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. 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.