hours |
Why Coating Thickness Matters
Zinc coating thickness is normally measured in micrometers (μm). When the base material, surface preparation, passivation, and sealing process are comparable, a thicker and more uniform zinc layer generally provides longer corrosion protection.
Thickness is not the only factor. Uneven plating, incomplete pretreatment, uncovered edges, poor sealing, and scratches during production or transportation can all reduce corrosion resistance.
Zinc-plating quality should therefore be evaluated through thickness, uniformity, process control, and salt spray performance together.
Why EDL Uses Rack PlatingEDL uses rack plating for all light-duty and heavier caster series. Separating the brackets during plating reduces collisions and scratches while helping the zinc layer remain uniform across the surface. The zinc coating on EDL caster brackets normally reaches 6–8 μm, with routine salt spray performance of up to 72 hours. For stricter quality verification, EDL also carries out internal evaluation using requirements of up to 120 hours, depending on the product and agreed specification. |
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The Difference Is Hidden in the Details
Customers sometimes tell us that EDL casters do not look very different from other products, yet they last longer in actual use.
The reason is that coating thickness, rack-plating control, sealing quality, edge coverage, and salt spray testing cannot be judged from a product photo. Two new casters may look similar, but the difference becomes visible after transportation, installation, and long-term exposure.
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Plating Method
Barrel plating or rack plating? |
Coating Thickness
How many micrometers? |
Sealing Process
Is sealing included? |
Salt Spray Test
How many hours can it achieve? |
Durability Starts Beneath the Surface
Zinc plating is common, but not every zinc-plated caster provides the same corrosion resistance. Plating method, coating thickness, uniformity, passivation, sealing, and salt spray performance all affect long-term durability.
At EDL, many of the details that improve service life may not be immediately visible—but they are built into the product from the beginning.
Looking for More Durable Zinc-Plated Casters? Tell EDL your working environment, required load, corrosion exposure, and salt spray requirement. Our team can recommend a suitable caster bracket and surface treatment. | Get A Quote |
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