Chapter 1.

7
Coating Galvanized Steel
Richard W. Drisko

Introduction in ounces of zinc metal/ft.2 Typically, electrogalvanizing

Galvanizing is merely a coat of zinc metal. It
has been used for more than 150 years to protect steel
from corrosion. Typical examples of galvanized
structures are highway guard rails and antenna
towers. The thickness of the zinc layer and the prevail-
ing weather influence the period of corrosion protec-
tion galvanizing provides.
The zinc can be applied to steel by hot dip-
ping, electrodeposition, thermal spraying, sheradizing
(tumbling cleaned steel items such as fasteners with
powdered zinc), application of zinc-rich coatings, and
other methods. Hot dipping cleaned steel into molten
zinc has the unique feature of forming a metallurgical
bond between the zinc and the steel. A typical hot dip
galvanizing consists of three zinc-iron alloy layers plus
the surface layer of metallic zinc.
More recently, galvanizing has been coated
with conventional organic coatings, a duplex system,
to enhance its appearance and to extend the period of
corrosion control.1 Tall galvanized structures, such as
towers and tanks, may require alternating bands of
orange and white to meet Federal Aviation Agency
(FAA) criteria for visibility. This chapter describes
currently used methods of preparing galvanized steel
surfaces for coating and applying protective coatings
to them.
Mechanisms of Protecting Steel by
Galvanizing
There are two basic mechanisms of protecting
steel by galvanizing: barrier and galvanic protection.
Barrier protection by the impermeable zinc coating
isolates the underlying steel from the electrolytes that
are necessary for corrosion to occur. In galvanic
protection (a type of cathodic protection), the more
chemically active zinc sacrifices itself by preferential
corrosion to protect the steel. It converts all the anodes
on the exposed steel to cathodes.
The length of protection time zinc coatings
provide is directly proportional to the weight of the
zinc.2 The weight of galvanizing is generally specified
has less than 0.3 oz./ft.2 of metal substrate (equivalent
to 0.5 mil; 13 micrometers dry film thickness), while hot
dip galvanizing has a minimum of 2 oz./ft.2 (3.4 mils;
27.4 micrometers). Hot dip galvanizing on structural
steel typically has a weight of 2.1 to 2.9 oz./ft.2 (3.5 to
5.0 mils; 89 to 127 microns dry film thickness) of zinc.
One half of this thickness is zinc metal and the other
half is zinc-iron alloy layers.
Figure 1. Galvanizing layers.
Hot Dipping
Steel surface preparation is the most impor-
tant component of successful galvanizing. The vast
majority of galvanizing failures are associated with
inadequate or improper surface preparation. The
typical three-step process for cleaning and treating the
surface of uncoated steel for hot dipping consist of:
• Caustic Cleaning. Uncoated steel is dipped into a
solution of hot alkali to remove grease, oil, and dirt.
(Coated steel must be abrasive blasted to remove the
coatings. Abrasive blasting cleans the steel surface so
that it does not require alkali cleaning or acid pickling
before fluxing.)
• Acid Pickling. After rinsing the alkali-cleaned steel, it
is dipped into a dilute solution of hot sulfuric acid or an
ambient temperature solution of hydrochloric acid.
• Fluxing. After rinsing pickled steel, it is ready for
fluxing to remove any remaining oxides, prevent their
formation prior to hot dipping, and enhance adhesion nizing process can be found in various AGA publica-
of the zinc. In the dry galvanizing process, the cleaned tions from which information was taken for the descrip-
steel is dipped into an aqueous solution of zinc ammo- tion of galvanizing in this chapter.7
nium chloride and then thoroughly dried before immer-
sion in the molten zinc. In the wet galvanizing process,
a blanket of molten zinc ammonium chloride is used
for fluxing.
During the actual hot dipping, the cleaned
metal is completely immersed in 98% pure molten zinc
metal maintained at a temperature of 850oF (450oC).
The requirements for the purity of the zinc metal are
found in ASTM A 123.3
Articles too long for complete immersion in the
molten zinc can be double-end dipped to provide a
continuous zinc coating. Also, special facilities are
available for continuous galvanizing of sheet metal
rolls and wire. Cables consisting of stranded galva-
nized wires are used extensively for guy lines and
other industrial purposes.

Inspecting Galvanizing and Repairing

Defects

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
inclusions, etc.
• Dry Film Thickness. Using gauges and methods
described in SSPC-PA 24
• Adhesion. Using the equipment and methods
described in ASTM A 123 and ASTM A 1533, 5
Touch-Up of Repairable Galvanizing
Defects may arise in the hot dipping process
or in later shipment and handling. ASTM A 123 defines
the amount of bare spots and other imperfections on
galvanizing that can be repaired by touch-up to
achieve an acceptable condition.3 Methods of defect
repair include:
• Metallizing with zinc.
• Zinc-rich organic coatings. Described in SSPC-Guide
14.6
• Soldering with zinc-based alloys. Zinc-based alloys
in stick or powder form are applied to the defect area
preheated to about 650oF (315oC).
Additional information concerning the “galva-
Figure 2. Galvanizing bath.
Surface Treatment for Storage
While galvanizing may provide many years of
protection to steel in open atmospheric service, wet
storage staining may occur on galvanized articles
(e.g., a stack of galvanized steel siding) stored in a
damp exterior exposure where there is limited air
circulation. This condition is caused by the accelerated
(crevice) corrosion of the zinc to form white oxidation
products, mostly zinc hydroxide. Galvanizers may
provide protection from wet storage stain by applying a
thin film of oil to the galvanizing or by formation of a
chromate conversion coating. Both treatments must be
addressed before a coating is applied. Thus, purchas-
ers of galvanized steel to be coated should specify that
these surface treatments not be given to their
products.
Oil Coating. The presence of oil contamination can be
detected using the water-break test.8 A mist of water is
sprayed on the surface of the galvanizing. If the water

58
gathers in lens that last about 25 seconds before they
flow out (break), the surface is clean. If the water
gathers up into droplets, the surface is contaminated.
A coating or trace contamination of oil can be
removed by solvent cleaning (SSPC-SP 1).9 This
specification includes cleaning with mineral spirits and
high-flash naptha or with an alkaline solution of pH 11
to 12.
Chromate Conversion Coating. The presence of a zinc
conversion coating on galvanizing can be detected by
spot testing according to ASTM B 201.11 If detected, it
can be removed by light sanding or sweep blasting or
by allowing the galvanizing to weather for six months.
Figure 3. Rusting and streaking through galvanizing.
Removing Wet Storage Stain
Wet storage stain must be removed from
galvanizing before it is coated. Light brushing of the
stain using a soft bristle brush and a mild ammonia
solution will usually remove light or mild staining. For
more severe cases, more vigorous brushing with weak
acids such as acetic or citric acid at pH 3.5 to 4.5 may
be necessary. Strong mineral acids should not be
used, because they will rapidly attack the zinc.
The Changing Surface Composition of
Galvanized Surfaces
The surface of zinc begins to change immedi-
ately after galvanizing by corrosion to form a passive
zinc oxide layer. In the presence of moisture, the oxide
layer is converted into zinc hydroxide. This layer, in
turn, slowly reacts with carbon dioxide in the air to
form a stable, tightly-bonded layer of zinc carbonate.
The recommended surface treatment of galvanizing for
59
coating varies with its age and thus surface chemical
composition.11-12
Treating New and Partially Weathered
Galvanizing for Coating
Prior to surface treatment of new and partially
weathered galvanizing for coating, any surface irregu-
larities (rough edges, high spots, etc.) are usually
removed by hand or power tool cleaning to permit a
more uniform, continuous coating application.13-14
However, too smooth a surface may result in limited
coating adhesion.
Surface treatment and coating application is
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.
Mechanical Treatments to Prepare Galvanized
Surfaces for Coating
• Hand and Power Tool Cleaning. Hand and power
tool cleaning can be used to remove light surface
contaminants. However, it does not produce a surface
profile to enhance adhesion of coatings.
• Sweep Blasting. Sweep blasting is defined as a fast
pass of the abrasive blasting pattern over a surface to
remove loose material and to roughen the surface
sufficiently to successfully accept a coat of paint.15 This
can be used effectively on galvanizing if the abrasive
and the blasting conditions are selected to avoid
excessive loss of zinc metal. These are described
more fully in ASTM D 6386.11
Chemical Treatments
There are three basic treatments for preparing
clean galvanized surfaces for coating by controlling
corrosion of the zinc surface and providing a substrate
that will result in better coating adhesion. Old remedies
such as washing with vinegar should be avoided.
• Zinc Phosphate Conversion Treatment. A zinc
phosphate conversion coating can be obtained by
reacting new galvanizing with an acidic zinc phosphate
solution containing an oxidizing agent and accelera-
tors. Brush, spray, or immersion application can be
used successfully. After application, a period of 3 to 6
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
corrosion products and etches the surface to promote
adhesion. It is best applied by spraying, because it is
more difficult control film thickness when brush, dip, or
roller coating. There are several concerns about the
use of wash primers. These include:
–Criticality of the coating film
thickness. The dry film thickness
should be between 0.3 and 0.5 mils (8
and 13 micrometers). If less, the
protection may be significantly re-
duced; if more, cohesive failure may
occur.
–Presence of toxic chromate
pigment.
–High VOC content.
Surface Treatment of Fully Weathered
Galvanizing
Fully weathered galvanizing has a stable
surface texture suitable for coating. Complete weather-
ing may require only six months in a severe marine
atmospheric environment, or up to two years in a mild
environment. Fully weathered galvanizing requires
only that the surface be cleaned of loose contaminants
before coating. Some applicators prefer power wash-
ing with warm water at a pressure less than 1450 psi
(10 MPa) to avoid damage to the zinc carbonate
protective film. Others feel that sweep blasting is more
convenient and that the loss of zinc is minimal.
Old uncoated galvanizing may have pinpoint
rusting and rust streaking. The exposed rust should be
removed from the steel by hand or power tool cleaning
and the rust streaking removed by power washing.
If uniform corrosion of the zinc occurs, a
reddish-brown layer of zinc-iron alloy may be exposed.
This indicates that all of the pure zinc has been lost,
and coating for additional protection is appropriate.
60
Figure 4. Exposure racks in Bermuda with coated
galvanized steel test panels.
Coating Systems for Galvanizing
Two generic coating systems were shown in
long-term exposure studies to perform well in severe
marine atmospheric environments. Obviously, they will
protect steel even longer in milder atmospheric
environments.16
Epoxy Primer with Ultraviolet-Resistant Finish
Coats
A system of one coat each of epoxy polya-
mide primer and aliphatic polyurethane performed well
for more than 5 years in two different marine atmo-
spheric environments (Bermuda and Cape Canaveral,
Florida). The aliphatic polyurethane provided excellent
resistance to ultraviolet light.
An alternative system using an acrylic latex
finish coat rather one of aliphatic polyurethane also
performed well. Application of a tightly bonded acrylic
finish coat, however, was more difficult than with the
polyurethane finish.
Acrylic Latex System
Two coats of an acrylic latex also performed
well in the above study, but not quite as well as the
epoxy primer systems. This system had the advan-
tages of being easier to apply and touch-up.
Other Coating Systems
Alkyd and Other Drying Oil Systems. At one time,
standard alkyd systems, including those containing
zinc dust/zinc oxide pigmentation (e.g., TT-P-641),
were used extensively on galvanizing. These systems
failed relatively quickly because the naturally occurring
alkalinity on the zinc surface saponified (hydrolyzed)
the drying oils in the coatings. Pretreatment with wash
primer did increase performance slightly but not to the
levels of the two systems previously described.
Lacquers. Vinyl, acrylic, and chlorinated rubber
lacquer coatings have been successfully used on
galvanizing in the past. However, because of their high
contents of volatile organic compounds (VOCs), they
are seldom used today.
Bituminous (Coal Tar and Asphalt). Bituminous (coat
tar and asphalt) coatings are not recommended for
exterior service because they become embrittled by
the sun’s ultraviolet light. They are, however, quite
suitable for burial service.
Maintenance of Coatings on Galvanizing
As far as possible, coatings applied to galva-
nized structures should receive periodic maintenance,
so that the underlying zinc remains protected:
• If only chalking or soiling occurs on the organic
coating, it can readily be cleaned by detergent wash-
ing and coated with a compatible (usually the same)
finish coating. It is usually not necessary to sweep
blast the weathered coating for good topcoat adhe-
sion. A coat of acrylic latex can be used to restore the
appearance of a weathered coating to an acceptable
condition.
• If the organic coating peels, the loose coating must
be removed before repairs can be made. Careful
sweep blasting can usually accomplish this without too
much loss of zinc. The maintenance coating must be
compatible with the existing finish coat and any
exposed zinc.
• If corrosion of the galvanizing has exposed rusted
steel, the rust must be removed by hand or power tool
cleaning or by localized abrasive blasting. Again, the
maintenance coating must be compatible with all
exposed substrates.
References
1. Eijnsbergen, J.F.H. Duplex Systems—Hot-Dip
Galvanizing Plus Painting; Elsevier Science:
Amsterdam, 1994.
2. Brevort, Gordon H. Inorganic Zinc-Rich Coatings vs.
Galvanizing. Modern Steel Construction, December
1995.
3. ASTM A 123. Zinc (Hot-Dip) Coatings of Iron and
Steel Products; ASTM: West Conshohocken, PA.
61
4. SSPC-PA 2. Measurement of Dry Coating Thick-
ness With Magnetic Gages; SSPC: Pittsburgh, 1996.
5. ASTM 153. Zinc Coating (Hot Dip) on Iron and Steel
Hardware; ASTM: West Conshohocken, PA.
6. SSPC-Guide 14. Guide for Repair of Imperfections
in Galvanized or Inorganic Zinc-Coated Steel Using
Organic Zinc-Rich Coatings; SSPC: Pittsburgh, 1999.
7. American Galvanizers Association, 6881 South
Holly Circle, Suite 108, Englewood, Colorado, 80112.
8. The Inspection of Coatings and Linings; Bernard R.
Appleman, ed.; SSPC: Pittsburgh, 1997, p 380.
9. SSPC-SP 1. Solvent Cleaning; SSPC: Pittsburgh,
2000.
10. ASTM B 201. Practice for Testing Chromate
Coatings on Zinc and Cadmium Surfaces; ASTM:
West Conshohocken, PA.
11. ASTM D 6386. Standard Practice for Preparation
of Zinc (Hot-Dip Galvanized) Coated Iron and Steel
Products and Hardware Surfaces for Painting; ASTM:
West Conshohocken, PA.
12. Smith, Lloyd M. Cleaning and Painting Galvanized
Steel. Journal of Protective Coatings and Linings, April
2001, pp 51-55.
13. SSPC-SP 2. Hand Tool Cleaning; SSPC:
Pittsburgh, 2000.
14. SSPC-SP 3. Power Tool Cleaning; SSPC:
Pittsburgh, 2000.
15. Protective Coating Glossary; Drisko, Richard W.
ed., SSPC: Pittsburgh, 2000.
16. Drisko, Richard W. Research News: A Five-Year
Study Of Environmentally Acceptable Coatings for
Galvanized Steel. Journal of Protective Coatings and
Linings, September 1995.
About the Author
Dr. Richard W. Drisko
Dr. Richard W. Drisko has been the senior technical
advisor to SSPC: The Society for Protective Coatings
since January 1995. Prior to this, he was employed for
over 40 years at the Naval Civil Engineering Labora-
tory, Port Hueneme, California, where he conducted
research, evaluation, and testing, and served as the
Navy’s center of expertise on coatings for shore
structures. He is a professional corrosion engineer in
the state of California, an SSPC certified protective
coatings specialist (PCS), and a NACE International
certificated corrosion specialist. Dr. Drisko received his
BS, MS, and PhD degrees from Stanford.