Designation: A 780 01

Standard Practice for

Repair of Damaged and Uncoated Areas of Hot-Dip
Galvanized Coatings1
This standard is issued under the fixed designation A 780; the number immediately following the designation indicates the year of
original adoption or, in the case of revision, the year of last revision. A number in parentheses indicates the year of last reapproval. A
superscript epsilon (e) indicates an editorial change since the last revision or reapproval.

This standard has been approved for use by agencies of the Department of Defense.

1. Scope SSPC-PA2 Measurement of Dry Paint Thickness with Mag-

1.1 This practice describes methods which may be used to netic Gages4
repair damaged hot-dip galvanized coatings on hardware, SSPC-SP2 Hand Tool Cleaning4
structural shapes, and other products fabricated prior to hot-dip SSPC-SP5/NACE No.1 White Metal Blast Cleaning4
galvanizing, and uncoated areas remaining after initial hot-dip SSPC-SP10/NACE No.2 Near-White Blast Cleaning4
galvanizing. The damage may be the result of welding or SSPC-SP11 Power Tool Cleaning to Bare Metal4
cutting (flame), in which case the coating will be damaged 3. Terminology
predominantly by burning. This practice can also be used to
repair hot-dip galvanized coatings damaged by excessively 3.1 DefinitionsFor definitions of terms used in this
rough handling during shipping or erection. Requirements practice, refer to Terminology A 902.
concerning the renovation of uncoated areas remaining after 4. Materials
initial hot-dip galvanizing are contained within the applicable
material specification. 4.1 PropertiesThe material used for repairs shall have the
1.2 This practice describes the use of low melting point zinc following characteristics:
alloy repair rods or powders made specifically for this purpose, 4.1.1 One application of the material shall provide a coating
the use of paints containing zinc dust, and the use of sprayed thickness of at least 2.0 mils (50.8 m).
zinc (metallizing). 4.1.2 The applied coating shall provide barrier protection
1.3 The extent of repair shall be limited to an area mutually and shall preferably be anodic to steel.
agreeable to the contracting parties. Similarly, contracting 4.1.3 Application of the coating material shall be possible
parties shall agree to the repair method to be used. under shop or field conditions.
1.4 This standard does not purport to address the safety 4.2 TypesThere are three types of material that possess
problems, if any, associated with its use. It is the responsibility the required properties and may be used to repair damaged
of the user of this standard to establish appropriate safety and galvanized coatings, as follows:
health practices and determine the applicability of regulatory 4.2.1 Zinc-Based SoldersZinc alloy solders are to be used
limitations prior to use. for repairs. The most common types of solders are zinc-
1.5 The values stated in inch-pound units are to be regarded cadmium, zinc-tin-lead, and zinc-tin-copper alloys. Zinc-
as the standard. The values given in parentheses are for cadmium and zinc-tin-lead alloys have liquidus temperatures in
information only. the ranges from 518 to 527F (270 to 275C) and 446 to 500F
(230 to 260C), respectively. (The liquidus temperature is that
2. Referenced Documents temperature above which an alloy is completely molten.) The
2.1 ASTM Standards: zinc-tin-copper alloys have a liquidus temperature in the range
A 902 Terminology Relating to Metallic Coated Steel Prod- from 660 to 670F (349 to 354C), but they are applied while
ucts2 in a semisolid state in the preferred application temperature
D 520 Specification for Zinc Dust Pigment3 range from 480 to 570F (250 to 300C). The solders can be
2.2 Society for Protective Coatings (SSPC) Documents: used in rod form or as powders. Annex A1 describes the use of
zinc-based solders.
4.2.2 Paints Containing Zinc DustThese are usually
1
based on organic binders, pre-mixed and formulated specifi-
This practice is under the jurisdiction of ASTM Committee A05 on Metallic
cally for use on steel surfaces. Paints containing zinc dust, with
Coated Iron and Steel Products and is the direct responsibility of Subcommittee
A05.13 on Structural Shapes and Hardware Specifications. concentrations of zinc dust in the range of 65 to 69 % or above
Current edition approved April 10, 2001. Published June 2001. Originally
published as A 780 80. Last previous edition A 780 00.
2 4
Annual Book of ASTM Standards, Vol 01.06. Available from Steel Structures Painting Council, 4400 Fifth Ave., Pittsburgh,
3
Annual Book of ASTM Standards, Vol 06.03. PA 15213.

Copyright ASTM, 100 Barr Harbor Drive, West Conshohocken, PA 19428-2959, United States.

1
 A 780
92 % in the dried film, are considered equally effective for the droplets of molten metal using wire or ribbon, or powder
repair of damaged galvanized coatings. The repair paint to be processes. Annex A3 describes the use of sprayed zinc.
used shall be selected by the galvanizer, unless the purchaser 4.3 For further information, reference may be made to the
specifies a particular concentration or paint system. Corrosion papers, procedures, and specifications in Refs. (1) through (4)
resistance and service performance are very dependent on the (see list of references at the end of this practice).
properties of the paint system, the extent of surface prepara-
tion, and skills of individual applicators. Annex A2 describes 5. Keywords
the use of paints containing zinc dust. Specification D 520
describes the zinc dust component of these paints. 5.1 coatingszinc; galvanized coating repair; galvanized
4.2.3 Sprayed ZincThis method involves the application coatings; touch-up; zinc coating repair; zinc coatings
of a zinc coating by spraying the surface to be repaired with

ANNEXES

(Mandatory Information)

A1. REPAIR USING ZINC-BASED ALLOYS

A1.1 Clean the surface to be reconditioned using a wire burned. Wire brush the surface to be reconditioned during
brush, a light grinding action, or mild blasting. To ensure that preheating. Pre-flux, if necessary.
a smooth reconditioned coating can be effected, surface prepa-
A1.4 Rub the cleaned, preheated area with the repair stick
ration shall extend into the surrounding, undamaged galva-
to deposit an evenly distributed layer of the zinc alloy. When
nized coating.
powdered zinc alloys are used, sprinkle the powder on the
A1.2 If the area to be reconditioned includes welds, first cleaned, preheated surface and spread out with a spatula or
remove all weld flux residue and weld spatter (of a size that similar tool. The thickness of the applied coating shall be as
cannot be removed by wire brushing or blast cleaning) by agreed upon between the contracting parties.
mechanical means, such as chipping, grinding, or power A1.5 When the repair has been effected, remove flux
scaling, etc. residue by rinsing with water or wiping with a damp cloth.
A1.3 Preheat the cleaned area to be reconditioned to at least A1.6 Take thickness measurements with either a magnetic,
600F (315C). Do not overheat the surface beyond 750F electromagnetic, or eddy-current gage to ensure that the
(400C), nor allow the surrounding galvanized coating to be applied coating is as specified.

A2. REPAIR USING PAINTS CONTAINING ZINC DUST

A2.1 Preparation of the damaged surface will be influenced aged galvanized coating. The method and extent of surface
by the type of paint selected and the anticipated service preparation shall be mutually agreeable to the contracting
conditions. Experience shows that in general, organic zinc-rich parties.
systems are tolerant of marginal surface preparation. Most A2.1.3 If the area to be reconditioned includes welds, first
organic paints containing zinc dust are not critical of climatic remove all weld flux residue and weld spatter (of a size that
or atmospheric conditions for curing. The following general cannot be removed by wire brushing or blast cleaning) by
guidelines shall apply: mechanical means, such as chipping, grinding, or power
A2.1.1 Surfaces to be reconditioned with paints containing scaling, etc.
zinc dust shall be clean, dry, and free of oil, grease, preexisting A2.1.4 Spray or brush-apply the paints containing zinc dust
paint, and corrosion by-products. to the prepared area. Apply the paint as in accordance with the
A2.1.2 Where anticipated, field service conditions include manufacturers printed instructions in a single application
immersion, blast clean the surface in accordance with SSPC- employing multiple passes to achieve a dry film thickness to be
SP10/NACE No. 2 near white metal. For less critical field agreed upon between the contracting parties. Allow adequate
exposure conditions, clean the surface to bare metal, in curing time before subjecting repaired items to service condi-
accordance with SSPC-SP11, as a minimum. Where circum- tions in accordance with the manufacturers printed instruc-
stances do not allow blast or power tool cleaning, it is tions.
permissible to hand tool areas clean in accordance with A2.1.5 Take thickness measurements with either a mag-
SSPC-SP2. To ensure that a smooth reconditioned coating can netic, electromagnetic, or eddy-current gage to ensure that the
be effected, surface preparation shall extend into the undam- applied coating is as specified in accordance with SSPC-PA2.

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 A 780

A3. REPAIR USING SPRAYED ZINC (METALLIZING)

A3.1 Surfaces to be reconditioned by zinc metallizing shall zinc powder. Apply the sprayed coating as soon as possible
be clean, dry and free of oil, grease, and corrosion products. after surface preparation and before visible deterioration of the
surface has occurred.
A3.2 If the area to be reconditioned includes welds, first
remove all flux residue and weld spatter of a size or type that
A3.6 The surface of the sprayed coating shall be of uniform
cannot be removed by blast cleaning by mechanical means,
texture, free of lumps, coarse areas, and loosely adherent
that is, chipping, etc.
particles.
A3.3 Blast clean the surface to be reconditioned in accor-
dance with SSPC-SP5/NACE No. 1, white metal. A3.7 The nominal thickness of the sprayed zinc coating
shall be previously agreed upon between the contracting
A3.4 To ensure that a smooth reconditioned coating can be parties.
effected, surface preparation shall be extended into the sur-
rounding undamaged galvanized coating. A3.8 Take thickness measurements with either a magnetic,
A3.5 Apply the coating to the clean and dry surface by electromagnetic, or eddy-current gage to ensure that the
means of metal-spraying pistols fed with either zinc wire or applied coating is as specified.

REFERENCES

(1) Van Eijnsbergen, J. F. H., et al, Reconditioning Damaged Galvanized (3) MIL-P-21035 (Ships), Military Specification, Paint, High Zinc Dust
Surfaces, 6th International Conference on Hot Dip Galvanizing, Content, Galvanizing Repair, Amendment 1, U.S. Government
Interlaken, June 1961, pp. 128141. Printing Office, Washington, DC, 1970.
(2) SSPC-Paint-20, Zinc Rich Coatings, Type I Inorganic, Type II (4) Recommended Practices for Fused Thermal Sprayed Deposits,
Organic, Steel Structures Painting Council, 4400 Fifth Ave., Pitts- American Welding Society, Inc., 550 N.W. LeJeune Rd., Miami, FL
burgh, PA 15213, 1979. 33135, 1975.

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