CH 01.07 Galvin Steel
CH 01.07 Galvin Steel
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Coating Galvanized Steel
Richard W. Drisko
Inspection
After the hot dipping process, the coated items
are inspected to determine whether they meet all
industry standards:
• Visual. Bare spots, runs, surface irregularities, flux Figure 2. Galvanizing bath.
inclusions, etc.
• Dry Film Thickness. Using gauges and methods Surface Treatment for Storage
described in SSPC-PA 24 While galvanizing may provide many years of
• Adhesion. Using the equipment and methods protection to steel in open atmospheric service, wet
described in ASTM A 123 and ASTM A 1533, 5 storage staining may occur on galvanized articles
(e.g., a stack of galvanized steel siding) stored in a
Touch-Up of Repairable Galvanizing damp exterior exposure where there is limited air
Defects may arise in the hot dipping process circulation. This condition is caused by the accelerated
or in later shipment and handling. ASTM A 123 defines (crevice) corrosion of the zinc to form white oxidation
the amount of bare spots and other imperfections on products, mostly zinc hydroxide. Galvanizers may
galvanizing that can be repaired by touch-up to provide protection from wet storage stain by applying a
achieve an acceptable condition.3 Methods of defect thin film of oil to the galvanizing or by formation of a
repair include: chromate conversion coating. Both treatments must be
• Metallizing with zinc. addressed before a coating is applied. Thus, purchas-
• Zinc-rich organic coatings. Described in SSPC-Guide ers of galvanized steel to be coated should specify that
14.6 these surface treatments not be given to their
• Soldering with zinc-based alloys. Zinc-based alloys products.
in stick or powder form are applied to the defect area
preheated to about 650oF (315oC). Oil Coating. The presence of oil contamination can be
detected using the water-break test.8 A mist of water is
Additional information concerning the “galva- sprayed on the surface of the galvanizing. If the water
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gathers in lens that last about 25 seconds before they coating varies with its age and thus surface chemical
flow out (break), the surface is clean. If the water composition.11-12
gathers up into droplets, the surface is contaminated.
A coating or trace contamination of oil can be Treating New and Partially Weathered
removed by solvent cleaning (SSPC-SP 1).9 This Galvanizing for Coating
specification includes cleaning with mineral spirits and Prior to surface treatment of new and partially
high-flash naptha or with an alkaline solution of pH 11 weathered galvanizing for coating, any surface irregu-
to 12. larities (rough edges, high spots, etc.) are usually
removed by hand or power tool cleaning to permit a
Chromate Conversion Coating. The presence of a zinc more uniform, continuous coating application.13-14
conversion coating on galvanizing can be detected by However, too smooth a surface may result in limited
spot testing according to ASTM B 201.11 If detected, it coating adhesion.
can be removed by light sanding or sweep blasting or Surface treatment and coating application is
by allowing the galvanizing to weather for six months. best done in a shop under controlled conditions. Some
paint shops merely clean the surfaces of new galvaniz-
ing prior to coating. Other applicators feel that one or
more of the treatments described here is necessary to
achieve good coating adhesion and performance.
Applicators routinely coating galvanized steel should
determine the procedure that is best.
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minutes should be allowed before rinsing. Some shops
routinely use commercial phosphate treatment prod-
ucts on galvanizing before coating.
• Acrylic Passivation Treatment. Acrylic passivation
is accomplished by treating the cleaned surfaces with
an acidic acrylic solution. The 0.04 mil (1 µm) coating
provides passivation to the zinc and promotes coating
adhesion.
• Wash Primers. Polyvinyl butyral wash primers such
as SSPC-Paint 27 have been used as pretreatment for
galvanizing before coating for many years. The acid in
the wash primer neutralizes the alkalinity in the zinc Figure 4. Exposure racks in Bermuda with coated
corrosion products and etches the surface to promote galvanized steel test panels.
adhesion. It is best applied by spraying, because it is
more difficult control film thickness when brush, dip, or Coating Systems for Galvanizing
roller coating. There are several concerns about the Two generic coating systems were shown in
use of wash primers. These include: long-term exposure studies to perform well in severe
–Criticality of the coating film marine atmospheric environments. Obviously, they will
thickness. The dry film thickness protect steel even longer in milder atmospheric
should be between 0.3 and 0.5 mils (8 environments.16
and 13 micrometers). If less, the
protection may be significantly re- Epoxy Primer with Ultraviolet-Resistant Finish
duced; if more, cohesive failure may Coats
occur. A system of one coat each of epoxy polya-
–Presence of toxic chromate mide primer and aliphatic polyurethane performed well
pigment. for more than 5 years in two different marine atmo-
–High VOC content. spheric environments (Bermuda and Cape Canaveral,
Florida). The aliphatic polyurethane provided excellent
Surface Treatment of Fully Weathered resistance to ultraviolet light.
Galvanizing An alternative system using an acrylic latex
Fully weathered galvanizing has a stable finish coat rather one of aliphatic polyurethane also
surface texture suitable for coating. Complete weather- performed well. Application of a tightly bonded acrylic
ing may require only six months in a severe marine finish coat, however, was more difficult than with the
atmospheric environment, or up to two years in a mild polyurethane finish.
environment. Fully weathered galvanizing requires
only that the surface be cleaned of loose contaminants Acrylic Latex System
before coating. Some applicators prefer power wash- Two coats of an acrylic latex also performed
ing with warm water at a pressure less than 1450 psi well in the above study, but not quite as well as the
(10 MPa) to avoid damage to the zinc carbonate epoxy primer systems. This system had the advan-
protective film. Others feel that sweep blasting is more tages of being easier to apply and touch-up.
convenient and that the loss of zinc is minimal.
Old uncoated galvanizing may have pinpoint Other Coating Systems
rusting and rust streaking. The exposed rust should be
removed from the steel by hand or power tool cleaning Alkyd and Other Drying Oil Systems. At one time,
and the rust streaking removed by power washing. standard alkyd systems, including those containing
If uniform corrosion of the zinc occurs, a zinc dust/zinc oxide pigmentation (e.g., TT-P-641),
reddish-brown layer of zinc-iron alloy may be exposed. were used extensively on galvanizing. These systems
This indicates that all of the pure zinc has been lost, failed relatively quickly because the naturally occurring
and coating for additional protection is appropriate. alkalinity on the zinc surface saponified (hydrolyzed)
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the drying oils in the coatings. Pretreatment with wash 4. SSPC-PA 2. Measurement of Dry Coating Thick-
primer did increase performance slightly but not to the ness With Magnetic Gages; SSPC: Pittsburgh, 1996.
levels of the two systems previously described. 5. ASTM 153. Zinc Coating (Hot Dip) on Iron and Steel
Hardware; ASTM: West Conshohocken, PA.
Lacquers. Vinyl, acrylic, and chlorinated rubber 6. SSPC-Guide 14. Guide for Repair of Imperfections
lacquer coatings have been successfully used on in Galvanized or Inorganic Zinc-Coated Steel Using
galvanizing in the past. However, because of their high Organic Zinc-Rich Coatings; SSPC: Pittsburgh, 1999.
contents of volatile organic compounds (VOCs), they 7. American Galvanizers Association, 6881 South
are seldom used today. Holly Circle, Suite 108, Englewood, Colorado, 80112.
8. The Inspection of Coatings and Linings; Bernard R.
Bituminous (Coal Tar and Asphalt). Bituminous (coat Appleman, ed.; SSPC: Pittsburgh, 1997, p 380.
tar and asphalt) coatings are not recommended for 9. SSPC-SP 1. Solvent Cleaning; SSPC: Pittsburgh,
exterior service because they become embrittled by 2000.
the sun’s ultraviolet light. They are, however, quite 10. ASTM B 201. Practice for Testing Chromate
suitable for burial service. Coatings on Zinc and Cadmium Surfaces; ASTM:
West Conshohocken, PA.
Maintenance of Coatings on Galvanizing 11. ASTM D 6386. Standard Practice for Preparation
As far as possible, coatings applied to galva- of Zinc (Hot-Dip Galvanized) Coated Iron and Steel
nized structures should receive periodic maintenance, Products and Hardware Surfaces for Painting; ASTM:
so that the underlying zinc remains protected: West Conshohocken, PA.
• If only chalking or soiling occurs on the organic 12. Smith, Lloyd M. Cleaning and Painting Galvanized
coating, it can readily be cleaned by detergent wash- Steel. Journal of Protective Coatings and Linings, April
ing and coated with a compatible (usually the same) 2001, pp 51-55.
finish coating. It is usually not necessary to sweep 13. SSPC-SP 2. Hand Tool Cleaning; SSPC:
blast the weathered coating for good topcoat adhe- Pittsburgh, 2000.
sion. A coat of acrylic latex can be used to restore the 14. SSPC-SP 3. Power Tool Cleaning; SSPC:
appearance of a weathered coating to an acceptable Pittsburgh, 2000.
condition. 15. Protective Coating Glossary; Drisko, Richard W.
• If the organic coating peels, the loose coating must ed., SSPC: Pittsburgh, 2000.
be removed before repairs can be made. Careful 16. Drisko, Richard W. Research News: A Five-Year
sweep blasting can usually accomplish this without too Study Of Environmentally Acceptable Coatings for
much loss of zinc. The maintenance coating must be Galvanized Steel. Journal of Protective Coatings and
compatible with the existing finish coat and any Linings, September 1995.
exposed zinc.
• If corrosion of the galvanizing has exposed rusted About the Author
steel, the rust must be removed by hand or power tool
cleaning or by localized abrasive blasting. Again, the Dr. Richard W. Drisko
maintenance coating must be compatible with all Dr. Richard W. Drisko has been the senior technical
exposed substrates. advisor to SSPC: The Society for Protective Coatings
since January 1995. Prior to this, he was employed for
References over 40 years at the Naval Civil Engineering Labora-
1. Eijnsbergen, J.F.H. Duplex Systems—Hot-Dip tory, Port Hueneme, California, where he conducted
Galvanizing Plus Painting; Elsevier Science: research, evaluation, and testing, and served as the
Amsterdam, 1994. Navy’s center of expertise on coatings for shore
2. Brevort, Gordon H. Inorganic Zinc-Rich Coatings vs. structures. He is a professional corrosion engineer in
Galvanizing. Modern Steel Construction, December the state of California, an SSPC certified protective
1995. coatings specialist (PCS), and a NACE International
3. ASTM A 123. Zinc (Hot-Dip) Coatings of Iron and certificated corrosion specialist. Dr. Drisko received his
Steel Products; ASTM: West Conshohocken, PA. BS, MS, and PhD degrees from Stanford.
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