Galvanizing - White Rust Cures and Prevention

Galvanizing ­ White Rust Cures and Prevention

Written by AZoM Feb 1 2002

Bogdan Vija / Shutterstock

“White rust” or “white storage stain” is one of the typical problems faced in
galvanized coatings. It occurs as a white, bulky, powdery deposit that forms
rapidly on the surface of the galvanized coating, under particular environments.

White rust can cause substantial damage to the galvanized coating and is detrimental to
its appearance. The surface of the galvanized coatings mostly contains zinc. The
outstanding anti­corrosion performance of steel is credited to zinc’s durability; however,
zinc is a relatively “reactive” metal.

Zinc’s durability is established by the stable oxides that form on the surface of this
element and these oxides form slowly as zinc is exposed to air. Mostly, carbon dioxide
contributes to the formation of these stable oxides.

The freshly galvanized steelwork makes zinc’s surface extremely susceptible since it has
been exposed to some level of oxidation. Hence, chromate passivation should be used
along with galvanizing operations to protect the galvanized coating during its “youth”

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Galvanizing - White Rust Cures and Prevention

phase. This passivation coating provides limited protection to zinc, offering time for the
stable oxides to develop on the surface.

White Rust Formation

Pure water (H2O) does not contain any dissolved salts or minerals, and will react swiftly
with zinc to form zinc hydroxide—a bulky white and moderately unstable oxide of zinc.
When newly galvanized steel is exposed to pure water (for example, rain, dew, or
condensation) in an oxygen­deficient setting, the water will continue to react with zinc
and slowly corrode the coating.

The typical circumstance where white rust is formed is when galvanized products are
securely packed, compactly arranged, or when water seeps into the items and stays for
extended periods.

Avoiding White Rust Formation

The formation of white rust can be considerably minimized or completely prevented by
following these basic steps:

The packed work must be dry

The items must be packed to allow air circulation between the surfaces
The packed items must be piled up to allow water to drain out
The surface must be treated with barrier or proprietary water­repellent coatings to
prevent moisture from touching the galvanized surface

Treating Galvanized Surfaces Affected by White Rust

After the galvanized surface has been compromised and the zinc hydroxide compounds
have developed, it is better to remove the oxide products from the surface, as:

Their presence stops the development of stable carbonate­based oxides

They are unappealing

The effect on the galvanized coating can differ from extremely trivial to extremely serious,
and various levels of remedial treatment are available to handle various problems relating
to white rust.

Light White Rusting

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Galvanizing - White Rust Cures and Prevention

This is characterized by the formation of a light film of white powdery residue, and
frequently occurs on galvanized products during heavy rain seasons. It is particularly
evident in regions that have been buffed or filed during quality assurance operations. In
these treatments, the passivated surface is taken off, and un­oxidized zinc is open to
attack from rainwater. Furthermore, if the items are well­drained and well­ventilated,
white rust barely forms beyond this superficial phase.

If required, it can be brushed off; however, it will usually wash off in normal weather. This
level typically does not require any remedial treatment.

Moderate White Rusting

This can be seen as a distinct darkening and etching of the galvanized coating under the
damaged region, with the formation of white rust appearing large. It is crucial to analyze
the thickness of the galvanized coating to estimate the degree of the attack on the
coating.

In the majority of cases, below 5% of the galvanized coating will have been taken off and
there is no need for corrective action as long as the appearance of the affected area is
satisfactory for the use of the product. Residues of zinc hydroxide are removed by wire
brushing. If the appearance is unappealing, the area affected by white rust can be treated
as mentioned below:

Using a cloth pad wet with aluminum paint, the surface should be rubbed to apply a
thin film of aluminum paint to the affected area to blend it with the neighboring
unaffected galvanized surfaces
Using a wire brush, all white corrosion products must be eliminated from the
problem area

Severe White Rusting

Severe white rusting is characterized by extremely heavy oxide deposits. The products
may be fixed together. Regions under the oxidized area may be almost black, and display
signs of red rust. The degree to which the galvanized coating has been damaged can be
established by checking the thickness of the coating. Remedial treatment to restore the
coating should be performed as given below:

The affected region should be buffed or wire brushed, to remove all oxidation
products and rust

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Galvanizing - White Rust Cures and Prevention

One or two coatings of approved epoxy zinc­rich paint should be applied, to

achieve the necessary dry film thickness of at least 100 µm

Re­Passivating the Galvanized Surface

The surface can be re­passivated where white rusting has occurred, and the item can be
continuously exposed to spread the same kind of corrosion. Re­passivation of a surface
can be achieved by treating the surface with a solution of 0.1% sulfuric acid and 5%
sodium dichromate, then brushing with a solid wire brush for 30 seconds, and finally
rinsing the surface thoroughly.

Conclusion
White rust is an occurrence that happens following galvanization. The way it is handled,
packed, and stored prior to the installation, and use of the galvanized product is crucial
for its prevention.

The formation of white rust is not an indication of the performance of the galvanized
coating, but rather highlights the responsibility of all those involved in the supply chain.
This ensures that the causes of white rust are known and the possibilities of its
occurrence are minimized on the newly galvanized steel.

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