Bare Spots

Figure 24: Bare Spots

Bare spots, defined as uncoated areas on the steel surface, are the
most common surface defect and occur because of inadequate surface
preparation, welding slag, sand embedded in castings, excess aluminum
in the galvanizing kettle, or lifting aids that prevent the coating from
forming in asmall area. Only very small areas, less than 1 inch in the
narrowest dimension with a total of no more than 0.5%of the accessible
surface area, may be renovated using ASTM A 780. This means narrow,
bare areas may be repaired; however, if they are greater than one inchsquare areas, the product must be regalvanized. In order to avoid bare
spots, like those seen in Figure 24, the galvanizer must ensure the
surfaces are clean and no contaminants are present after pretreatment.
If the size of the bare spot or total surface area causes rejection, the
parts may be stripped, regalvanized, and then re-inspected for
compliance to the standards and specifications.

Chain and Wire

Marks
Figure 26: Chain and Wire Marks

Another type of surface defect occurs when steel is lifted and

transported around the galvanizing plant using a chain or wire. These
lifting aids can leave uncoated areas on the finished product that will
need to be repaired. The superficial marks, like those seen in Figure 26,
left on the galvanized coatingfrom the lifting attachments are not
grounds for rejection as long as marks can be
repaired. ASTM specifications do not allow any bare spots on the
finished galvanized part.

Clogged Threads
Figure 28: Clogged Threads

Clogged threads are caused by poor drainage of a threaded section

after the product is withdrawn from the galvanizing kettle. These clogged
threads, as seen in Figure 28, can be cleaned by using post-galvanizing
cleaning operations such as a centrifuge or by heating them with a torch
to about 500 F (260 C) and then brushing them off with a wire brush to
remove the excess zinc. Clogged threads must be cleaned before the
part can be accepted.

Delamination
Delamination or peeling creates a rough coating on the steel where the
zinc has peeled off. There are a number of causes for zinc peeling.
Many large galvanized parts take a long time to cool in the air and form
zinc-iron layers after they have been removed from the galvanizing
kettle. This continued coating formation leaves behind a void between
the top two layers of thegalvanized coating. If there are many voids
formed, the top layer of zinc can separate from the rest of the coating
and peel off the part. If the remaining coating still meets the minimum
specification requirements, then the part is still acceptable. If the coating
does not meet the minimum specification requirements then the part
must be rejected and regalvanized. If delamination, as seen in Figure
29, occurs as a result of fabrication after galvanizing, such as blasting
before painting, then the galvanizer is not responsible for the defect.

Distortion
Figure 30: Distortion

Distortion, as seen in Figure 30, is defined as the buckling of a thin, flat

steel plate or other flat material such as wire mesh. The cause of this is
differential thermal expansion and contraction rates for the thin, flat plate
and mesh than the thicker steel of the surrounding frame. In order to
avoid distortion, use a thicker plate, ribs, or corrugations to stiffen flat
sections or make the entire assembly out of the same thickness steel.
Distortion is acceptable, unless distortion changes the part so that it is
no longer suitable for its intended use.

Drainage Spikes
Figure 31: Drainage Spikes

Drainage spikes or drips are spikes or tear drops of zinc along the
bottom edges of the product. These result when the surfaces of the
product are processed horizontal to the galvanizing kettle, preventing
proper drainage of the zinc from the surface as the product is withdrawn
from the kettle. Drainage spikes, as seen in Figure 31, are typically
removed during the inspection stage by a buffing or grinding process.
Drainage spikes or drips are excess zinc and will not affect corrosion
protection, but are potentially dangerous for anyone who handles the
parts. These defects must be removed before the part can be accepted.

Dross Inclusions
Figure 32: Dross Inclusions

Dross inclusions are a distinct zinc-iron intermetallic alloy that becomes

entrapped or entrained in the zinc coating. This is caused by picking up
zinc-iron particles from the bottom of the kettle. Dross, as seen in Figure
32, may be avoided by changing the lifting orientation or redesigning the
product to allow for proper drainage. If the dross particles are small and
completely covered by zinc metal, they will not affect the corrosion
protection and are acceptable. If the dross particles are large, then the
dross must be removed and the area repaired.

Excess
Aluminum in Galvanizing Bath
Figure 33: Excess Aluminum in Galvanizing Bath

Another type of surface defect, shown in Figure 33, is caused by an

excess amount of aluminum in the galvanizing bath. This creates bare
spots and black marks on the surface of the steel. The excess aluminum
can be avoided by ensuring proper control of the aluminum level in the
galvanizing bath by means of regular sampling and analysis, and by
adjusting the levels in a regular and controlled manner. For small areas
of bare spots, the part may be repaired as detailed in the specification. If
this condition occurs over the entire part, then it must be rejected and
regalvanized.

Fish Boning
Figure 34: Fish Boning

Fish boning is an irregular pattern over the entire surface of the steel
part. This is caused by differences in the surface chemistry of a large
diameter steel piece and variations in the reaction rate between the steel
and zinc. These reaction differences cause the thickness of the
galvanized coating to vary in sharply defined zones across the surface.
Fish boning, as seen inFigure 34, has no effect on the corrosion
protection provided by the zinc coating and is not cause for rejection of
the hot-dip galvanized part.

Flaking
Figure 35: Micrograph of Flaking

Flaking results when heavy coatings develop in the galvanizing process,

usually 12 mils or greater. This generates high stresses at
the interface of the steel and the galvanized coating and causes the zinc
to become flaky and separate from the surface of the steel. Flaking can
be avoided by minimizing the immersion time in the galvanizing kettle
and cooling of the galvanized steel parts as quickly as possible. Figure
35 shows a micrograph of flaking. In addition, using a different steel
grade, if possible, may also help avoid flaking. If the area of flaking is
small, it can be repaired and the part can be accepted; however, if the
area of flaking is larger than allowed by the specifications, the part must
be rejected and regalvanized.

Flux Inclusions
Figure 36: Flux Inclusion

Flux inclusion can be created by the failure of the flux to release during
the hot-dip galvanizing process. If this occurs, the galvanized coating will
not form under this flux spot. If the area is small enough, it must be
cleaned and repaired; otherwise, the part must be rejected. Flux spots
can increase if the flux is applied using the wet galvanizing method,
which is when the flux floats on the zinc bath surface. Flux deposits on
the interior of a hollow part, such as a pipe or tube, as seen in Figure 36,
cannot be repaired, thus the part must be rejected. Any flux spots or
deposits,picked up during withdrawal from the galvanizing kettle do not
warrant rejection if the underlying coating is not harmed, and the flux is
properly removed.

Oxide Lines
Figure 37: Oxide Lines

Oxide lines are light colored oxide film lines on the galvanized steel
surface. Oxide lines are caused when the product is not removed from
the galvanizing kettle at a constant rate. This may be due to the shape of
the product or the drainage conditions. Oxide lines, as seen in Figure 37,
will fade over time as the entire zinc surface oxidizes. They will have no
effect on the corrosion performance; only the initial appearance will be
affected. This condition is not a cause for rejection of the hot-dip
galvanized parts.

Products in
Contact
Figure 38: Products in Contact

Another type of surface defect is caused by products that come in

contact with each other or are stuck together. This usually occurs when
many small products are hung on the same fixture, which creates the
chance products may become connected or overlapped during the
galvanizing process, as seen in Figure 38. The galvanizer is responsible
for proper handling of all products in order to avoid this defect. In
addition, if the surface of a product has a larger bare area than the
specified repair requirement allows, then that product must be rejected
and regalvanized.

Rough
Surface Condition
Figure 39: Rough Surface Condition

Rough surface condition or appearance is a uniformly rough coating with

a textured appearance over the entire product. The cause for this rough
surface condition is hot-rolled steel with a high level of silicon content.
This can be avoided by purchasing steel with a silicon content less than
0.03% of the steel by weight. Rough surface condition, as seen in Figure
39, can actually have a positive effect on corrosion performance
because of the thicker zinc coating produced. One of the few situations
where rough coating is cause for rejection is if it occurs on handrails.
The corrosion performance of galvanized steel with rough coatings is not
affected by the surface roughness.

Runs
Figure 40: Runs

Runs are localized thick areas of zinc on the surface. Runs occur when
zinc freezes on the surface of the product during removal from the zinc
bath. This is more likely to occur on thinner sections with large surface
areas that cool quickly. In order to avoid runs, as seen in Figure 40,
adjustments of the dipping angles can be made, if possible, to alter the
drainage pattern to a more acceptable mode. If runs are unavoidable
and will interfere with the intended application, they can be buffed. Runs
are not cause for rejection.

Rust
Bleeding
Figure 41: Rust Bleeding

Rust bleeding appears as a brown or red stain that leaks from unsealed
joints after the product has been hot-dip galvanized. It is caused by pretreatment chemicals that penetrate an unsealed joint. During galvanizing
of the product, moisture boils off the trapped treatment chemicals leaving
anhydrous crystal residues in the joint. Over time, these crystal residues
absorb water from the atmosphere and attack the steel on both surfaces
of the joint, creating rust that seeps out of the joint. Rust bleeding, as
seen in Figure 41, can be avoided by seal welding the joint where
possible or by leaving a gap greater than 3/32 (2.4mm) wide in order to
allow solutions to escape and zinc to penetrate during hot-dip
galvanizing. If bleeding occurs, it can be cleaned up by washing the joint
after the crystals are hydrolyzed. Bleeding from unsealed joints is not the
responsibility of the galvanizers and is not cause for rejection.

Sand
Embedded in Casting
Figure 42: Sand Embedded in Casting

Another type of surface defect occurs when sand becomes embedded in

the castings and creates rough or bare spots on the surface of the
galvanized steel. Sand inclusions are not removed by conventional acid
pickling, so abrasive cleaning should be done at the foundry before the
products are sent to the galvanizer. This type of defect also leaves bare
spots and must be cleaned and repaired or the part must be rejected,
stripped, and regalvanized. Sand embedded in a casting can be seen
in Figure 42.

Striations
Figure 43: Striations

Striations are characterized by raised parallel ridges in the galvanized

coating, mostly in the longitudinal direction. This can be caused when
sections of the steel surface are more highly reactive then the areas
around them. These sections are usually associated with segregation of
steel impurities, especially phosphorous, created during the rolling
process in steel making. Striations, as seen in Figure 43, are related to
the type of steel galvanized and while the appearance is affected, the
performance of thecorrosion protection is not. Striations are acceptable
on most parts; however, if the striations happen to occur on handrails,
then the parts must be rejected and regalvanized. Sometimes
regalvanizing does not improve the striations and the handrail must be
refabricated out of better quality steel.

Surface
Contaminant
Figure 44: Surface Contaminents

When surface contaminants create an ungalvanized area where the

contaminant was originally applied, a surface defect may occur. This is
caused by paint, oil, wax, or lacquer not removed during the
pretreatment cleaning steps. Surface contaminants, as seen in Figure
44, should be mechanically removed prior to the galvanizing process. If
they result in bare areas, then the repair requirements apply and small
areas may be repaired, but a large area is grounds for rejection and the
entire part must be regalvanized.

Touch
Marks
Figure 45: Touch Marks

Another type of surface defect is known as touch marks, which are

damaged or uncoated areas on the surface of the product. Touch marks
are caused by galvanized products resting on each other or by
the material handling equipment used during the galvanizing operation.
Touch marks, as seen inFigure 45, are not cause for rejection if they
meet the size criteria for repairable areas. They must be repaired before
the part is accepted.

Weeping
Weld
Figure 46: Weeping Weld

Weeping welds stain the zinc surface at the welded connections on the
steel. They are caused by entrapped cleaning solutions that penetrate
the incomplete weld. In order to avoid weeping welds for small
overlapping surfaces, completely seal weld the edges of the overlapping
area. For larger overlapping areas, the area cannot be seal welded since
the volume expansion of air in the trapped area can cause explosions in
the galvanizing kettle. To avoid weeping welds in large overlapping
areas, the best plan is to provide a 3/32 (2.4mm) or larger gap between
the two pieces when welding them and let the zinc fill the gap between
the pieces. This will actually make a stronger joint when the process is
complete. Weeping welds, as seen in Figure 46, are not the
responsibility of the galvanizer and are not cause for rejection.

Welding
Spatter
Figure 48: Welding Spatter

Welding spatter appears as lumps in the galvanized coating adjacent to

weld areas. It is created when welding spatter is left on the surface of the
part before it is hot-dip galvanized. In order to avoid welding spatter,
welding residues should be removed prior to hot-dip galvanizing. Welding
spatter, as seen in Figure 48, appears to be covered by the zinc coating,
but the coating does not adhere well and can be easily removed. This type
of defect can leave an uncoated area or bare spot if the zinc coating is
damaged and must be cleaned and properly repaired.

Wet Storage Stain

Wet storage stain is a white, powdery surface deposit on freshly galvanized
surfaces. It is caused by newly galvanized surfaces being exposed to fresh
water, such as rain, dew, or condensation that react with the zinc metal on
the surface to form zinc oxide and zinc hydroxide. It is found most often on
tightly stacked and bundled items, such as galvanized sheets, plates,
angles, bars, and pipes. Wet storage stain can have the appearance of
light, medium, or heavy white powder on the galvanized steel product.
Each of these appearances can be seen from right to left in Figure 49.
One method to avoid wet storage stains is to passivate the product after
galvanizing by using a chromate quench solution. Another precaution is to
avoid stacking products in poorly ventilated, damp conditions. Light or
medium wet storage stain will weather over time in service and is
acceptable. In most cases, wet storage stain does not indicate serious
degradation of the zinc coating, nor does it necessarily imply any likely
reduction in the expected life of the product. However, heavy wet storage
stain should be removed mechanically or with appropriate chemical
treatments before the galvanized part is put into service. Heavy storage
stain must be removed or the part must be rejected and regalvanized.

Zinc
Skimmings
Figure 50: Zinc Skimming Inclusions

Skimming deposits are usually caused when there is no access to remove

the skimmings during the withdrawal of the steel from the galvanizing
kettle. The skimmings on the liquid zinc surface are trapped on the zinc
coating. In order to remove zinc skimmings without harming the soft zinc
coating underneath, lightly brush them off the surface of the galvanized
steel during the in-house inspection stage with a nylon-bristle brush. Zinc
skimmings, as seen in Figure 50, are not grounds for rejection. The zinc
coating underneath is not harmed during their removal and it meets the
necessary specifications.

Zinc Splatter
Figure 51: Zinc Splatter

Zinc splatter is defined as splashes and flakes of zinc that loosely adhere to
the galvanized coating surface. Zinc splatter is created when moisture on
the surface of the galvanizing kettle causes liquid zinc to pop and splash
droplets onto the product. These splashes create flakes of zinc loosely
adherent to the galvanized surface. Zinc splatter, as seen in Figure 51, will
not affect the corrosion performance of the zinc coating and is not cause for
rejection. The splatter does not need to be cleaned off the zinc coating
surface, but can be if a consistent, smooth coating is required.

Adherence
Test
Figure 52: Stout Knife Test

Testing of the zinc coating adherence to the steel is achieved using a stout
knife. The steps used in this test are listed below and a photo of the test
being performed can be seen in Figure 52. The coating shall be deemed
not adherent if it flakes off and exposes the base metal in advance of the
knifepoint. The test is not an attempt to pare or whittle the zinc coating. If
the coating is adherent the knife should put a slight mark in the zinc metal
surface, but should not cause any delamination of the coating layers.
Adhesion Test with a Stout Knife

Push down point of stout knife

Coating must not flake off exposing the base metal

Do not perform at edges or corners of the product

No paring or whittling with knife is acceptable

Bending Test
The hot-dip galvanized coating on a steel bar must withstand bending
without flaking or peeling when the bending test is preformed in accordance
with the specifications in ASTM A 143. There are various tests used to
assess the ductility of steel when subjected to bending. One test may
include the determination of the minimum radius or diameter required to
make a satisfactory bend. Another test may include the number of repeated
bends that the material can withstand without failure when it is bent through
a given angle and over a definite radius.
Rebar is commonly bent prior to the hot-dip galvanizing process. Steel
reinforcing bars bent cold prior to hot-dip galvanizing should be fabricated
to a bend diameter equal to or greater than the specified value in ASTM A
767/A 767M. However, steel reinforcing bars can be bent to diameters
tighter than the specified values if they are stress relieved at a temperature
of 900 to 1050 F (480 to 560 C) for one hour per inch (25mm) of diameter.

Chromating Test
The specification to determine the presence of chromate on zinc surfaces
is ASTM B 201. This test involves placing drops of a lead acetate solution
on the surface of the product, waiting 5 seconds, and then blotting it gently.
If this solution creates a dark deposit or black stain, then there is
unpassivated zinc present. A clear result indicates the presence of a
chromate passivation coating.

Embrittlement Test

When there is suspicion of potential embrittlement of a product, it may be

necessary to test a small group of the products to measure the ductility.
These tests are usually destructive to the zinc coating and possibly to the
product as well. Products suspected of embrittlement shall be tested
according to the specification ASTM A 143. Depending on the service
conditions the product will be exposed to, one of three embrittlement tests
may need to be performed. These embrittlement tests include the similar
bend radius test, sharp blow test, and steel angle test. The embrittlement
test uses a known force to provide a stress that should be lower than the
yield stress of the part. If there is a fracture or permanent damage created
during the testing process, the parts must be rejected.

Sampling
A sampling protocol has been developed by ASTM to ensure high quality
products because the inspection of the coating thickness for every piece of
material galvanized in a project would not be practical. ASTM A123/A123M
states for a unit of products whose surface area is equal to or less than 160
in (1032 cm), the entire surface of each test product constitutes a
specimen. In the case of a product containing more than one material
category or steel thickness range, that product will contain more than one
specimen. In addition, products with surface areas greater than 160 in
(1032 cm) are multi-specimen products. There are four important terms
used in the ASTM specifications and each is defined below.

Sampling Terms

Lot unit of production or shipment from which a sample is taken for

testing

Sample a collection of individual units of product from a single lot

Specimen the surface of an individual test product or a portion of a

test product which is a member of a lot or a member of a sample
representing that lot

Test Product an individual unit of product that is a member of the

sample
For single specimen products, each randomly selected product is a
specimen. In thickness measurement tests, five measurements are taken
widely dispersed over the surface area of the specimen in order to
represent the total coating thickness. The mean value of the five coating
thicknesses for one specimen must have a minimum average coating
thickness grade of not less than one grade below the minimum average
coating thickness for the material category. In Figure 53, the separation of a
lot into a sample and individual specimen is shown.

A multi-specimen product is defined as having a surface area that may be

larger than 160 in (1032 cm), have multiple steel thicknesses, or contain
more than one coating category. In order to test coating thickness of

products whose surface area is greater than 160 in (1032 cm), they are
subdivided into three continuous local sections with equivalent surface
areas, each of which constitutes a unique specimen. In the case of any
such local section containing more than one material category or steel
thickness range, that section will contain more than one specimen.
In Figure 54, the separation of a lot into a sample and individual specimen
is shown.

For products hot-dip galvanized to either ASTM A123/A123M or

A153/A153M, Table 6 is used to determine the minimum number of
specimens for sampling from a given lot size.
No. of Pieces in Lot

No. of Specimens

3 or less

All

4 to 500

501 to 1200

1201 to 3200

3201 to 10,000

13

10,001+

20

Table 6: Minimum Number of Specimens

for ASTM A123 and A153

For rebar hot-dip galvanized according to ASTM A767, the information

below is used to determine the minimum number of samples per lot,
measurements per sample, and the total number of measurements
required for each of the different coating thickness
measurement techniques.

Magnetic Thickness:

3 samples per lot

5 or more measurements per sample

15 measurements, at the minimum, comprise the average

Microscopy Method:

5 samples per lot

4 measurements per sample

20 measurements, at minimum, comprise the average

Stripping and Weighing:

3 samples per lot
The minimum average coating thickness for a lot is the average of the
specimen values and must meet the minimum for the material category.
The minimum for an individual specimen is one grade below the minimum
for the material category. An individual measurement has no minimum, but
bare areas are not allowed on the part. The final inspection of a part shall
include thickness measurements and visual inspection. All parts that do not

meet the requirement must be resorted and reinspected or rejected and

then regalvanized.

Repair
If the galvanized product does not meet all of the requirements of the
specification, it must be repaired or rejected along with the lot it represents.
When repair of the product is allowed by the specification or bare spots are
present, the galvanizer is responsible for the repair unless directed
otherwise by the purchaser. The specifications allow for some retesting of
products that represent lots or retesting after the lot has been sorted for
non-conformance. The coating thickness of the repaired area must match
the coating thickness of the surrounding area. However, if zinc-rich paint is
used for repair, the coating thickness must be 50% higher than the
surrounding area, but not greater than 4.0 mils because mud cracking
tends to result when the paint coating is too thick. The maximum sizes for
allowable areas that can be repaired during in-plant production are defined
in the specifications as summarized below.

Maximum Size of Repairable Area

ASTM A 123/A 123M:

One inch or less in narrowest dimension

Total area can be no more than 0.5% of the accessible surface

area to be coated or 36 square inches per piece, whichever is less

ASTM A 153/A 153M:

The bare spots shall have an area totaling no more than 1% of

the total surface area to be coated, excluding threaded areas of the piece

ASTM A 767/A 767M:

No area given

If the coating fails to meet the requirement for finish and

adherence, the bar may be stripped, regalvanized, and resubmitted

Damage done to the coating due to fabrication or handling shall

be repaired with a zinc-rich formulation

Sheared ends shall be coated with a zinc-rich formulation

Repair Methods
Any repairs made to galvanized products must follow the requirements of
ASTM A 780, which defines the acceptable materials and the required
procedures. Repairs are normally completed by the galvanizer before the
products are delivered, but under certain circumstances, the purchaser
may perform the repairs on their own. The touch-up and repair materials
are formulated to deliver an excellent color that matches either brightly
coated, newly galvanized products or matte gray, aged galvanized
products. Materials used to repair hot-dip galvanized products include zincbased solder, zinc-rich paint, and zinc spray metallizing, and are explained
in the following sections.

Zinc-Based Solder

Figure 55: Zinc-Based Solder

Soldering with zinc-based alloys is achieved by applying zinc alloy in either

a stick or powder form. The area being repaired needs to be preheated to
approximately 600 F (315 C). The most commonly used solders for repair,
as seen in Figure 55, include zinc-tin-lead, zinc-cadmium, and zinc-tincopper alloys.

Surface Preparation
According to ASTM A 780, the surface to be reconditioned shall be wire
brushed, lightly ground, or mildly blast cleaned. In addition, if wire brushing
or light blasting is inadequate, all weld flux and spatter must be removed by
mechanical methods. The cleaned area also needs be preheated to 600 F
(315 C) and wire brushed while heated. Pre-flux may also be necessary to
provide chemical cleaning of the bare spot. Finally, special care should be
given to insure that the surrounding galvanized coating is not overheated
and burned by the preheating.

Application

The soldering method is the most difficult of the three repair methods to
complete. A high level of caution must be taken while heating the bare spot
to prevent oxidizing the exposed steel or damaging the surrounding
galvanized coating. Solders are typically not economically suited for touchup of large areas because of the time involved in the process and because
heating of a large surface area to the same temperature is very difficult.
When the repair has been completed, the flux residue needs to be removed
by rinsing the surface with water or wiping with a damp cloth.

Final Repaired Product

The final coating thickness for this repair shall be agreed upon between the
galvanizer and the purchaser, and is generally in the 1 to 2 mil range. The
thickness shall be measured by any of the methods in ASTM A 123/A 123M
that are non-destructive. Zinc-based solder products closely match the
surrounding zinc and blend in well with the existing coating appearance.

Zinc-Rich Paint

Figure 56: Zinc-Rich Paint

Zinc-rich paint is applied to a clean, dry steel surface by either a brush or

spray as seen in Figure 56, and usually contains an organic binder pre-mix.
Zinc-rich paints must contain either between 65% to 69% metallic zinc by
weight or greater than 92% metallic zinc by weight in dry film. Paints
containing zinc dust are classified as organic or inorganic, depending on
the binder they contain. Inorganic binders are particularly suitable for paints
applied in touch-up applications around and over undamaged hot-dip
galvanized areas.

Surface Preparation
According to ASTM A 780, the surface to be repaired shall be blast cleaned
to SSPC-SP10/NACE No.2 near white metal for immersion applications
and SSPC-SP11 near bare metal for less aggressive field conditions.
When blasting or power tool cleaning is not practical, hand tools may be
used to clean areas to be reconditioned. The blast cleaning must extend
into the surrounding, undamaged, galvanized coating.

Application
This method of repairing galvanized surfaces must take place as soon as
possible after preparation is completed and prior to the development of any
visible oxides. The spraying or brushing should be in an application of
multiple passes and must follow the paint manufacturers specific written
instructions. In addition, proper curing of the repaired area must occur
before the product is put through the final inspection process. This repair
can be done either in the galvanizing plant or on the job site and is the
easiest repair method to apply because limited equipment is required. Zinc-

rich painting should be avoided if high humidity and/or low temperature

conditions exist because adhesion may be adversely affected.

Final Repaired Product

The coating thickness for the paint must be 50% higher than the
surrounding coating thickness, but not greater than 4.0 mils, and
measurements should be taken with either a magnetic, electromagnetic or
eddy current gauge. Finally, the surface of the painted coating on the
repaired area should be free of lumps, coarse areas, and loose particles.

Zinc Spray Metallizing

Figure 57: Zinc Spray

Metallizing

Zinc spray, which is also referred to as metallizing, is done by melting zinc

powder or zinc wire in a flame or electric arc and projecting the liquid zinc
droplets by air or gas onto the surface to be coated, as seen in Figure 57.
The zinc used is nominally 99.5% pure or better and the corrosion
resistance of the wire or powder is approximately equal.

Surface Preparation
According to ASTM A 780, the surface to be reconditioned shall be blast
cleaned to SSPC-SP5/NACE No.1 near white metal and must be free of oil,

grease, weld flux residue, weld spatter and corrosion products. The blast
cleaning must extend into the surrounding, undamaged, galvanized
coating.

Application
Zinc spraying of the clean, dry surface must be completed by skilled
workers and should take place within four hours after preparation or prior to
development of visible oxides. Spraying should also be done in horizontal
overlapping lines, which yield a uniform thickness more consistent than the
crosshatch technique. The zinc coating can be sealed with a thin coating of
low viscosity polyurethane, epoxy-phenolic, epoxy, or vinyl resin. The
details of the application sequence and procedures can be found in
ANSI/AWS C2.18-93. The application of zinc spray can be done either in
the galvanizers plant or at the job site. In addition, if high humidity
conditions exist during spraying, adhesion may be degraded.

Final Repaired Product

The renovated area shall have a zinc coating thickness at least as thick as
that specified in ASTM A 123/A 123M for the thickness grade required for
the appropriate material category. These thickness measurements should
be taken with either a magnetic or an electromagnetic gauge for best
results. The plain zinc sprays or the sprays with aluminum additives both
provide a good match for newly galvanized, bright surfaces. Finally, the
surface of the sprayed zinc coating should be free of any lumps, coarse
areas, and loose particles.

Galvanizing Standards
There are certain specifications that have been developed for hot-dip
galvanizing in order to produce a high-quality coating. The most commonly
used specifications design engineers and fabricators should become
familiar with in order to promote a high-quality coating and ensure their
steel design is suitable for hot-dip galvanizing are:

ASTM A 123/A 123M: Standard Specification for Zinc (Hot-Dip

Galvanized) Coatings on Iron and Steel Products
Single pieces of steel or fabrications with different types of steel products

ASTM A 153/A 153M: Standard Specification for Zinc Coating (HotDip) on Iron and Hardware
Fasteners and small products that are centrifuged after galvanizing to
remove excess zinc

ASTM A 767/A 767M: Standard Specification for Zinc-Coated

(Galvanized) Steel Bars for Concrete Reinforcement
Reinforcing steel or rebar

ASTM A 780: Standard Practice for Repair of Damaged and

Uncoated Areas of Hot-Dip Galvanized Coatings
Touch-up procedures for coating bare spots on an existing hot-dip
galvanized product
Other commonly used specifications in the hot-dip galvanizing industry
include:

ASTM A 143/A 143M: Standard Practice for Safeguarding Against

Embrittlement of Hot-Dip Galvanized Structural Steel Products and
Procedure for Detecting Embrittlement

ASTM A 384/A 384M: Standard Practice for Safeguarding Against

Warpage and Distortion During Hot-Dip Galvanizing of Steel Assemblies

ASTM A 385/A 385M: Standard Practice for Providing High-Quality

Zinc Coatings (Hot-Dip)

ASTM B 6: Standard Specification for Zinc

ASTM D 6386: Standard Practice for Preparation of Zinc (Hot-Dip

Galvanized) Coated Iron and Steel Product and Hardware Surfaces for
Paint

ASTM E 376: Standard Practice for Measuring Coating Thickness by

Magnetic-Field or Eddy-Current (Electromagnetic) Examination Methods

CAN/CSA G 164: Hot-Dip Galvanizing of Irregularly Shaped Articles

ISO 1461 Hot-Dip Galvanized Coatings on Fabricated Iron and Steel

Assemblies
Specifications and Test Methods

ASTM A 123 for

Structural Steel
Products

Figure 11: Single Fabrication

with Multiple Material Categories

The ASTM A 123/A 123M specification covers individual steel pieces as

well as assemblies of various classes of material. The four material
categories covered in ASTM A 123/A 123M include structural steel and
plates, strips and bars, pipes and tubing, and wires. A fabrication can have
more than one material category such as a frame assembly. Any
combination of these products can be assembled into a single fabrication
and then can be hot-dip galvanized, as seen in Figure 11.
It is the responsibility of the designer and fabricator to ensure the product
has been properly designed and built before the hot-dip galvanizing

process. The galvanizer should be made aware of any necessary special

instructions or requests in advance of shipping the materials to the
galvanizing plant. These requests should be stated on the purchase
order for the hot-dip galvanizing.
It is the responsibility of the galvanizer to ensure compliance with the
specifications as long as the product has been designed and fabricated in
accordance with the referenced specifications. However, if the galvanizer
has to perform additional work in order to prepare the product for hot-dip
galvanizing, such as drilling holes to facilitate drainage or venting, it must
be approved by the customer. Once the material has been hot-dip
galvanized, it can be fully inspected at the galvanizing plant prior to
shipment.
Any materials rejected by the inspectors for reasons other than
embrittlement may be stripped, regalvanized, and resubmitted for
inspection. The ASTM specifications A 143/A 143M, ASTM A 384/A 384M,
and ASTM A 385 provide guidelines for preparing products for hot-dip
galvanizing. The requirements listed in ASTM A 123/A 123M includecoating
thickness, finish, appearance, and adherence. These are each defined
below and discussed in more detail later in this course.

ASTM A 123/A 123M Requirements

Coating Thickness / Weight dependent upon material category

and steel thickness

Finish continuous, smooth, uniform

Appearance free from uncoated areas, blisters, flux deposits and

gross dross inclusions as well as having no heavy zinc deposits that
interfere with intended use

Adherence the entire coating should have a strong adherence

throughout the service life of galvanized steel
The hot-dip galvanized coating is intended for products fabricated into their
final shape that will be exposed to corrosive environmental conditions.
Once a product has been hot-dip galvanized, any further fabrication, which
very rarely occurs, may have negative effects on the corrosion protection of
the coating. The coating grade is defined as the required thickness of the
coating and is given in microns. All coating thickness requirements in
specification ASTM A 123/A 123M, as seen in Tables 1 & 2, are minimums;
there are no maximum coating thickness requirements in either
specification.
Table 1: Minimum Average Coating Thickness Grade by Material Category (From ASTM
A123) Table 2: Coating Thickness Grade (From ASTM A 123)

The time to first maintenance of hot-dip galvanized steel is directly

proportional to the thickness of the hot-dip galvanized coating. With all
other variables held constant, the thicker the zinc coating, the longer the life
of the steel. The aim of the finish and appearance requirements is to
ensure no coatings have problem areas that are deficient of zinc or have
surface defects that would interfere with the intended use of the product. In
addition, the coating should have a strong adherence throughout the
service of the hot-dip galvanized steel.

Types of Inspection
In this section, the type of inspections performed on hot-dip galvanized
steel will be discussed. The various inspections are used to verify the
necessary specifications for the galvanized product are met. These
techniques for each test method are specified in ASTM A 123/A 123M, A
153/A 153M, or A 767/A 767M, depending upon the type of product being
inspected. The most common inspections, listed below, range from a
simple visual inspection to more sophisticated tests to determine
embrittlement or adhesion.

Coating Thickness magnetic gauges, optical microscopy

Coating Weight weigh-galvanize-weigh, and weigh-strip-weigh

Finish and Appearance visual inspection

Additional Tests

Adherence stout knife

Embrittlement similar bend radius, sharp blow, and steel

angle

Chromating spot test

Bending minimum finished bend diameter table

Sampling