Galvanizing vs.

Zinc-rich Coatings –
Comparative Performance
Introduction

• Both are used to protect steel structures against

corrosion

• Galvanizing
– Hot Dip
– To Form a Layer of Pure Zinc

• Zinc-rich coatings
– Inorganic Zinc Silicate Primer – Interzinc 22
– Organic Zinc (Epoxy Zinc-rich Primer) – Interzinc 52
– Zinc Particles in a Inorganic or Organic Binder
Anti-corrosion Mechanism

• Why Use Zinc to Protect Steel Structures

– Lower Corrosion Potential Than Carbon Steel
– Electrochemical Reaction – Cathodic Protection

Zn2+

Electrolyte

Steel - Cathode Zinc - Anode

Mechanism of Anti-corrosion

• Zinc either by galvanizing or by application of a zinc-rich

coating, the same anti-corrosive mechanism:
– Barrier
– Anode: sacrifice itself and protect the steel

• Basic differences between galvanizing and coatings

– In an aggressive environment, the inert binder matrix in
zinc-rich coatings will retard the zinc degradation
– For galvanizing, however, zinc will degrade rapidly
Application

Zinc-rich primers Galvanizing

Application Place Shop or field Shop only

Small parts due to

Structure Size Any size
limited bath size

When to Apply Before or after erection Most before erection

Mechanical Properties

• Similar Abrasion Resistance

• Friction Coefficient
– Zinc Silicate: 0.52 – can be used in faying surfaces
– Galvanizing: 0.25 – can NOT be used in faying surfaces
Comparison of Anti-corrosive Performance – Without Topcoat

• Marine Environment:
– Zinc silicate primers are outlasting galvanizing by both laboratory
accelerated test and outside exposure

Hot Salt Spray - ASTM D117, 1440 Hours

Zinc Silicate Primer @ 75µm DFT Galvanizing @ 75µm DFT

– Florida, 2 Years exposure – No appreciable corrosion for zinc

silicate, but severe pinpoint rusting for galvanizing
FIELD TESTING

Panels of steel
immersed in
seawater for two
years.
Fig 3 are racks
containing two
different inorganic
silicate coatings.
Fig 4 was protected
by galvanizing but
has since corroded.
Figure 3 Figure 4
FIELD TESTING

• Galvanising alone has not always been successful e.g. Coal

washeries at Sth Blackwater, Saxonvale, Mt Thorley etc, have
shown dramatic depletion of zinc to the point of rusting and major
repaints have had to be conducted.

• Conversely, Curragh Coal Mine was painted with IOZ primer only
in 1981 and largely remains untopcoated today 20 years later.

• This is a testimony to the performance of such products in their

correct usage areas.

• There are numerous other examples of the use of IOZ alone on

major structures such as power stations, alumina refineries,
bridges, mines etc.
Mt Thorley Wash Plant -- Original galvanising
Blackwater Coal Washplant - Originally galvanised.
CURRAGH COAL MINE Inorganic Zinc Silicate
Dalrymple Bay 1991
Figure 9 Further example of IOZ on port machinery
Comparison of Anti-corrosive Performance – Without Topcoat

• In severe chloride or sulfide environments

-- water-soluble zinc chloride and zinc sulphide salts are

formed on surface of galvanizing. The water-soluble
zinc salt will prevent formation a stable oxide layer – which
will normally provide some protection to zinc. How ever
washable zinc salt can expose fresh zinc surface, which will
results in rapid zinc corrosion. Overtime, When approximate
25µm of the original zinc remain, active rusting will occur.

-- It is very difficult to complete removal of water-

soluble salts and rust, that make maintenance of degrade
galvanized surface very costly.
Comparison of Anti-corrosive Performance – Without Topcoat

• Industrial Environment & Humid Conditions:

– Zinc silicate primers has good chemical resistance and

humidity resistance compared to hot dip galvanizing

– Inorganic poly-silicate matrix, surrounding the metallic zinc

particles, retards the degradation

• Temperature
Zinc Silicate Galvanizing
Max. Service
540°C 400°C
Temperature
Comparison of Anti-corrosive Performance – Without Topcoat

• Galvanising, however, is substantially free of transportation and

erection damage. It is very difficult to repair transportation and
erection damage and the cost of repairing will be very high.

• Because of the high temperatures of the bath, the possibility of

heat distortion cannot be discounted. High tensile strength steels
are susceptible to embrittlement due to acid cleaning and may
have to be abrasive blast cleaned.
Comparison single coat of galvanized steel and Zinc Silicate
according ASTM B117 2000h

Galvanized single coat Zinc Silicate single coat

Comparison of Anti-corrosive Performance – Top coated

• Why apply top coatings?

– Aesthetical purpose
– Barrier – extend the effective use of zinc

• Cautions must be taken when apply top coatings

– Sufficient film thickness 75 – 150 µm
– Top coatings subject to saponification are NOT suitable.
E.g. Alkyds, Epoxy Ester
Comparison of Anti-corrosive Performance – Top coated

• Top coating of galvanized steel is LESS

reliable than zinc silicate primers (Figure 10)
– Too smooth surface to provide adhesion – sweep blasting
required
– More “white rust” causing adhesion and blistering problems
– Compounds such as Chromate used as surface passivate
galvanized
– Need more adequate cleaning to remove contaminants, corrosion
products
– To eliminate potential intercoat adhesion problems, zinc rich
coatings are preferred rather than hot dip galvanizing. Epoxy
zinc such as Interzinc 52 provide similar performance in multi-
coat system and offer the benefit of reduced cure problems
under adverse climitic conditions. (eg. Cold , Dry)
 Comparison of galvanized steel and Zinc Rich with top
coating according ASTM B117 2000 hours

Figure 10 Unreliable top coating of Figure 11 Reliable top coating of Figure 12 Reliable top coating of
galvanized steel Zinc Silicate Epoxy Zinc
Failures of coating over gal causes by poor surface prep and
exposure to corrosive environment. Approx 2 years service.
Inorganic Zinc Silicate Primer vs. Epoxy Zinc-rich Primer

• As a single coating, inorganic zinc primer has better

anti-corrosive performance than epoxy zinc primer

Zinc Epoxy, SSPC Paint 29 (50%

Zinc in DFT)

Zinc Epoxy, SSPC Paint 20 (80%

Zinc in DFT)

Zinc Silicate (85% Zinc in DFT)

Note: Open circuit potential – more negative grading

corresponds to a high degree of corrosion protection
Inorganic Zinc Silicate Primer vs. Epoxy Zinc-rich Primer

• As a primer of a coating system, both have similar anti-corrosive

performance, Epoxy zinc are likely much less to have cure problems
(eg. In cold, dry conditions), where IOZ will not cure.

Coating System Test Methods Results

2mm Average
Zinc Silicate Primer 75µ ASTM D5894 (4200hours) Corrosion Creep.
Tie Coat 25µ No coating defects.
Epoxy Intermediate 200µ
Polyurethane Top-coat 50µ Outside Exposure in an Industrial 2mm Average
Environment (C4) Corrosion Creep.
( 30 Months） No coating defects.

1mm Average
Epoxy Zinc-rich Primer 75µ ASTM D5894 (4200hours) Corrosion Creep.
Epoxy Intermediate 200µ No coating defects.
Polyurethane Top-coat 50µ
Outside Exposure in an Industrial 0mm Average
Environment (C4) Corrosion Creep.
( 30 Months) No coating defects.
Summary

• Both zinc-rich coatings and galvanizing provide

effective long term corrosion protection

• However zinc-rich coatings offer

– Improved resistance under high humidity conditions, also in
marine and chemical environments
– No limitation of structure size for application
– Improved top-coatability – less possibility of adhesion and
blistering problems
– Zinc silicate can be used in faying surface
Summary

• For a single coat, inorganic zinc silicate has better anti-

corrosive performance than epoxy zinc-rich primer.

• However in a coating system epoxy zinc primer has

similar anti-corrosive performance to zinc silicate.

• In severe chloride or sulfide environments, zinc-rich

coating system has much better anti-corrosive
performance than galvanizing
Comparison of Cost Considerations

• It is generally cheaper to galvanize most small pieces and small irregular

shapes such as handrails, small angles, open floor grating, ladders, bolts,
and nuts

• As a general rule, galvanizing is cheaper if the piece is less than 152 mm

wide, less than16mm thick, or lighter than 146 kg/sq m, or more than 38
sq m/ton

• It is usually cheaper to abrasive blast and apply inorganic zinc to large

structural pieces, pipe, tank plates, vessels, and large irregular shapes of
all types.

• Storage: Freshly galvanised steel needs to be stored (cost) in a specific

manner to prevent “white rust” which occurs on contact with rain or
condensate water – this can complicate the construction schedule and
lead to increased overheads
Comparison of Cost Considerations

• In china, the cost of galvanizing per ton of Structure Steel is about

1300 -1400RMB/ton

• The cost of three coats system is about 1000 – 1100RMB/ton, the

price include paint, abrasive blast and paint application.

• The direct cost of three coats system is 15% - 20% cheaper than
galvanizing
Track Record 1: Three coats system of BASF--IPS

• Zinc Silicate Primer DFT: 75µm

Interzinc 22

• MIO Intermediate DFT: 75µm

Intergard 475HS

• Polyurethane Top-coat DFT: 50µm

Interthane 990

• BASF-IPS is located in Nanjing Chemical Industry Park and

beside Yangtze River
Bird's-eye picture of BASF-IPS IOU
Track Record 2: Three coats system of CSPC in Huizhou

• Zinc Silicate Primer DFT: 75µm

Interzinc 22

• MIO Intermediate DFT: 75µm

Intergard 475HS

• Polyurethane Top-coat DFT: 75µm

Interthane 990

• CSPC is located in south coast area of China

Track Record 3: Two coats system of BP SECCO

• Zinc Silicate Primer DFT: 62 – 75 µm

Interzinc 22

• MIO Intermediate DFT: 100 – 150 µm

Intergard 475HS

• BP SECCO is located in Shanghai Chemical Industry Park and at

the same area of BASF IIP
Pipe Rack of BP SECCO
Quality Management: The way to keep high surface quality

• We can provide 5 years Product Performance Guarantee

According ISO 12944-5:1998(E) and IIP project specification GEN-0-
TECH-SP-0001, the 250 µm paint system can provide more than 15
years to first major maintenance.
(According ISO 12944-2:1998(E), In C5-I environment, the galvanizing
thickness loss is from 4.2 µm to 8.4 µm per year. If the galvanizing
thickness below than 25µm, the steel will rusting. So, the 85 µm
galvanizing film just can provide 7-14 years protection or shorter.)

• Material manufacturers should provide fingerprints of their materials from

their headquarters and EPC contractor reserves the right to verify
material at any time during the contract.

• Attention should be paid to and points should be given to manufacturing

the materials inside China to avoid logistics problems.
Quality Management on job site

• International Paint will provide bi-lingual on jobsite NACE coating

certified inspector or equivalent.
• The duty of Inspectors:
9 Monitor and record environmental conditions and surface
preparation
9 Ensure that paint mixing and thinning (when required) are
properly carried out.
9 Present at the initial paint application on new projects to
set/agree the standard.
9 Measure wet and dry film thickness or arrange volume/area
control as and when appropriate.
9 Ensure that maximum and minimum overcoating interval and
time are adhered to.
9 Check coating sequence and application