I had this problem too - and after some discussion on another thread we discovered the cause. The server was set to offer GZipped versions of ALL files - which can dramtically reduce server download bandwidth The receiving browser is supposed to transparently un-GZip the file and return it to its original format However when using older versions of Internet Explorer a downloaded ZIPfile remains GZipped - which baffles most UNZIP utilities. Downloading using Chrome or Firefox should work OK - the file is saved as a plain ZIP file as expected. Apparently this was a known issue with IE6, IE7 and IE8 - but was never fixed. Supposed to be fixed in IE9 and newer Documented by MS as a fast published "emerging issues" article (2009/2010) - but no fix was ever implemented. http://support.microsoft.com/kb/2002350 The two offered resolutions are basically: Option 1 - Disable HTTP (GZIP) compression for .ZIP files on the web server. Option 2 - Change the MIME type for .ZIP files on the web server from application/x-zip-compressed to application/octet-stream. Also discussed here: http://serverfault.com/questions/77740/corrupt-zip-file-when-downloaded-from-apache-with-internet-explorer GZipping compressed files - such as ZIP files - is generally a waste of CPU time, for no significant reduction of filesize.