Preparation of galvanized steel before painting

Guidelines for the pretreatment of galvanized surfaces have been drawn up as a

result of (i) a study carried out by an independent research centre and a leading
UK paint manufacturer into the performance of commercially available pre-
treatment and paint systems and the parameters affecting their performance on
hot dip galvanized coatings, and (ii) many years experience with duplex coatings.

Although pretreatment of galvanized components is best carried out immediately

after galvanizing, before the surface has become contaminated in any way, this
is not always practical. Pre-treatment can be carried out later but it is vital that
the surface is adequately cleaned to remove all traces of contaminants such as
oil, grease and dirt. The cleaning operation must leave no residues on the
cleaned surface and any wet storage staining should be removed using a stiff
brush. Washing down the coating with water will help to remove soluble salts.

There are four recognised methods of surface pretreatment that produce a sound
substrate for paint coating:
1. T-Wash (or its proprietary equivalent) and when to paint galvanized steel
Despite the fact that this preparation process has been available for some
considerable time, T-Wash is still generally considered to be the best
pretreatment method for painting galvanized steel.

T-Wash is a modified zinc phosphate solution which contains a small amount of

copper salts. When applied, a dark grey or black discolouration of the zinc
surface will result.

T-Wash must not be allowed to pool on horizontal surfaces or this will prevent
maximum paint adhesion. Any excess should be removed by water.
How long to leave the T-wash on galvanised steel for

T-wash is most suitable for application to new galvanizing and should not be
used on weathered galvanizing (see etch primers below). Sufficient time must be
allowed for the T-Wash to react and dry thoroughly before the first coat of paint is
applied. (Suppliers’ information will give recommended time intervals).

While research has shown that T-Washed surfaces can be left for up to 30 days
before painting and good paint adhesion can still result, it is advisable to
minimise the time between pre-treatment and paint application. Any white salt
formed by the exposure of the T-Washed surface to moisture must be removed
before painting, using a stiff brush. If the T-Washed surface has become
contaminated it must be cleaned in accordance with the suppliers’
recommendations.
Constituents of T-Wash

The constituents of T-Wash are phosphoric acid (9.0%), ethyl cellusolve (16.5%),
methylated spirit (16.5%), water (57.0%) and copper carbonate (1.0%).
Variations to this composition may exist and so it is wise to consult the supplier if
a successful result is to be achieved.
2. Etch primers
Etch primers have also been used successfully. Their major disadvantage is the
absence of any visible colour change as is the case with T-Wash. Therefore,
there can never be complete confidence that all surfaces have reacted with the
primer. Etch primers are most suited to application on older, weathered
galvanizing.
3. Sweep blasting
A mechanical method of pre-treatment is sweep blasting using fine copper slag, J
blast or carborundum powder with a blast pressure of no greater than 40psi (2.7
bar). This will ensure that only the minimum amount of oxide is removed and the
zinc surface is left in a slightly roughened condition. Care should be taken when
carrying out sweep blasting on very thick galvanized coatings to avoid damage to
the coating. The optimum nozzle-to-work piece distance and angle of blasting
needs to be identified for all surfaces on the galvanized steelwork if optimum
results are to be achieved. Angular iron blasting grit must not be used under any
circumstances. Sweep blasting is often used in addition to the chemical
preparation stage.
4. Weathering
This process only becomes fully effective after a galvanized surface has been
exposed to the atmosphere for a period of at least six months. The surface is
prepared using either abrasive pads or a stiff brush to remove all loose adherent
materials and making sure that the bright zinc surface is not restored.

This is followed by a hot detergent wash and rinsing with fresh clean water. The
surface must be fully dry before any paint is applied. Weathering should not be
used as a method of surface preparation in marine environments with high
chloride levels.

How to choose the paint for galvanised metal

All paint systems used should be specifically formulated for use on galvanized
steel and applied in accordance with the paint manufacturer’s recommendations.
What paint can you use on galvanized steel?

The choices of paint systems will depend upon both the application and service
environment. With the decline in the use of chlorinated rubber and alkyd paints,
high-build epoxy products and vinyl/vinyl co-polymer systems are increasingly
utilised with glass reinforced epoxy being an option for more severe
environments. In multi-coat systems the use of micaceous iron oxide (MIO)
primer has been shown to give improved adhesion.

Two-pack polyurethane and acrylic urethanes are commonly used as top coats
and offer good durability and colour retention. Alternatives include acrylic epoxies
and polysiloxanes, the latter offering increased abrasion resistance along with
good gloss and colour retention.

At present, high-build epoxies are widely used although water-based products,

including polyurethanes, are now being specified. They are less tolerant of poor
pre-treatment but their use could continue to grow as the Solvent Emissions
Directive becomes more stringent.

Preparing and Painting Galvanizing

Galvanizing is the application of a zinc layer to steel by a variety of methods such as hot dip,
continuous or electro-deposition. In many instances galvanized steel is not painted since the service
life of galvanizing alone typically exceeds that of conventional protective coatings. When paint is
applied to galvanizing it often is referred to as a “duplex system.” The service life of a duplex
coating system has been reported in studies to be a factor of 1.5 to 2.3 times the sum of the
individual service lives for bare galvanizing or painting alone.[i] However, the actual increase in
service life depends on the exposure environment; i.e., the duplex system in a mild exposure will
have a longer service life than in a more severe exposure.
To achieve the expected long service life, proper preparation of galvanizing is critical. New
galvanized steel has a smooth surface that inhibits coating adhesion. In addition, some post-
treatments (discussed below) that frequently follow the galvanizing process may adversely affect
coating performance.
Galvanizing Post Treatments
Galvanized steel is sometimes post treated or passivated to stop the reaction between the iron and
zinc or to slow the subsequent oxidation (i.e. exposure to weathering) of the zinc surface. The most
common post treatments are water quenching, chromate quenching and phosphating. In water
quenching, freshly galvanized steel is dipped into a water bath to help accelerate the cooling process
and stop the reaction between the iron and zinc. A consequence of water quenching is that the
water often becomes contaminated with oil or dirt that gets deposited on the zinc surface. These
contaminants can interfere with adhesion if they are not adequately removed prior to painting.
Chromate quenching is primarily used to prevent the formation of “white rust” or “wet storage stain”
from occurring when galvanized steel is closely packed during transportation or storage. White rust
refers to the zinc salts that naturally form on the galvanized surface as the zinc oxidizes during
atmospheric exposure. Wet storage stain is an accelerated form of oxidation that takes place when
higher concentrations of moisture and oxygen are trapped between pieces or sheets of galvanized
steel that are closely stacked. Although the chromate treatment can prevent this oxidation, it can
also interfere with adhesion if paint is later applied. Chromate treatment may be desired if painting
is not intended after galvanizing, as the treatment typically results in a more uniform appearance as
the zinc surface oxidizes and weathers. The “shiny” and “spangled” appearance of new galvanizing
typically becomes gray, duller and mottled with age.
Phosphating treatments on steel after galvanizing form a non-reactive zinc phosphate layer over the
zinc surface. In this process, the galvanized surfaces are first cleaned and degreased, and then
immersed in a phosphating solution. Phosphating prevents corrosion products from forming on the
surface and promotes adhesion with a subsequently applied paint layer.
Weathering of Galvanizing
Corrosion products (white zinc salts) start to form on a zinc surface as soon as it is exposed to the
environment. Generally, the initial zinc compounds that are formed are water soluble, porous and
loosely adhered to the surface. Over time, these compounds are converted to a tightly adherent
water insoluble film that serves to protect the zinc surface from further corrosion. Corrosion
products are formed from the zinc reacting with atmospheric oxygen, carbon dioxide and
water. The time to reach different weathering stages, however, varies greatly with the actual
environmental exposure conditions in a particular location. The following categorizations of zinc
“weathering” should be considered as average times.
Newly galvanized – less than 48 hours
No appreciable corrosion products are formed in the first 48 hours of galvanizing. Ideally, shop
coating of the galvanizing should occur during this time period, if planned.
Partially weathered – 48 hours to 2 years
Oxidation of the surface begins as soon as zinc galvanizing is applied to steel. These oxidative
products are relatively porous and loosely adhered to the steel surface during the early formation.
Initially, zinc oxides and hydroxides that are water soluble form on the galvanized surface. This
early corrosion product is sometimes referred to as white rust. As the zinc continues to weather,
the initial corrosion products are slowly converted to water insoluble compounds consisting mostly of
zinc carbonates.
Fully weathered – over 2 years
After an extended period, corrosion products are converted to a dense layer of zinc carbonates that
are tightly adhered to the steel surface. This oxidized layer helps to protect the zinc from further
corrosion.
If the application of a coating system is desired, the different stages of weathering dictate that
separate surface preparation procedures be followed, depending on the age of
galvanizing. Generally, painting galvanizing is divided into two categories– new galvanized and
existing galvanized surfaces. Preparation of galvanized surfaces for paint application is further
explored in a KTA University article by Kenneth Trimber titled, “Preparing Hot Dip Galvanizing for
Painting – It’s not Overly Complicated.”
Painting New Galvanizing
The preparation of new galvanizing for painting assumes that a minimal period (less than 48 hours)
has passed since galvanizing has occurred. However, the zinc surfaces may need additional
cleaning if the material has been in storage prior to painting.
Freshly galvanized steel must first be cleaned and degreased in accordance with the SSPC-SP 1,
Solvent Cleaning. This is particularly important if water quenching was used as a post treatment
and dirt and/or oil residues were deposited on the surfaces. Additionally, new galvanizing intended
for painting should not be chromate quenched. Any chromate compounds present on the
galvanized surface will cause adhesion problems for subsequently applied coatings. If a chromate
treatment was used, the surfaces must be thoroughly cleaned to remove the treatment and then
tested for chromate compounds to ensure removal. Ideally, specifications for galvanized steel
should not allow chromate treatment and instead should specify a phosphating post treatment. As
previously described, phosphating produces a surface conducive to subsequently applied
coatings. The phosphating passivates the zinc surface and produces a conversion coating layer that
is ideal for the application of a coating system.
Following cleaning in accordance with SSPC-SP 1, new galvanized surfaces can be prepared for
painting by application of a wash primer, chemical treatment or brush-off blast cleaning.
Wash Primers
One option for surface preparation consists of applying a wash primer to the cleaned galvanized
surface. Wash primers are typically vinyl butyral-based materials that acid etch the galvanized
surface to promote adhesion of coatings. The wash primer must be compatible with the intended
coating system and care should be taken not to apply the primer any thicker than recommended, or
cracking may occur. It should be noted that VOC (volatile organic compound) compliance of wash
primers must be considered. Many wash primers may not meet the Federal, State or Local VOC
content limits for shop or field application.
Chemical Treatments
Another option is chemical treatment using mildly acidic or basic solutions that etch the zinc
surface. These products may be referred to as “pre-paint cleaners” and should be specifically
designed for use on galvanizing. Pre-paint cleaning products are typically diluted with water,
applied to the galvanized surface, and allowed a short dwell time. Although rinsing the surface with
water is usually needed to remove any cleaner residues, there are some “no rinse” cleaners
available.
Brush-off Blast Cleaning
Brush-off blast cleaning can also be used to prepare galvanized surfaces for coating. However, an
obvious concern is that blast cleaning can damage and even remove a significant portion of the
protective zinc layer if not properly controlled. Galvanized surfaces should be brush-off blast
cleaned in accordance with SSPC-SP 16, “Brush-Off Blast Cleaning of Coated and Uncoated
Galvanized Steel, Stainless Steels, and Non-Ferrous Metals.”
Painting Existing Galvanizing
As previously described, the age and exposure environment of the galvanized surface determines
the stage of weathering. However, the procedures described in this section for “existing”
galvanizing apply to all stages of weathering; the stage of weathering will determine the amount of
cleaning necessary to achieve standard well-adhered coating. Note that these procedures are for
bare, weathered galvanizing, and assume that paint has not previously been applied; however, the
procedures would require only slight modification to address the removal of old, loosely adhered
paint.
The preparation of existing galvanizing should include removal of dirt and other contaminants,
loosely adhered zinc compounds, and all rust to result in a surface suitable for coating
application. The first step should always be solvent cleaning per SSPC-SP 1 to remove contaminants
such as dirt, oil, or grease. Testing for chromate or other post treatments may also be performed,
although it is unlikely that problems from post treatment will still be present on fully weathered
galvanizing. Subsequent surface preparation is most commonly achieved by pressurized water
cleaning.
Pressurized Water Cleaning
Pressurized water cleaning is the preferred cleaning method for existing galvanizing since it has a
lower potential of damaging or removing the galvanized layer versus other methods (e.g., abrasive
blast cleaning or power tool cleaning). Although it is necessary to clean the galvanized surface for
painting, the zinc layer should remain intact since this is what provides galvanic protection to the
steel.
All surfaces should be cleaned in accordance with SSPC-SP WJ-4 /NACE WJ-4, “Water Jet Cleaning
of Metals – Light Cleaning,” using pressurized water from 3,000 to 5,000 psi. The water pressure
and cleaning stand-off distances should be adjusted as necessary to achieve the specified level of
cleaning while minimizing damage to the protective zinc layer. The pressurized water will remove
loose corrosion material, soluble salts, and other contaminants. Supplemental cleaning using hand
or power tools may be necessary if rusting of the underlying steel has occurred.
Coating Systems
There are various coating systems that have a successful performance history on galvanizing. The
typical systems include acrylic coatings, epoxy/polyurethane coatings, or moisture-cure
urethanes. A corrosion resistant or zinc-rich spot primer is commonly recommended for touch-up of
bare rusted areas on existing weathered galvanized steel prior to full coating.
It is important to note that alkyd (oil-based) coatings should not be applied to galvanizing due to the
potential for reaction between alkaline zinc corrosion products (white rust) and the alkyd resin of the
coating. When this occurs, the coating will often degrade (saponify) and fail.
Another option for new galvanizing is the use of shop-applied powder coating. Powder coatings are
applied by electrostatic spray or by fluidized beds, making the process much more specialized
compared to typical spray applied liquid coatings. The powder is deposited and held to the metal
surface by the electrostatic charge and then baked at high temperatures to melt and fuse the
powder into a solid coating film. Powder coatings for weathering exposures are typically polyester
based materials such as triglycidylisocyanurate or TGIC, but epoxy powder coatings are also widely
used on buried pipe (e.g. piping for gas and oil distribution). Powder coatings offer excellent
adhesion, high abrasion resistance, low VOC emissions and little material loss. Polyester powders
also offer excellent weathering characteristics (color and gloss retention). A concern when using
powder coatings over galvanizing is the potential for outgassing during the film formation and curing
process, causing pinholes in the finished coating surface. This can be minimized by pre-baking the
galvanized component prior to powder coating.