Coating Galvanic Steel

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Coating Characteristics of Galvanic Steel

The corrosion protection characteristics of hot dip galvanizing and paint largely affect how the two coatings will perform as a duplex
system. Understanding the nature of both coatings helps ensure the success of a duplex system.
Hot Dip Galvanizing After Fabrication

Hot dip galvanizing is the factory-controlled process of dipping properly cleaned steel into a bath of molten zinc. Prior to immersion
in the zinc, the steel is thoroughly cleaned in both alkaline and acid baths. Zinc will not adhere to unclean steel, so the integrity of the
coating is immediately apparent as the steel is removed from the galvanizing bath.
The galvanized coating is metallurgically bonded to the steel through a series zinc-iron alloy layers capped by a free zinc layer. A
galvanized coating is more than just a barrier coating; it actually becomes part of the steel surface and is anodic to the steel substrate.
Because zinc reacts with the atmosphere, the galvanized coating is constantly changing. Zinc reacts with the environment to form zinc
oxides, zinc hydroxides and zinc carbonates. These zinc reaction products are known as the zinc patina. The zinc patina actually helps
protect the free zinc layer, thus providing additional corrosion protection. These changes and reactions affect how paint will adhere to
the galvanized surface.
Paints
Painted steel provides a barrier film between the steel and the environment. A paint system involves the use of layers of coating,
sometimes different types of paint, depending on the type of environment in which the structure will be exposed.
The most important factors for the success of paint systems are adhesion and continuity, and in the case of zinc-rich paints, electrical
conductivity. If the paint does not adhere to the steel, it cannot protect the steel from the corrosive effects of the environment. Surface
preparation is extremely important because the degree of paint adhesions may not be apparent immediately after application. Only
after a few months in the field may poor surface preparation manifest itself in paint failure. Having a clean, properly prepared surface
helps ensure the full potential of the paint system is realized. This is especially true about duplex systems. Continuity of the paint
systems is extremely important for carbon steel, since pinholes and other imperfections quickly become rust pits. However, continuity
is not as important in a duplex system because the zinc coating will not allow the steel to rust at these sites. Zinc-rich paints must be
electrically conductive in order to provide cathodic protection.
Synergistic Effect
When hot dip galvanized steel is painted, the duplex system provides a more sophisticated manner of corrosion protection. The
galvanized coating protects the base steel, supplying cathodic and barrier protection. Paint, in turn, grants barrier protection to the
galvanized coating. The paint slows down the rate at which the zinc is consumed, greatly extending the life of the galvanized steel. In
return, once the paint has been weathered down or damaged, the zinc is still available to provide cathodic and barrier protection. When
painted steel corrodes, voluminous rust grows under the paint and eventually causes the paint to peel. However, if the steel is
galvanized, the corrosion is minimal and the paint will not peel, thereby greatly increasing the life of the structure and minimizing
paint peeling. As one of the most frequent reasons for paint failure is discontinuity in the coating, a galvanized coating will eliminate
early rusting at pinholes. In turn, the life of the product is greatly increased.
The synergistic effect is particularly important as areas such as corners, where paint film tends to be thinner. By contrast, galvanized
coatings are often thicker at corners and edges due to the metallurgical bond of the zinc to the base steel. A duplex system affords
greater corrosion protection than either coating can provide alone. In fact, many tests have shown that a duplex system lasts from 1.5
to 2.5 times the normal combined lifetimes of both the zinc and the paint systems. A periodic maintenance painting schedule can
extend this synergistic lifetime even longer.

Coating Galvanic Steel

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Coating Galvanic Steel

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Coating Characteristics of Galvanic Steel

Hot Dip Galvanizing After Fabrication

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