by Kenneth M. de Souza, Technical Consultant at the International Zinc Association
As India’s urban infrastructure expands at an unprecedented pace, the nation faces a parallel rise in fire hazards. Residential high-rise buildings, industrial complexes and commercial hubs are increasingly vulnerable due to recurring heat waves, erratic weather conditions, inadequate fire safety measures and regulatory loopholes. Fire incidents in India have surged significantly, often aggravated by neglected safety norms. Among the many risk factors, one silent yet devastating threat that stands out is rust in fire safety sprinkler pipe. To combat this challenge, zinc galvanization is emerging as a definitive solution for safeguarding lives and critical building infrastructure.
Zinc galvanization is proving to be a game-changer in fire safety equipment. Rust severely compromises fire suppression systems, involving water-based sprinklers, fire extinguishers and pipelines. While rust-related failures in piping and HVAC (Heating, ventilation and air conditioning) systems are widely acknowledged, their impact on fire extinguishers is often underestimated. Fire extinguishers are particularly vulnerable to rust, especially in valve assemblies, cylinder bottoms and hose fittings. These components are constantly exposed to moisture and humidity. A National Fire Protection Association (NFPA) report found that nearly one-third of fire extinguishers in Indian buildings are non-functional due to rust and poor maintenance. With zinc galvanization, these live-saving devices can be protected from rust-related failures.
Rust buildup leads to weakened components, clogging, leakage and eventual system failure, particularly under high-pressure scenarios when these systems are needed the most. Even more concerning is the thermite reaction, a highly exothermic process that occurs when rusted fire-retardant and HVAC pipes come into contact with aluminium and oxygen during a fire, further intensifying the hazard.
Zinc galvanization provides a durable, corrosion-resistant barrier that extends the lifespan of fire safety systems while ensuring their reliability in emergencies. Through hot-dip galvanization, iron or steel is coated with a protective layer of zinc by immersion in molten zinc at approximately 450°C. This process prevents rust formation in fire safety equipment, protecting pipes, extinguishers and sprinkler systems from deterioration. The metallurgically bonded zinc layer enhances structural strength, preventing cracks, ruptures and clogging in critical fire suppression pipelines. Unlike paint coatings, which tend to chip and degrade under extreme heat, galvanized iron remains intact, ensuring long-term system reliability. Galvanized Iron (GI) pipes last for decades with minimal maintenance, reducing long-term costs and system failures.
In a landmark move, the fire department of Maharashtra has mandated the use of galvanized iron (GI) pipes in the pipework connecting to the water motor. Fire departments of other states, particularly industrialised ones like Gujarat, need to emulate this best practice. This strategic move underpins the importance of zinc in the fire safety equipment, however, leaves significant gaps in safety protocols. A more comprehensive national policy is urgently needed to enforce standardized fire safety guidelines across industries. A proactive approach to galvanization can prevent catastrophic losses, protect lives and ensure that India’s infrastructure remains resilient against both fire hazards and rust.
To elevate India’s fire safety standards to global benchmarks, a paradigm shift is needed. Galvanization must be institutionalized as a foundational standard in fire protection. Policymakers, infrastructure developers, facility managers and safety regulators must enforce stringent fire safety regulations mandating the use of galvanized iron (GI) pipes in all fire protection infrastructure. The urgency is reinforced by the alarming rise in fire hazards. According to the Delhi Fire Services, Delhi has witnessed a 32% rise in fire-related calls in 2024. Nationally, over 25,000 people die annually in fire-related incidents with women accounting for 66% of fatalities. These numbers underscore the dire need for immediate and systemic intervention.
Fire-related incidents claim thousands of lives and result in significant financial losses each year. The most effective safeguard against rust-induced failures is zinc galvanization which is an industry best practice that must be recognized as a fundamental necessity for fire safety. Integrating galvanized iron (GI) pipes into fire protection systems will reinforce India’s defences against rust-related malfunctions, ensuring that fire safety infrastructure remains resilient, reliable and long-lasting. By prioritizing galvanization, the nation can move toward a future where fire safety is not undermined by neglect but reinforced through innovation, stringent standards and proactive responsibility.
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