Inorganic Zinc vs Galvanising

DEFG

Most people in our

industry
know
that
galvanising
is
the
dipping of prepared
steel into a bath of
molten zinc metal. The
zinc then adheres to the
surface of the steel
forming an amalgam
with pure zinc on the
surface.
The zinc is
usually
treated
to
prevent white rusting of
the zinc in wet oxygen
deficient atmospheres.
This treatment used to
be done with chromates
but these days it is likely
to employ thin coatings
of acrylic or polyurethane.
Inorganic zincs are a wet paint coating formed from the mixing of very high levels of zinc powder with a silicate
resin in either a solution of water or solvent. The silicate resin is a type of glass. It is quite reactive with the bare
steel surface and with the surface of the zinc particles to give a coating chemically bonded to the steel surface.
This process is quite distinct from the adhesive forces generated by normal paint coatings. Those are unable to
react with a metal surface and only adhere by dint of their electronic forces. These fall off quite rapidly if the
surface has a coat of dust or grease on it.
How the two systems work:
Surprisingly, zinc galvanising and inorganic zinc coatings work by quite different mechanisms. Zinc protects
steel by galvanically sacrificing itself in place of the more noble iron on the galvanic table. Hence zinc has a
limited life. It does, however, have the advantage that, in non-aggressive conditions, the life of a zinc coating
can be calculated on the basis of depletion rate.
Inorganic zincs work in a much more economical fashion. In the initial service life, the zinc particles do act
galvanically, protecting the steel sacrificially. In this process, the zinc forms slightly soluble zinc hydroxide,
which spreads over the coating and fills up the pores being formed by the reacting zinc.
The zinc hydroxide reacts with carbon dioxide in the atmosphere to form zinc carbonates. These are quite
insoluble and form an impervious barrier to further moisture or corrosive iron penetration. Thus, after the initial
dissipation, the coating no longer protects sacrificially like galvanising but by forming an impermeable barrier. In
effect inorganic zinc coatings give you two protective coats for the price of one.

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Release Date:28-Oct-02
Ref: JT/els

Inorganic Zinc vs Galvanising

DEFG

Which, where?
In general, inorganic zinc coatings are the most economical form of corrosion protection for steel members,
which have a surface area of less than 25 square metres per tonne. As a rule of thumb, if you can pick it up
yourself, then galvanise it. If you cannot lift it unaided, then coat it with inorganic zinc.
Aside from the cost aspect, inorganic coatings and galvanising share the virtue of being substantially immune to
transportation and erection damage.
The application of inorganic zinc coatings can now be controlled to the same degree of quality as galvanising.
The product is controlled to high composition and performance standards under AS2105. The surface
preparation, application and the cure of coatings are well controlled by AS1627.4 and also the new AS3894
standards for field-testing of coatings. With a correctly worded specification, your quality is assured.
International Paints would be happy to assist you in writing a suitable specification.
Appearance
Would you drive an unpainted car? Of course not! Why erect a dull grey metallic finish when it is possible these
days to ensure your project is aesthetically pleasing as well as protected from corrosion. When it comes to top
coating, inorganic zincs are far more economical than galvanising.
Galvanising requires brush blasting for correct preparation of the surface for painting. Inorganic zincs require no
further preparation. Correctly chosen topcoats can go straight on to the inorganic coating. Painting over
galvanising can be problematical in that moisture can always penetrate the coating and react with the pure zinc
surface, leading to paint flaking and some-times premature rusting. Whereas topcoats actually bond into the
inorganic silicate surface of inorganic zincs and the adhesion is much more stable and intact. It is almost
unknown for paint to flake from an inorganic zinc coating.
Unique feature
These days, when it is impossible or prohibitively expensive to blast-clean an existing structure, the application
of inorganic zinc has an additional unique feature. Because it binds chemically to the steel surface, it protects
that surface from corrosion like no other treatment.
Inorganic zinc coatings do not undercut with corrosive products. Any corrosion due to damage to the paint
coating is contained until repair can be effected at the owners timing.
Where do you use them?
Inorganic zinc coatings are used alone or top coated on offshore oil rigs, coal washeries, road bridges, oil
refineries, wharf facilities, mineral processing plants and on steel exposed to temperatures up co 450C.

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Release Date:28-Oct-02
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Inorganic Zinc vs Galvanising

DEFG

There is a downside
Inorganic zinc coatings should not be used on small section steelwork such as purlins, or where there is a high
chance of acid spills onto the coated surface.
Conclusion
It is now being recognised that inorganic zinc coatings are the most economical method of protecting large
section steel against corrosion, especially when putting a decorative finish on it as there is no need for further
surface preparation.

Disclaimer
The information given in this sheet is not intended to be exhaustive and any person using the product for any purpose other than that specifically recommended in this sheet without first
obtaining written confirmation from us as to the suitability of the product for the intended purpose does so at his own risk. Any warranty, if given, or specific Terms & Conditions of Sale are
contained in Internationals Terms & Conditions of Sale, a copy of which can be obtained on request. Whilst we endeavor to ensure that all advice we give about the product (whether in
this sheet or otherwise) is correct we have no control over either the quality or condition of the substrate or the many factors affecting the use and application of the product. Therefore,
unless we specifically agree in writing to do so, we do not accept any liability whatsoever or howsoever arising for the performance of the product or for any loss or damage (other than
death or personal injury resulting from our negligence) arising out of the use of the product. The information contained in this sheet is liable to modification from time to time in the light of
experience and our policy of continuous product development.

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Release Date:28-Oct-02
Ref: JT/els