6/23/20

Coating over Hot-Dip Galvanizing: Improving

Communication and Specification
Alana Fossa
American Galvanizers Association
Sr. Corrosion Engineer

1
 6/23/20

Duplex Systems
Today’s webinar will discuss:
• Benefits and when to specify paint/powder coating with hot-dip
galvanizing in a duplex system
• Specification Updates that Address Responsibilities of the
Specifier, Galvanizer & Painter
• Practical discussion points to ensure successful specification and
surface preparation prior to paint/powder coating
• Preparation of HDG for Maintenance of Duplex Systems

About the American Galvanizers Association

Non-profit trade association established in 1933
• Serves as a unified voice and provides expertise in the after
fabrication hot-dip galvanizing industry
Provides technical support on innovative application and
technological developments in hot-dip galvanizing for
corrosion protection
• Free assistance for North American
specifiers
• Resource for our members

2
 6/23/20

Duplex Systems: Corrosion Protection + Color

• Duplex system is paint or powder
coating over hot-dip galvanized steel
• Best of both worlds:
• Hot-dip galvanizing (HDG) provides long lasting
corrosion protection, durability, longevity
• Paint or powder coating provides additional
protection and endless aesthetic options
• Synergy between the coatings provides longer
life and longer paint maintenance cycles
Duplex Longevity = (1.5 to 2.3) x (HDG + Paint)
Paint Maintenance Cycles over HDG = 1.5x longer

Applications for Duplex Systems

• Extending Paint Maintenance Cycles
• Buried in Harsh Soil Conditions
• Exposure to Acidic/Alkaline Chemical
Fumes and Condensation
• Frequent Exposure to Road Salting
• Marine/Coastal Environments
• Waterparks, Pools, and Aquatic Facilities
• Immersion Applications
• Under Insulation
• Aesthetics

3
 6/23/20

Surface Preparation Critical for Duplex Systems

• Poor surface preparation of the HDG
surface is primary cause for Duplex
System failure.
• Miscommunication about responsibilities
for surface prep
• HDG repair products or filler materials
incompatible with primer
• Incorrect identification of initial condition
• Insufficient smoothing
• Insufficient cleaning
• Insufficient roughening

Specifying Surface Prep for Duplex Systems

Standards, Responsibilities, and Communication

4
 6/23/20

Relevant Standards
• ASTM D6386: Surface Prep for painting based on
identified initial HDG surface condition
• Avoid galvanizing post treatments (water or
chromate quench)
• Smooth, clean, profile

• ASTM D7803: Surface Prep for powder coating based

on identified initial HDG surface condition
• Avoid galvanizing post treatments (water or
chromate quench)
• Smooth, clean, profile
• Pre-bake to reduce outgassing AGA has instructional DVDs and guide booklets
that cover prep for paint (D6386) and
• SSPC-SP 16: Brush-Off Blast Cleaning for HDG Steel
powder coating (D7803) over HDG
• SSPC Guide 19: Selecting Coatings for use over HDG

Roles & Responsibilities for Surface Preparation

Specifier
• Inform all parties the
article is to be
duplexed
• Mutually agree with all
parties on
responsibility for
surface smoothing
after HDG
Galvanizer
• Refrain from HDG post
treatments (i.e.
quenching)
• Mutually agree with all
parties on
responsibility for
surface smoothing
Paint/Powder
Coating Applicator
• Cleaning, Profiling, and
potential Outgassing
• Mutually agree with all
parties on
responsibility for
surface smoothing

10

5
 6/23/20

Updated Specification Language to Address

Communication on Surface Smoothing
• New verbiage ASTM A123 Paragraph 6.4

Surface roughness of articles to be painted or powder coated

and the smoothing of the galvanized coating before painting or
powder coating shall be mutually determined by the galvanizer
and the purchaser. Further preparation of galvanized coatings
for painting or powder coating including cleaning, profiling and
outgassing shall be in accordance with Practice D6386 for
painting and Practice D7803 for powder coating and are the
responsibility of the paint or powder coating applicator.

11

Preparation of the HDG Surface

Discussion Points for Specification and
Project Bidding

12

6
 6/23/20

Discussion Point: Galvanizing Finish

• Galvanizing Post Treatments
• Water Quenching (avoid)
• Chromate Quenching (avoid)
• Phosphatizing (not common, but can be acceptable)

• Surface conditions normally acceptable if

galvanizing-only (ASTM A123), but may
negatively impact adhesion of paint/powder:
• Roughness
• Dross Inclusions
• Zinc Skimmings
• Zinc Runs or Excess Zinc

13

Discussion Point: HDG Repairs

• In-plant, at paint shop, at jobsite
• ASTM A780 Practice for Repair of
Damaged and Uncoated Areas of Hot-Dip
Galvanized Coatings

• Discuss Repair Methods:

• Zinc-Rich Paint
• Discuss with paint applicator (who applies?)
• Recoat windows need to be considered
• Coating compatibility should be tested
• Zinc-Based Solder
• Discuss curved/overhead surfaces
• Zinc-Spray Metallizing
• Discuss accessibility with equipment

14

7

Discussion Point: Identifying Surface Condition
• HDG goes through passivation/
weathering cycle to form a patina
• Steps for each condition given in D6386 & D7803
Free flowing air
O2
Zinc Oxide ZnO
Moisture from rain (dew)
H 2O
Zinc Hydroxide Zn(OH) 2
Free flowing air O 2 +
CO 2
Zinc Carbonate 2ZnCO3
15
Discussion Point: Surface Smoothing
16
6/23/20
• Newly Galvanized
• Typically < 48 hours
• No visible oxide formation, minimal cleaning
• Do not assume -- can be impractical, especially
when galvanizer/painter are different parties
• Partially Weathered (or Unknown)
• Typically 48 hours – 12 months
• All preparation steps required
• Assumed when surface condition unknown
• Fully Weathered
• Typically >12 months
• Matte color zinc patina (zinc carbonate)
• Easiest to prepare – may not need to roughen
• Primary Goal:
• Remove high spots or roughness
above and beyond standard
galvanizing finish (ASTM A123) to
achieve a smooth surface
acceptable for paint/powder.
• Responsibility:
• Galvanizer? Painter? Both?
• Often overlooked
8
 6/23/20

Smoothing the Surface

• Grind/file surface smooth and flat to
remove bumps, runs, drips.
• SSPC-SP 2 Hand Tool Cleaning
• SSPC-SP 3 Power Tool Cleaning

• Confirm HDG coating thickness after

smoothing. Repair as needed (ASTM
A780)

17

Discussion Point: Use of Filler Materials

• Projects with elevated smoothing
or aesthetic requirements

• Filler materials used to smooth

depressions, divots, chain/wire
marks or vent hole plugs
• Caulking/Silicone/Putty
• Compatibility with the primer?
• Who applies?

18

9
 6/23/20

Clean the Surface

• Required for partially and fully
weathered surface conditions
• May be required on newly galvanized

• Remove dirt, oil, grease, or other

surface contaminants
• Methods listed in D6386 & D7803:
• Alkaline wash (10:1 water to alkaline)
• Acidic solution (25:1 water to acid)
• Solvent cleaning (SSPC-SP 1)
• Thoroughly rinse and dry

19

Profile/Roughen the Surface

• Roughen the surface to create anchor for
paint/powder
• Required for newly galvanized and partially
weathered surfaces
• Could be required for fully weathered if
increased profile height ( >0.5 – 1 mil) required

• Available Methods:
• Brush-Off (Sweep) Blasting per SSPC-SP 16
• Surface Grinding per SSPC-SP 11
• Zinc Phosphate Solution
• Wash Primer
• Acrylic Pretreatment

20

10
 6/23/20

Brush-Off Blasting SSPC-SP 16 (most common)

• SSPC-SP 16, Brush-Off Blast Cleaning of Coated
and Uncoated Galvanized Steel, Stainless
Steels, and Non-Ferrous Metals
• Sweep angle 30 to 60 degrees
• 0.75 mils minimum profile height
HDG with dark/matte initial HDG with light/shiny initial
• Lower pressures and softer/finer abrasives appearance (reactive steel or appearance (steel with
• Look for change in appearance (not as pronounced steel outside recommended recommended Si% content)
on reactive steel) Si% content)

• Avoid removing base zinc:

• Avoid full pressure at 90 degrees
• Rapid nozzle movements
• Begin at low nozzle pressure/increased stand-off HDG matte/etched appearance
then slowly increase pressure or decrease standoff after sweep blasting (regardless of
initial HDG appearance) Avoid Over-Blasted Surfaces

21

Discussion Point: Abrasives for Brush-Off Blast

• Current Industry • Current recommendations may not be
Recommendations: effective at producing surfaces
• Mohs hardness <5 acceptable for industrial or thick
• Sized 35 to 70 mesh coatings requiring increased peak
• corn cobs height or angularity
• walnut shells • Epoxies, High-Build Coatings, Polyurethanes
• aluminum/magnesium silicate
• soft mineral sands
• soft crushed glass
• glass bead

• Produces clean surface with low

profile height (<1.5 mil)

22

11
 6/23/20

Discussion Point: Use of Alternative Abrasives

• Paint and Powder Coating applicators
turning to different abrasives to
achieve increased profile heights:
• Increased Mohs hardness (>5)
• Mineral sands and inorganic mixtures
• Course grades, larger mesh sizes
• Mitigations may be required to reduce
risk of HDG damage
• Nozzle pressure and abrasive size most often
correlated to changes in surface profile and
likelihood of coating damage
• Protecting the zinc will likely require an
inefficient use of abrasive
• 0.4 – 0.6 mils reduction in coating
thickness found to be typical
• Often acceptable for Duplex Systems maintained
for aesthetics
• Embedment of abrasives common for
zinc surfaces – care should be used with
metallic abrasives

23

Grinders and Sanders

• SSPC-SP 11 Power Tool
Cleaning to Bare Metal
• Discuss:
• ASTM D6386 allows removal of HDG
coating up to 1 mil – is this acceptable
to project?
• Profile height expectations
• Practical means to paint surface
immediately in humid conditions

24

12
 6/23/20

Zinc-Phosphate Treatment
• Discuss:
• Availability as galvanizing post-
treatment
• Immersion vs. spray or brush
applications
• Surface profile height
requirements
• Powder coating cure temp

25

Wash Primers
• SSPC-Paint 27 Basic Zinc
Chromate-Vinyl Butyral
Wash Primer
• Material, application and
inspection requirements
• Chromate-free and low
VOC options available
• Discuss:
• Galvanizing post treatments
• Compatibility with primer

26

13
 6/23/20

Pre-Bake (Powder Coating Only)

• HDG coating and surface oxides can
retain moisture or air.
• Upon heating during the curing of the
powder coating, water vapor or air is
released and can lead to outgassing.
• To avoid outgassing:
• Remove all surface oxides during cleaning.
• Pre-bake (~1 hour) at a temp higher than the curing
temp (typically +50-65 F).
• Do not exceed 535 F if zinc phosphate treatment used
• Powder coat ASAP to avoid surface oxides reforming

27

Preparation for Maintenance Painting

• Removal of existing coating
• Paint Strippers
• Power Wash < 1450 psi
• Other methods possible, but key is to avoid
damaging galvanizing beneath
• Communicate requirements for inspection
of HDG
• Discuss galvanizing repairs and method
• Overcoating compatibility and recoat windows if
using zinc rich paint
• Discuss potential to utilize existing
profiled surface beneath the paint with
minimal surface preparation

28

14
 6/23/20

Summary
Preparing HDG for Painting and Powder

29

Duplex Systems: The Best of Both Worlds

• Duplex systems provide corrosion protection
and aesthetics with longer life and less
maintenance
• Specifying duplex systems is simple, but
requires communication and clear division of
responsibility
• Properly identifying the initial surface
condition and specifying practical surface
preparation methods are critical to a
successful duplex system

30

15
 6/23/20

AGA Resources
• Galvanizer Locator
• galvanizeit.org/galvanizers
• Technical Assistance/Expertise
• aga@galvanizeit.org
• 720.554.0900
• Dr. Galv KnowledgeBase
• galvanizeit.org/knowledgebase
• AGA Project Gallery
• galvanizeit.org/project-gallery
• Galvanizing Insights quarterly
newsletter
• Technical Library

31

Questions & Comments

• American Galvanizers
Association
• www.galvanizeit.org

• Contact Information
• Alana Fossa
• Sr. Corrosion Engineer
• afossa@galvanizeit.org
• 720.361.4485

32

16