How much Zinc is needed for galvanic protection?

Mike Winter
Technical Manager International Paint

For internal use only not to be circulated outside AkzoNobel

Traditional Wisdom

Zinc silicates are all the same they only differ in zinc
content

The only important consideration is how much is in the

coating

The more Zinc the better

Zinc Levels how much is needed?

Most standards use % Zn dust by weight in dry film:

BS5493 >90%
SSPC Paint 20 Level 1 >85%
ISO12944 >80%
SSPC Paint 20 Level 2 77% - 85%
SSPC Paint 20 Level 3 65% - 77%
SSPC Paint 29 >65%

Some use % Zinc metal:

BS5462 > 85%

UNE48293 (Spain) > 80%
Caltrans > 78%

Laboratory Test Protocols Commonly Used

ASTM B117 continuous hot salt spray

e.g SSPC Paint 20/29 3,000 hr test requirement

ISO 20340 - 4,200 hrs cyclic salt spray/QUV (3 days/3 days)

with 1 day freeze cycle @ -20C
e.g. Norsok M501

ASTM D5894 cyclic prohesion/QUV (7 days/7 days)

e.g. AASHTO R31-04 5,000 hrs test requirement

Outdoor exposure

ASTM B 117 Salt Spray 3,000 hrs

85% zinc in dry film

80% zinc in dry film

77% zinc in dry film

65% zinc in dry film

ISO 20340 4,200 hours

85% zinc

80% zinc

77% zinc

ISO 20340 creep data 4,200 hours

Single coat IOZ system
% Zn vs creep 1 coat

85%
Similar formula types

Zinc epoxy

100
90

77%

50%

% Zn in dry film

65%

80
70
60
50

% Zn

40
30
20
10
0
0

ISO20340 creep (mm)

10

ISO 20340 Creep data 4,200 hours

Zinc silicate/epoxy/polyurethane systems
Similar formula types

% Zn vs creep 3 coat system

Zinc epoxy

85%

100
90
80

65%

50%

% zn in dry film

77%

70
60
50

% Zn

40
30
20
10
0
0

ISO20340 creep (mm)

10

12

Mechanism of Zinc Silicate Protection

Untopcoated Zinc silicates in corrosive environments protect

galvanically for approx 3 months

Over time, the open porous film of a zinc silicate coating

becomes plugged with reaction products of zinc metal and
oxygen, carbon dioxide, sulfur dioxide, sodium chloride etc

The porous zinc silicate film becomes a tight, dense, passive

barrier coating

This mechanism does not occur with topcoated zinc silicates

Single Coat Zinc Rich Epoxy Systems

Paint A

Note: both paints have 80% Zn/dry film

3,000 hrs ASTM B117

3,024 hrs ASTM D5894

Paint B

Three Coat Zinc Epoxy/Epoxy/PU Systems

A

3,000 hrs ASTM B117

Scribe cleaned using ISO

20340 method

A and B both
have 80% Zn in dry
film

3,024 hrs ASTM D5894

Scribe cleaned using

ASTM D1654 method

Outdoor Exposure (ISO12944 C3 environment)

65% Zn

85% Zn

77% Zn

85% Zn

16 Mth exposure

50% Zn

Outdoor exposure (ISO12944 C3 environment)

65% Zn
85% Zn

77% Zn

85% Zn

3 coat system:
Zinc sil/epoxy/pu
16 mths exposure

50% Zn

Zinc Rich Performance Trends

Single coat Zinc Silicate systems always give less scribe

creep than 3 coat systems

Single coat zinc epoxy systems usually give less scribe

creep than 3 coat systems

Different formulations at same zinc level perform differently

Within similar formula types, higher zinc loads usually give

less scribe creep

Testing with an acidic spray (e.g. ASTM D5894 type tests),

always gives higher creep values than testing with neutral
(e.g. ASTM B117) spray

Other Factors Affecting Performance

of Zinc Silicate Systems

Cure conditions
Zinc silicates typically require >50% RH, and some require
>65% RH
Application at low %RH gives poor curing and poor performance

Cure time prior to topcoating

most zinc silicates require 24 hrs, but fast recoating is a benefit

for the applicator

Quality of application dry spray, film roughness, film

porosity, bubbling of topcoats

Type of zinc dust high lead contents may improve

anticorrosive performance, but..its lead. Particle size
distribution may also affect performance.

Overcoating of Zinc Rich Systems

Zinc silicates must be well cured prior to overcoating

Typically 16-24 hrs at 77F/60% RH
Require a sealer or mist coat to prevent pinholing of topcoats

Zinc epoxies may be overcoated in as little as 3 hours under

similar conditions

Time to complete a 3 coat zinc/epoxy/polyurethane system

(actual data from a job*)
Zinc silicate movable in 100 hrs
Zinc epoxy movable in 36 hrs

Faster curing zinc silicates can reduce the time gap between
zinc epoxy and zinc silicate system application

* See Inorganic Zinc Primer vs Organic Zinc primer, M.Cornago, ENI Exploration & Production,
presented at Corrrosion 2007

Flaking due to overcoating before full cure

Pinholing of topcoats over IOZ

Conclusions

% Zinc is not sole determining factor in IOZ or OZ

performance

Generally, in equivalent type formulations, % Zinc will affect

performance, depending on the system/exposure
environment

Selection of % Zn required (or even if zinc rich is

appropriate) should be based on application and exposure
environment

Topcoated IOZ systems perform poorer in lab testing than

single coat IOZ systems

Performance of a Zinc rich coating should be considered as

a blend of anticorrosive and application related properties
(cure speed, application tolerance, ease of application etc)

Traditional Wisdom?

Zinc silicates are all the same they only differ in zinc
content (wrong)
The only important consideration is how much is in the
coating (no, theres more to it than that)

The more Zinc the better (maybe, but depends on

what youre doing with it)