is formed in one year, but the possible presence of a light oil After washing the surface,
layer and weather conditions may actually extend the time.) examine it for zinc ash. Zinc
Wet storage stain, if present, must be removed before ash residue consists of parti-
surface preparation. This can be done by brushing the stain cles of oxidized zinc that float
with a 12% ammonia solution such as diluted household on the surface in the galvaniz-
ammonia. Severe cases of wet storage stain will require a ing bath. It can be removed by
mild acid solution such as one part of acetic or citric acid washing the surface with a
Zinc ash residue on galvanized item
diluted with 25 parts of water. Remove the ammonia or 12% ammonia solution.
acid with a warm water rinse. Thoroughly rinse the surface with hot water and let it dry.
The first step in surface preparation is to wash off oil, The next step in surface preparation is to repair any de-
grease, and dirt. In North America, this is accomplished by fects or handling damage. Galvanizing can leave high spots
solvent cleaning (SSPC-SP 1). (This standard is not com- and zinc droplets. High spots occur when excess zinc runs
monly used in Europe.) Water-based emulsifiers or alkaline down the edges as the galvanized piece is withdrawn from
cleaners work best. Make sure that an alkaline cleaner has the bath, and the zinc runs into a protrusion or irregular
a pH of less than 12 or 13, because zinc will dissolve in edge. Droplets form at edges where zinc drains from the
highly alkaline solutions. Apply the cleaning solution by piece. Droplets are knocked off with hand tools. High spots
dipping, spraying, or brushing with soft bristle brushes. A are usually ground off with power tools, but care is needed
temperature range of 6085 C (140185 F) works best, es- not to remove so much zinc that the thickness is below the
pecially when dipping or spraying. Thoroughly rinse the specified minimum.
surface with hot water after cleaning and allow it to dry. In Damaged galvanizing can be repaired with organic zinc-rich
countries where organic solvents can also be used for paints. Consult the coating manufacturer about specific prod-
cleaning purposes, lint-free rags should be used. Change ucts and the method of surface preparation required. SSPC-
them often so as not to cover the surface with fibres. Guide 14, Guide for Repair of Imperfections in Galvanized or
One way to determine if oil was applied to the galvanized Inorganic Zinc-Coated Steel Using Organic Zinc-Rich Coating,
surface to prevent wet storage stain is to contact the galva- may be consulted.
nizer. Another way is to perform a water bead test. Place a The unstable zinc oxide or zinc hydroxide may not have
drop of water on the surface. If it beads, oil probably is pre- been entirely removed during the initial cleaning process.
sent. The best advice is that when in doubt, clean the en- There is no simple method for identifying the presence of ei-
tire surface as described above. ther, so the surface must be further treated. The common
methods for treating the surface in the field are phosphating,
use of wash primers, acrylic passivation, and sweep blasting.
The Galvanizing Process
Hot-dip galvanizing is a batch process in which the coating is
applied in a molten bath of zinc at about 450 C (840 F) after the Phosphating
workpiece has been cleaned and a flux has been applied to promote Phosphating (use of acidic zinc phosphate solution, mor-
fusion of the zinc to the steel. dant solution, or T-Wash) is accomplished by applying a
Chemical reactions be- phosphate-containing solution that forms a non-reactive
tween the iron in the steel zinc phosphate layer on the surface. The process slightly
and the molten zinc take etches the surface and blocks the formation of zinc oxides.
place, forming four distinct The solution is applied by immersion, spray, or soft bris-
layers, as shown at left.
tle brush. It should be left on the surface for 3 to 6 minutes
The gamma layer closest
and then washed off with clean water. The treatment will
to the steel is 75% zinc and
25% iron. This is followed by the delta (90% zinc), zeta (94% zinc), give a black colouration to the surface. Therefore, any areas
and eta (100% zinc) layers. that were missed will be visible after washing, and they can
The overall thickness of the galvanizing is determined primarily by be re-treated. Allow the surface to dry before painting.
the chemistry of the steel, provided the workpiece has remained in Phosphating can also be done at the galvanizing plant in
the bath for a sufficient length of time. The thickness of the eta lay- a process called phosphate quenching. The workpiece is
er is also affected by how quickly the molten zinc can drain from the placed in a phosphating bath after galvanizing. If youre in-
surface when the item is removed from the bath. volved with a new construction project, contact the galva-
Galvanizing is known for its bright, spangled surface. However,
nizer to see if the pieces will be treated with phosphate. It
bath chemistry can affect the appearance and a dull finish can occur.
will be less expensive, and the quality will be more consis-
This is an aesthetic issue and does not affect the corrosion protec-
tion of the galvanizing. Exposing the zeta layer will result in a brown tent compared to field phosphating.
appearance due to the presence of an iron alloy. Phosphating is not recommended if a zinc-rich primer is
going to be applied. Zinc-rich primers require intimate con-
tact between the zinc particles in the paint and the zinc Sweep Blasting
metal on the galvanized surface. Zinc phosphate acts as an Sweep blastinga method of lightly blast cleaningcan
insulator in the same way that iron oxide (rust) acts as an remove zinc oxides on the surface and roughen it without
insulator on steel surfaces. significant removal of the galvanizing.
Sweep blasting should be performed with soft abrasives
Wash Primers such as aluminium/magnesium silicate, corn cobs, walnut
Wash primers are coatings used to neutralise the surface ox- shells, limestone, or some mineral sands. Use an abrasive
ides or hydroxides and to etch the galvanized surface. The with a Mohs scale hardness of 5 or less. The particle size
most common wash primer is polyvinyl butyral (e.g., SSPC- should be in the range of 200500 microns (820 mils).
Paint 27), although other products are available. Use a relatively low angle when blasting. Holding the
These materials are applied very thin (i.e., 713 microns nozzle perpendicular to the surface can quickly remove the
[0.3 to 0.5 mil]) by brush or spray. Follow the manufactur- galvanizing layer rather than just the zinc oxide particles
ers instructions. The galvanized surface should shadow on the surface. The recommended ambient conditions for
through the coating at this thickness. If the galvanized sur- sweep blasting are a minimum temperature of 21 C (70 F)
face is completely hidden, the wash primer is too thick. and relative humidity of 50% or less.
Wash primers have poor cohesive strength and will split
apart if they are too thick, resulting in paint disbondment. Fully Weathered and Aged Galvanizing
Fully weathered galvanizing (i.e., galvanizing that has
Acrylic Passivation been outdoors for at least one year and preferably two)
Acrylic passivation is accomplished with an acidic acrylic should have a fully formed layer of protective zinc carbon-
solution that passivates and roughens the surface. Acrylic ate. All that is normally needed to prepare the surface is
passivating materials are applied at 1 micron (0.04 mils). power washing at about 97 bar (1,450 psi). Spot repairs of
In essence, acrylic passivation is a surface treatment. It any damage also would be necessary.
must dry completely before the paint is applied. Continued
Old, aged galvanizing that has been Surface preparation of old, aged gal- surface was prepared. However, there
in service, uncoated, for a number of vanizing involves cleaning any rusted are certain types of coatings that are
years and is showing signs of failure in- or stained areas as well as power not recommended, especially oil-based
troduces a different concern. There may washing the entire surface. Areas with alkyds. Most coatings can be applied
be areas of reddish-brown staining, red rust should be cleaned to bare met- by brush, roller, or spray. Check with
which many people think is corrosion of al while areas with brown staining the coating manufacturer on applica-
the base steel. However, just below the from the zinc-iron alloy require only tion methods. The most common coat-
pure zinc on hot-dip galvanized steel hand or power tool cleaning. Care ings applied directly to galvanizing are
are zinc-iron alloy layers. What might must be taken when cleaning areas of epoxies and water-bornes.
be visible is the staining from these lay- red rust to remove as little galvanizing Epoxies come in many varieties.
ers. Zinc-iron alloy is brown, while rust- from the edges of the spot as possible. Those selected must be specifically for-
ed steel is redder, but telling the differ- It is common to use an organic zinc- mulated for use over galvanizing. Make
ence can be difficult. The best way to do rich primer when refurbishing old, sure the manufacturers technical data
this is with a magnetic or electronic dry aged galvanizing. Usually some of the sheet for a particular product says it can
film thickness gauge. Measure the layer galvanizing has been consumed, and be applied to galvanizing. Epoxies gen-
of galvanizing at any rusted or stained the intent is to add more zinc for cor- erally chalk in sunlight, so a topcoat
areas. Since galvanizing is non-magnet- rosion protection. Sweep blasting would be needed for outdoor exposure.
ic, the gauge will measure it as if it were would be recommended prior to apply- Aliphatic urethanes give good appear-
paint. If the gauge finds no layer of gal- ing the primer to promote adhesion. ance and chemical resistance, so they
vanizing, the area is most likely rusted. are commonly used for this purpose.
Mark the area for repair. The specified Coatings For Galvanizing Water-borne acrylic coatings are fast
galvanizing thickness is related to the Many types of coatings can be applied drying. They make good topcoats and
steel thickness and is usually in the over galvanizing. The choice some- are easy to maintain. Acrylic latexes are
range of 50125 microns (25 mils). times depends, in part, on how the preferred. Other water-borne latexes