Nomura Research Institute estimates ₹49,580 crore annual savings from galvanised steel in infrastructure

The use of galvanised steel in infrastructure projects could save India up to ₹49,580 crore annually, according to a study by Nomura Research Institute (NRI) Consulting & Solutions India. The research estimates that corrosion currently costs India’s infrastructure sector about ₹1.42 lakh crore every year, which is equivalent to 2.9 per cent of the sector’s GDP.

According to NRI, applying a zinc coating to structural steel, reinforcement, and other exposed steel components offers a longer service life and lower lifecycle costs compared to alternative materials. The report points out that conventional TMT reinforcement typically provides a durability of 40 to 50 years, depending on environmental conditions. In contrast, galvanised TMT carries a higher upfront cost but is estimated by NRI to deliver a service life exceeding 100 years—even in high-chloride marine environments—alongside a lower annualised lifecycle cost.

Similarly, while conventional multi-coat paint systems for structural steel generally have a coating life of 10 to 25 years and require regular repainting, hot-dip galvanising can provide durability beyond 100 years under suitable conditions. This approach yields better lifecycle economics, particularly in high-moisture settings.

The study highlights significant expansion in India's infrastructure over the decade between 2015 and 2025. The national highway network has expanded to approximately 1.46 lakh km, airports have increased from 74 to 157, port capacity has doubled from about 800 MTPA to 1,600 MTPA, and roughly 25,871 km of new railway tracks have been added.

Despite this growth, the report warns that inadequate material selection and poor adherence to inspection and maintenance schedules can weaken structural integrity and shorten the useful life of assets. Citing the example of Mumbai, where more than 2,000 buildings were under redevelopment in 2025, NRI noted the broader challenge of maintaining ageing urban assets.

To address these concerns, NRI has called for stronger corrosion-protection requirements, particularly in coastal and high-humidity regions. The institute referenced countries like the US and Japan, where protection requirements are linked more closely to specific exposure conditions.

Rahul Sharma, Director – India at the International Zinc Association, noted that galvanisation helps reduce recurring maintenance requirements and extend asset life in corrosion-prone environments. He added that for long-life infrastructure, lifecycle performance should increasingly become as important a consideration as the initial upfront cost.

As infrastructure spending continues to rise, NRI concludes that there is a growing case for procurement standards that move beyond initial construction expenses to account for maintenance, durability, and the full lifecycle cost of an asset.

"This study offers critical economic perspective for heavy industries and infrastructure planners. When building large-scale assets, focusing solely on initial material expenses can lead to significant long-term maintenance liabilities. Factoring in lifecycle costs and utilizing durable materials like galvanised steel not only protects public investments but also opens up sustainable business opportunities for material manufacturers and construction startups focusing on asset longevity." — Dr. Shishir Gupta, Founder & CEO, StartupLanes