ADVISORY

NOTE #11
ABRASION RESISTANCE OF HOT DIP
GALVANIZED COATINGS
Issue 2: July 2014
TABLE OF CONTENTS

Contents
ABRASION RESISTANCE OF HOT DIP GALVANIZED COATINGS _________________________________1
Introduction ____________________________________________________________________________ 1
Abrasion resistance comparasion with zinc rich primers _________________________________________ 1
Hardness of hot dip galvanized coating ______________________________________________________ 2
References: __________________________________________________________________________ 2
 ADVISORY NOTE #11

ABRASION RESISTANCE OF HOT DIP GALVANIZED COATINGS

INTRODUCTION
The toughness of a galvanized coating makes it particularly suitable in situations where abrasion could be a
problem either in assembly or in use. Conveyor systems, including buckets for quarried material and hoppers
for coal wagons, are well suited. Galvanizing also limits the damage when spanners or other tools slip or if
nuts or bolt heads turn on a galvanized surface during tightening. The toughness of the coating greatly
simplifies the handling of large, heavy sections and reduces any remedial measures that may be necessary.
Even where base steel is exposed, the sacrificial corrosion protection properties of the hot dip galvanized
coating will protect these exposed areas and prevent unsightly and detrimental rust.

ABRASION RESISTANCE COMPARASION WITH ZINC RICH PRIMERS

Abrasion tests show that if abrasion resistance for epoxy zinc-rich primers and most other conventional
paints is taken as unity, polystyrene zinc-rich primers are 5 times better, zinc silicate primers 50 times better
and hot-dip galvanized steel 400 times better. The relative performance is assessed by comparing the weight
of silicon carbide (in g) needed to erase 100 µm of coating using a Taber Abraser.

COATING TYPE WEIGHT OF SILICON CARBIDE (g)

Epoxy zinc-rich primer 0.05-0.06
Polystyrene zinc-rich primer 0.2-0.3
Zinc silicate primer 2-3
Galvanized steel 20-25

Figure 1: In this project, HDG was a practical solution for handling and abrasion resistance

Abrasion Resistance of Hot Dip Galvanized Coatings Page 1

ADVISORY NOTE #11

HARDNESS OF HOT DIP GALVANIZED COATING

The cross section of the galvanized coating (Figure 2) shows the various zinc-iron alloy layers metallurgically
bonded to the steel base and covered by an outer layer of pure zinc. While the pure zinc outer layer is
relatively soft, the zinc-iron alloy layers have been found to be harder than the mild steel base. The abrasion
resistance of a hot dip galvanized coating can be likened to a buffer stop. The soft outer zinc absorbs much of
the shock of an initial impact and then the underlying zinc-iron alloy layers prevent or greatly reduce
penetration of the coating and exposure of bare steel.

Eta η
(100% Zn)
70 HV
Zeta ζ
(94% Zn 6% Fe)
179 HV
Delta δ
(90% Zn 10% Fe)
244 HV
Gamma γ
(75% Zn 25% Fe)
250 HV
Base Steel
159 HV
Figure 2: Cross-section of typical hot dip galvanized coating showing hardness of layers

References:
Zinc Handbook, International Lead Zinc Research Organization, 1991
After Fabrication Hot Dip Galvanizing – A Practical Reference for Designers, Specifiers, Engineers, Consultants, Manufacturers and Users,
Galvanizers Association of Australia, 4th Edition, 2013

This Advisory Note is intended to keep readers abreast of current issues and developments in the field of galvanizing. The Galvanizers
Association of Australia has made every effort to ensure that the information provided is accurate, however its accuracy, reliability or
completeness is not guaranteed. Any advice given, information provided or procedures recommended by GAA represent its best
solutions based on its information and research, however may be based on assumptions which while reasonable, may not be applicable
to all environments and potential fields of application. Due and proper consideration has been given to all information provided but no
warranty is made regarding the accuracy or reliability of either the information contained in this publication or any specific
recommendation made to the recipient. Comments made are of a general nature only and are not intended to be relied upon or to be
used as a substitute for professional advice. GAA and its employees disclaim all liability and responsibility for any direct or indirect loss
or damage which may be suffered by the recipient through relying on anything contained or omitted in this publication.

Galvanizers Association of Australia T: +61 3 9654 1266

Level 5, 124 Exhibition Street E: gaa@gaa.com.au
Melbourne, VIC, 3000 W: www.gaa.com.au
Australia Life Cycle Cost: http://lccc.gaa.com.au

Abrasion Resistance of Hot Dip Galvanized Coatings Page 2