The two methods differ in their principles. Electro-galvanizing applies a zinc coating to the steel surface using an electrochemical method, while hot-dip galvanizing involves immersing the steel in molten zinc to create the zinc coating.

The two methods also differ in appearance. Electro-galvanized steel has a smoother surface, while hot-dip galvanized steel has a rougher surface. Electro-galvanized coatings are typically 5 to 30 μm thick, while hot-dip galvanized coatings are typically 30 to 60 μm thick.

The applications also differ. Hot-dip galvanizing is often used for outdoor steel structures such as highway fences, while electro-galvanizing is more commonly used for indoor steel structures such as panels.

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