Ensuring durability in India's automobile industry through zinc galvanization to meet new-age consumer expectations
13 Feb 2025 | 2646 Views | By Kenneth M de Souza, International Zinc Association
India’s automobile market has grown significantly over the last decade, reflecting a transformation not just in scale but in consumer aspirations. With the country poised as the third-largest automobile market in the world, the industry is witnessing a significant shift in priorities from affordability to premiumisation. Amidst this evolution, the ...
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India’s automobile market has grown significantly over the last decade, reflecting a transformation not just in scale but in consumer aspirations. With the country poised as the third-largest automobile market in the world, the industry is witnessing a significant shift in priorities from affordability to premiumisation. Amidst this evolution, the narrative around vehicle safety and durability has matured, sparking a crucial conversation about materials that enhance performance, sustainability and strength of the car bodies.
A generation ago, the quintessential Indian car buyer prioritized practicality and affordability. Durability, while important, often took a back seat to cost. Today, cars are more than transportation, they are lifestyle statements. Lack of features like advanced driver-assistance systems, sunroofs and premium interiors are now deal-breakers for car buyers. However, ensuring that the car body can withstand the test of time and remain rust-free, safe and secure is essential as a car is often the second-largest investment for car buyers, after a home.
Amid this pursuit of aesthetics and innovation, one critical aspect often gets overlooked: the car body’s ability to withstand wear and tear over time. In a country with diverse and extreme weather conditions, durability isn’t a luxury, it’s a necessity. Car manufacturers can easily address this by using zinc galvanized steel for car bodies. Steel constitutes 95% of most vehicle bodies and is highly susceptible to corrosion unless protected. Zinc is the single most effective material to protect steel from corrosion in a way that paints and anti-rust treatments are ill-equipped to do.
India’s climate presents a unique challenge to vehicle longevity. Cars in India are predominantly parked outdoors, directly exposed to erratic weather conditions. High humidity, coastal sea salt and extended monsoons create an ideal environment for rust and corrosion. Reports have highlighted instances of new vehicles showing visible rusting within just two years. A 2015 IIT Bombay survey found that 65% of non-galvanized vehicles in Mumbai experienced corrosion within five years, while galvanized vehicles remained unscathed. A similar 2017 study in Chennai painted an even grimmer picture, underscoring the urgent need for robust anti-corrosion measures.
As a steel-intensive industry, car manufacturers must prioritize zinc coating in various vehicle components, such as body-in-white (skeleton of the body), engines, chassis, power steering systems, brake parts, seat belts, windscreen wiper, sunroof, air-conditioning units and fuel systems. Zinc acts as a powerful protector against corrosion and red rust. When steel is galvanized with zinc, it creates a durable, metallurgical bond that shields the body from environmental damage. Unlike paint, which can chip and peel, zinc provides sacrificial protection, ensuring the steel remains intact even when scratched or dented.
Globally, over 90% of vehicles in markets like North America, Europe, and Japan use zinc-coated bodies, a stark contrast to India, where the figure lingers between 0-25%. Ironically, Indian-manufactured cars for export boast up to 70% galvanized bodies, highlighting the disparity domestic consumers face. International cars come with 'corrosion-free' warranties that cover anti-perforation, cosmetic paint fading and peeling.
Cosmetic and anti-perforation warranties are offered by car manufacturers for five and ten years respectively. These warranties are possible only when the car body parts are made from galvanized (zinc-coated) steel. Indian car buyers must actively seek these warranties to ensure their vehicles don’t succumb to rust and corrosion within 2 years of purchase.
The initial cost of galvanization is negligible, less than 0.1% of a car’s selling price and the cost is recovered within a year through reduced inspection, maintenance and repair costs. Galvanized cars not only offer a rust-free lifespan of up to 10 years but also enhance resale value. For Indian consumers, this translates to a lower cost of ownership.
Indian automakers are beginning to recognize the importance of zinc coatings, especially in the body-in-white (BIW) stage of manufacturing. Some forward-thinking manufacturers are already prioritizing galvanized steel for better durability and international competitiveness. With India producing over 4.7 million cars and SUVs in 2023-24, embracing zinc galvanization isn’t just about meeting global standards, it’s about safeguarding the investments of millions of consumers.
As car buyers, Indians are more informed and discerning than ever. However, the onus also lies on consumers to demand better standards. Asking a simple question, “Is this car galvanized?” can make a world of difference. Such awareness will push car manufacturers to prioritize corrosion resistance and durability as much as they do aesthetics and features.
The true mark of a premium car isn’t just its technology or design, it’s its ability to perform durably. Durability is the bridge between aspiration and value, and it’s time the Indian auto industry and its consumers crossed it together.
Kenneth M. de Souza is Technical Consultant at the International Zinc Association. Authors' views are personal.