SSPC-Guide 19

November 8, 2012

SSPC: The Society for Protective Coatings

Technology Guide No. 19
Selection of Protective Coatings
for Use Over Galvanized Substrates
1. Scope SP 16 %UXVK2II %ODVW &OHDQLQJ RI &RDWHG
and Uncoated Galvanized Steel,
This guide contains recommendations for selection of Stainless Steels, and Non-Ferrous
protective coatings over new, partially-weathered, fully-weath- Metals
ered or deteriorated hot-dip galvanizing on steel substrates. Guide 14 Guide for the Repair of Imperfections
The service environment, the condition of the galvanized LQ *DOYDQL]HG 2UJDQLF RU ,QRUJDQLF
surface, and the extent and degree of surface preparation =LQF&RDWHG6WHHO8VLQJ2UJDQLF=LQF
required will affect the type of coating selected. This guide Rich Coatings
assumes that the decision to coat the galvanized surface has VIS 2/ASTM D 610 Standard Method of Evaluating
already been made and focuses on selection of the coating to Degree of Rusting on Painted Steel
be applied. Substrates

2. Background and Use 3.2 ASTM International Standards:1

Hot-dip galvanizing consists of a layer of zinc applied over D 6386 Standard Practice for Preparation of
a steel substrate to provide corrosion protection to the under- Zinc (Hot-Dip Galvanized) Coated Iron
lying steel and offers effective long-term corrosion protection and Steel Products and Hardware
for steel in chemically neutral atmospheric service. However, Surfaces for Painting
in service environments where rapid depletion of the zinc D 7091 Standard Practice for Nondestructive
(galvanized) layer can occur, protective coatings are frequently Measurement of Dry Film Thickness
applied over the galvanized surface to provide a more effec- of Nonmagnetic Coatings Applied to
tive corrosion protection system. Protective coatings are also Ferrous Metals and Nonmagnetic,
used to overcoat aging and deteriorating galvanizing to restore Nonconductive Coatings Applied to
corrosion protection to steel no longer fully protected by the Non-Ferrous Metals
VDFULÀFLDO]LQFJDOYDQL]HGOD\HU2YHUFRDWLQJDOORZVDYDULHW\
RIÀQLVKFRORUVWREHDSSOLHGWRJDOYDQL]HGVXUIDFHVIRUVDIHW\ 4. Determine Service Environment
LGHQWLÀFDWLRQ DQG DHVWKHWLF SXUSRVHV 7KLV JXLGH ZLOO DVVLVW
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nized steel by following the steps below: acterize the service environment and identify the requirements
for a coating that will provide optimum protection in that service
1. Determine the service environment for the coating to environment. Service environments for coatings over galva-
be applied (Section 4). QL]HGVWHHOPD\EHJHQHUDOO\FODVVLÀHGDV
2. Determine the condition of the galvanized steel over
4.1 Chemical Atmospheric (pH under 5.0 or above
which the coating will be applied and the surface
10.0): In these service environments, the coating selected
preparation required (Section 5).
must protect the galvanized surface from premature zinc
3. Refer to Table 1 to select an appropriate coating or
depletion as a result of exposure to acidic or alkaline chemical
coating system based on the service environment
fumes and condensation. (Note 2 to Table 1 provides addi-
and the current condition of the galvanized steel
tional information.)
(Section 6).
 
4.2 Buried: In this service environment, the coating
3. Referenced Documents
selected must protect the galvanized surface from premature
depletion of the zinc as a result of high levels of moisture, alka-
3.1 SSPC and Joint Standards:
linity, or acidity in the soil.
SP 1 Solvent Cleaning
SP 5/NACE No. 1 White Metal Blast Cleaning
4.3 Marine Atmospheric: In this service environment,
SP 7/NACE No. 4 %UXVK2II%ODVW&OHDQLQJ
the coating selected must protect the galvanized surface from
SP 10/NACE No. 2 Near-White Metal Blast Cleaning
SP 11 Power Tool Cleaning to Bare Metal 1
ASTM International, 100 Barr Harbor Drive, West Conshohocken, PA 19428-2959. For
referenced ASTM standards, visit the ASTM website, www.astm.org, or contact ASTM
Customer Service at service@astm.org. For Annual Book of ASTM Standards volume infor-
PDWLRQUHIHUWRWKHVWDQGDUG·V'RFXPHQW6XPPDU\SDJHRQWKH$670ZHEVLWH

1
SSPC-Guide 10
November 8, 2012

premature depletion of the zinc due to high levels of humidity If no rust is present or suspected, the intermetallic layer
and salt mist, as well as be resistant to ultraviolet light and can be left undisturbed and will still protect the steel, provided
moisture penetration. that organic contaminants are removed prior to application of
a repair coating. When individual areas of damage or dete-
4.4 Immersion in Fresh or Salt Water: In this service rioration are less than 1 square foot in size, but the overall
environment, the coating selected must seal the pores of the condition of the galvanized item permits spot cleaning and
galvanized surface to prevent premature depletion of the zinc repair, damaged areas are typically prepared for coating by
due to the presence of constant moisture. power tool cleaning per SSPC-SP 11. The coating selected
would therefore be one suitable for use in spot repairs (see
4.5 Under Insulation: In this service environment, the Table 1 Notes 1 and 6).
coating selected must seal the pores of the galvanized surface If the galvanized surface exhibits depletion of the zinc
to provide protection from corrosive conditions resulting from OD\HU DQG UXVW RQ  RI WKH VXUIDFH RI D GHÀQHG DUHD DV
condensation in insulation materials at anticipated service illustrated in SSPC VIS 2, restoration of corrosion protection
temperatures. can be accomplished by application of a full coat(s) of the
selected coating over the entire surface. Localized abrasive
4.6 Aesthetic Concerns, Atmospheric Exposure: blast cleaning to SSPC-SP 5/NACE No. 1 or SSPC-SP 10/
*DOYDQL]LQJLVRQO\DYDLODEOHLQDPDWWHJUH\ÀQLVK$GLIIHUHQW NACE No. 2 may be required prior to application of a repair
ÀQLVK FRORU RU JORVV LV UHTXLUHG IRU LPSURYHG DSSHDUDQFH coating. In these circumstances, inorganic zinc coatings may
safety designation (safety colors) or service designation. be an additional option for use as a repair coating (see Table 1
The actual service environment may overlap one or more and Notes 1 and 5).
of the categories above, requiring a combination of protection
features. 6. Selection of Coatings
5. Determine Condition of Galvanized Table 1 shows the generic coating materials typically used
Substrate and Surface Preparation Method in conjunction with hot dip galvanizing in various service envi-
Required ronments. As shown, the condition of the existing galvanizing
and the need for spot repair or full overcoat should be consid-
The condition of the galvanized substrate will affect ered when selecting a coating.
surface preparation requirements prior to coating application.
It is essential that the galvanized surface be properly prepared
to support additional coatings and ensure optimum coating 7. Disclaimer
adhesion over a long service life.
While every precaution is taken to ensure that all informa-
New, Partially Weathered, and Weathered Galvanized tion furnished in SSPC standards and guides is as accurate,
Surfaces:$670'SURYLGHVGHÀQLWLRQVRIQHZZHDWK- complete, and useful as possible, SSPC cannot assume
ered, and partially weathered galvanized surfaces as well as responsibility nor incur any obligation resulting from the use of
information on appropriate surface preparation techniques for DQ\PDWHULDOVFRDWLQJVRUPHWKRGVVSHFLÀHGKHUHLQRURIWKH
each of these substrate conditions. It is recommended that guide or standard itself.
SSPC-SP 16 be referenced in place of SSPC-SP 7/NACE No This guide does not attempt to address problems
8 for brush-off blast cleaning of galvanized substrates prior to concerning safety associated with its use. The user of this
coating. SSPC-SP 16 contains information on brush-off blast guide, as well as the user of all products or practices described
cleaning of non-ferrous metals (including galvanized surfaces). herein, is responsible for instituting appropriate health and
The surface preparation method used and the service environ- safety practices and for ensuring compliance with all govern-
ment will affect coating selection. If the galvanized layer shows mental regulations.
no signs of deterioration, a full overcoat of the selected coating
will provide optimum protection (see Table 1, Note 2).

Deteriorated Substrates: Reddish brown discoloration

on galvanized surfaces may indicate either (a) the complete
loss of galvanizing and rusting of the underlying steel or (b)
Copyright ©
that the reddish-brown layer of zinc-iron alloy (the “intermetallic
SSPC standards, guides, and technical reports are copyrighted
layer”) which forms at the interface between the galvanizing
world-wide by SSPC: The Society for Protective Coatings. Any photo-
and the steel substrate has been exposed due to the loss of
copying, re-selling, or redistribution of these standards, guides, and
VXUIDFH]LQF$GU\ÀOPWKLFNQHVVJDJHFDQEHXVHGLQDFFRU-
technical reports by printed, electronic, or any other means is strictly
dance with ASTM D 7091 to check for the presence of zinc in
prohibited without the express written consent of SSPC: The Society of
discolored areas. If the gage is capable of measuring surface
Protective Coatings and a formal licensing agreement.
duplex coatings, it may also determine if any coating is present
above the zinc.

2
 SSPC-Guide 19
November 8, 2012

Table 1
Suitable Generic Liquid Coating Types
Full Overcoats (Note 2)
Galvanizing Condition
Service Environment (see Section 4)
Spot (see Section 5 )
Coating Type
Repair Partially
(Note 1) Chemical
New Weathered/ Deteriorated
Aesthetic (<5 pH or Buried Marine Immersion Insulated
(Note 4) Weathered (Note 5)
>10 pH)
(Note 4)

Acrylics No Yes Yes No Yes No No Yes No No

Bituminous No Yes Yes Yes No Yes Yes No Yes No

Chlorinated
No Yes No No Yes Yes No Yes Yes No
Rubbers

Coal Tar Epoxies No Yes Yes Yes No Yes Yes Yes Yes Yes

Yes
Epoxies Yes Yes Yes Note 3 Yes Yes Yes Yes Yes
Note 3

Inorganic Zinc- Yes

No No No No No No No No No
Rich Note 6 Note 5

Latex Acrylics No Yes Yes No Yes No No No No No

2UJDQLF=LQF
Yes No No Yes Note 4 No No Yes Yes No
Rich Note 6
Micaceous Iron
2[LGH5HLQIRUFHG Yes Yes Yes Yes No No No Yes Yes No
Polyurethane

Vinyls No Yes Yes Yes Yes Yes No Yes Yes No

Notes to Table 1:

1) Spot Repair: This column refers to coatings that may be used for localized repair of deteriorated coating or galvanizing (over less than 10% of the total
galvanized area has deteriorated) that is otherwise sound. Full corrosion protection can be restored by application of coating to damaged or deteriorated areas only,
without applying a full overcoat to the entire galvanized surface. When individual areas of damage or deterioration are less than 900 cm2 (or 1 square foot) in size,
and an organic coating is used, damaged areas are typically prepared for coating by power tool cleaning per SSPC-SP 11 to remove rust and other contamina-
tion from exposed steel and to taper, clean and texture the surrounding sound galvanizing to enable smooth transition between the repaired area and the intact
galvanizing. SSPC Guide 14 provides additional information on repair of damaged galvanizing or inorganic zinc coatings using organic zinc-rich coatings. Larger
continuous areas of damaged or deteriorated galvanizing may require brush-off blast cleaning and repairs coated with inorganic zinc.
2) Full Overcoat: This heading refers to coating materials used as full coats (topcoats) over a galvanized surface to provide a more effective and longer lasting
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3) Topcoats for Epoxy Coatings: (SR[\FRDWLQJVFDQEHWRSFRDWHGZLWKV\VWHPVWKDWLQFOXGHSRO\XUHWKDQHSRO\VLOR[DQHÁXRURSRO\PHURUDFU\OLFÀQLVKFRDWV
for improved aesthetics.
4) Surface Preparation of New, Partially Weathered, Weathered Galvanizing: Newly galvanized surfaces and partially weathered galvanized surfaces that
exhibit no rust may be prepared using one of the techniques described in ASTM D 6386, or by brush-off blast cleaning in accordance with SSPC-SP 16 prior to
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Stainless Steels, and Non-Ferrous Metals produces a uniformly roughened substrate that is free of visible contamination and removes a minimal amount of the
galvanized coating.
Fully weathered galvanized surfaces have developed a protective dull gray patina as a result of repeated wet-dry cycles. This patina should be preserved when
rust-free galvanized steel surfaces that are fully weathered are prepared for coating. Cleaning in accordance with SSPC-SP 1 using wiping or pressure washing
at pressures less than 5000 psi or 34 MPa is recommended. Brush-off blast cleaning in accordance with SP 16 is not needed or recommended for sound, fully
weathered galvanized surfaces that are completely free of rust.
5) Surface Preparation of Deteriorated Galvanizing: This condition differs from repairs referred to in Note 1 in that the damage or deterioration exceeds
10% of the total galvanized area, and a full overcoat is to be applied to the entire galvanized surface. The surface is prepared by abrasive blast cleaning or power
tool cleaning as if it were bare, rusted steel removing as much galvanizing as needed to achieve the level of cleanliness required. Note that inorganic zinc coating
requires abrasive blast cleaning of the substrate, normally SSPC-SP 10/NACE No. 2 at minimum.
6) Use of Zinc-Rich Coatings:2UJDQLFDQGLQRUJDQLF]LQFULFKFRDWLQJVDUHQRWW\SLFDOO\XVHGDVIXOOFRDWVRYHUVRXQGJDOYDQL]HGOD\HUVEXWUDWKHUDVUHSDLU
PDWHULDOVDSSOLHGWRH[SRVHGVWHHOVXUIDFHVWRUHVWRUHDOHYHORIFRUURVLRQSURWHFWLRQFRPSDUDEOHWRWKHVXUURXQGLQJJDOYDQL]LQJOD\HU2UJDQLF]LQFULFKFRDWLQJV
require less stringent surface preparation and are easier to apply than inorganic zinc coatings but are not suitable for use at the elevated temperatures that hot-dip
galvanizing is capable of resisting. When the service environment exposes galvanized surfaces to temperatures above 300 degrees F (149 degrees C) and the
galvanizing has deteriorated or requires repair, inorganic zinc is typically used due to its resistance to heat (up to 750 degrees F [398 degrees C] without topcoats).
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