ZINC COATINGS

A Comparative Analysis of Process and

Performance Characteristics
 Contents
INTRODUCTION 1

BATCH HOT-DIP GALVANIZING 2

CONTINUOUS SHEET GALVANIZING 4

ZINC PAINTING 6

ZINC SPRAY METALLIZING 7

MECHANICAL PLATING 8

ELECTROGALVANIZING 9

ZINC PLATING 10

SELECTION OF ZINC COATINGS 10

CONCLUSION 11

ZINC COATINGS COMPARISON 12

ACKNOWLEDGEMENTS 13

Zn
30 65.4
© 2011 American Galvanizers Association. The material provided herein has been
developed to provide accurate and authoritative information about after-fabrication
hot-dip galvanized steel. This material provides general information only and is not
intended as a substitute for competent professional examination and verification
as to suitability and applicability. The information provided herein is not intended
as a representation or warranty on the part of the AGA. Anyone making use of this
information assumes all liability arising from such use.

Zinc

American Galvanizers Association

INTRODUCTION
Zinc, a natural, healthy, and abundant element was first higher on the list will become anodic and preferentially
used in construction in 79 AD; thus, its characteristics corrode to protect metals lower in the series. Therefore,
as a well-suited corrosion protective coating for iron zinc is anodic to steel and will sacrificially corrode to
and steel products has long been known. The 27th most protect the underlying steel from corrosion.
abundant element in the Earth’s crust, zinc is naturally
There are a number of zinc coatings which are often
present in rocks, soil, air, water, and the biosphere, as
generically termed “galvanizing,” but each has unique
well as in plants, animals, and humans. In fact, zinc is
characteristics. These characteristics not only affect
essential to life as all organisms require it to survive and
applicability, but also economics and performance in
complete normal physiological functions.
the environment. The method of application, adhesion
Today, more than 13 million tons of zinc are produced to the base metal, hardness, corrosion resistance, and
annually worldwide, 70% from mined ores, and 30% thickness (Figure 2) of each zinc coating varies.
from recycled sources. More than half of the annual
This practical aid examines the following zinc coatings:
production is used in zinc coatings to protect steel
batch hot-dip galvanizing, continuous sheet galvanizing,
from corrosion. Because zinc is an infinitely recyclable
zinc painting, zinc spray metallizing, mechanical plating,
material, the level of recycling increases each year, and
electrogalvanizing, and zinc plating; to help architects,
currently 80% of the zinc available for recycling is indeed
engineers, and other specifiers assess and select the most
reclaimed. However, because of zinc’s excellent field
suitable zinc coating for corrosion protection.
performance as a corrosion protection coating, it often
remains in service for generations before recycling. Arrangement of Metals in Galvanic Series
CORRODED END: Anodic or less noble
Zinc, like all metals, corrodes when exposed to the (ELECTRONEGATIVE)
atmosphere. However, because of its ability to form Magnesium Cathodic protection can
dense, adherent corrosion byproducts, the rate of Zinc occur when two metals
corrosion is considerably lower than ferrous materials Aluminum are electrically connected.
Steel Any one of these metals
(10 to 100 times slower depending on the environment). Lead and alloys will theoretically
Zinc corrosion products develop naturally on the surface Tin corrode while offering
as the coating is exposed to natural wet and dry cycles Nickel protection to any other
Brass which is lower in the
in the atmosphere and are often referred to as the zinc Bronzes series, so long as both
patina. The zinc patina acts as an additional barrier Copper are electrically connected.
between the steel and the environment. Stainless Steel (passive) However, in actual practice,
Silver zinc is by far the most
In addition to the natural barrier protection of the coating Gold effective in this respect.
Platinum
and patina, zinc also protects the base steel cathodically.
PROTECTED END: Cathodic or More Noble
The Galvanic Series of Metals (Figure 1) lists metals in (ELECTROPOSITIVE)
order of their electrochemical potential in the presence
Figure 1: Cathodic Protection from Zinc
of salt water. When two metals are connected, those

1 mil

Metallized Hot-Dip Galvanized Zinc Paint Galvanized Sheet Electroplated

Figure 2: Microstructures of Various Zinc Coatings
1•
 BATCH HOT-DIP GALVANIZING
Zinc Application Process
Batch hot-dip galvanizing, also known as general After surface preparation, the steel is immersed in the
galvanizing, produces a zinc coating by completely molten (830 F) zinc bath. The bath consists of more than
immersing the steel product in a bath (kettle) of molten 98% pure zinc and less than 2% additives, most commonly
zinc (Figure 3). Prior to immersion in the zinc bath, the aluminum, nickel, and bismuth, which help with zinc
steel is chemically cleaned to remove all oils, greases, fluidity and consumption, coating appearance, etc. While
soil, mill scale, and oxides. The surface preparation in the galvanizing kettle, the molten zinc metallurgically
consists of three steps: degreasing to remove organic reacts with the iron in the steel to form the coating. After
contaminants, acid pickling to remove scale and rust, removal from the zinc bath, the coating is inspected for
and fluxing, which inhibits oxidation of the steel before conformance to ASTM, CSA, or ISO specifications.
dipping in the molten zinc. Surface preparation is critical
as the zinc will not react with unclean steel.

Galvanizing Process

Cooling and
Drying Zinc inspection
Flux bath
Rinsing solution
Pickling
Caustic Rinsing
cleaning
Figure 3: Batch hot-dip galvanizing processes

Coating Characteristics and Performance

The batch hot-dip galvanized coating consists of a series
of zinc-iron alloy layers with a surface layer of pure zinc
(Figure 4). The unique intermetallic layers are tightly
bonded (3,600 psi) to and harder than the base steel,
offering excellent abrasion resistance. The zinc-iron alloy
layers are metallurgically bonded to the steel; and thus,
become an integral part of the steel rather than just a
surface coating. Furthermore, as mentioned previously,
zinc is anodic to steel; therefore, even if the durable Figure 4: Photomicrograph of a Galvanized Coating
intermetallic layers of the hot-dip galvanized coating
are damaged (up to ¼” in diameter) adjacent zinc will surfaces of hollow structures and difficult to access
sacrificially protect the exposed steel until all of the recesses of complex pieces are coated. This complete,
surrounding zinc is consumed. uniform coverage means critical points where corrosion
commonly occurs are afforded the same protection as
Another unique characteristic of the batch hot-dip accessible flat, exterior surfaces.
galvanized coating is its uniform, complete coverage.
During the diffusion reaction in the kettle, the zinc-iron Batch hot-dip galvanizing produces a coating thicker
alloy layers grow perpendicular to all surfaces, ensuring and/or denser than other zinc coating processes. The
edges, corners, and threads have coating equal to or governing specifications for hot-dip galvanizing; ASTM
greater than flat surfaces. Additionally, because hot-dip A123, A153, and A767 as well as CSA specification G 164,
galvanizing is a total immersion process, all interior and ISO 1461 contain minimum coating thickness

•2 American Galvanizers Association

 100
90
Time to first maintenance* (years)

80
Key
70 Rural

60 Suburban
Temperate Marine
50 Tropical Marine

40 Industrial

30
20
10
0
1. 0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0
1 mil = 25.4μm = 0.56oz/ft2
Average Thickness of Zinc (mils)
*Time to first maintenance is defined as the time to 5% rusting of the steel surface.

Figure 5: Time to First Maintenance Chart

requirements based on steel type and thickness. The BATCH HOT-DIP

Time to First Maintenance Chart (Figure 5) shows the
linear relationship between zinc coating thickness and GALVANIZING SUMMARY
maintenance-free service life. For example, according • Factory controlled
to ASTM A123, structural steel greater than or equal • Available 24/7/365
to ¼ inch thick has a minimum coating requirement of
• Complete coverage
3.9 mils, which equates to a maintenance-free life of
around 72 years in an industrial environment. • Superior bond to steel
• Coating is harder than the steel
Applications/Exposure Conditions • Good for exterior and interior use
Hot-dip galvanized coatings are used on a multitude of
materials in myriad construction sectors from electric
utility to artistic sculptures. Ranging in size from small
parts such as nuts, bolts, and nails to very large structural
shapes, galvanizing is integral to the North American
infrastructure. Most commonly batch hot-dip galvanizing
is used in atmospherically exposed steel; however, it is
also used in fresh and salt water applications, buried in
the soil, embedded in concrete, and much more. For
more information on the performance of batch hot-dip
galvanizing in various environments, see the American
Galvanizers Association’s publication, Performance of
Hot-Dip Galvanized Steel Products.
Size can be one limitation to the application of batch hot-
dip galvanizing; however, the average length of zinc baths
in North America is 40 feet and 55-60 foot kettles are
common. Utilizing progressive dipping (immersing one
portion of the product and then the other) significantly
increases the maximum size that can be accommodated
to nearly double the bath size.

3•
 CONTINUOUS SHEET GALVANIZING
Zinc Application Process As the steel exits the furnace, it enters into a vacuum
Continuous sheet galvanizing is also a hot-dip process, chamber, or snout, before entering the molten zinc bath to
but is only applied to steel sheet, strip, and wire. A coil prevent any air from reoxidizing the heated steel product.
to coil process, steel sheet from 0.010 to 1.70 inches The steel is then sent around a submerged roll in the
(0.25 mm to 4.30 mm) thick and up to 72 inches (1,830 mm) molten bath to create the bonded coating and removed
wide is passed as a continuous ribbon through cleaning in a vertical direction. As the product is withdrawn from
baths and molten zinc at speeds up to 600 feet per minute. the bath, precisely regulated, high-pressure air (air knife)
is used to remove any excess zinc to create a closely
Preparing the steel for the continuous hot-dip coating controlled coating thickness. The steel is then allowed to
begins with cleaning in an alkaline liquid combined with cool and solidify before contacting another roll to avoid
brushing, rinsing, and drying. Then, the steel passes into transferring or damaging the coating.
the heating or annealing furnace to soften it and impart
the desired strength and formability. In this annealing Today, this continuous hot-dip process is used to
furnace, the steel is maintained under a reducing gas make seven different types of sheet products including
atmosphere, composed of hydrogen and nitrogen, to galvanized (zinc), galvannealed (90-92% zinc/8-10%
remove any oxide that may be on the surface. Just as in iron alloy), two alloys of zinc and aluminum (55%
the batch process, the steel must be completely clean of aluminum/45% zinc alloy and 95% zinc/5% aluminum
oxides and contaminants for a successful coating. alloy), two aluminum based alloys (100% aluminum,
89-95% aluminum/5-11% silicon alloy), and the terne
coating (85-97% lead/3-15% tin alloy).

Continuous Sheet Galvanizing

Total Both Sides Per Side
Coating Grade
oz/ft2
oz/ft2
mils μm
G360 3.60 1.80 3.24 82.3
G300 3.00 1.50 2.70 68.6
G235 2.35 1.18 2.12 53.7
G210 2.10 1.05 1.89 48.0
G185 1.85 0.93 1.67 42.3
G165 1.65 0.83 1.49 37.7
G140 1.40 0.70 1.26 32.0
G115 1.15 0.58 1.04 26.3
G90 0.90 0.45 0.81 20.6
G60 0.60 0.30 0.54 13.7
G40 0.40 0.20 0.36 09.1
G30 0.30 0.15 0.27 06.9
G01 no minimum
Continuous Sheet Galvanizing: The number following the ‘G’ coating grade designation correlates to the total thickness of
zinc applied to both sides of the steel sheet.
Table 1: Continuous Sheet Galvanizing Thicknesses

•4 American Galvanizers Association

Coating Characteristics & Performance As mentioned before, service life for all zinc coatings
Because both are hot-dip processes, continuous sheet is linear to zinc thickness (Figure 5, page 3). Because
and batch hot-dip galvanizing are often confused. One the continuous sheet coating is applied pre-fabrication,
major difference in the two coatings is the thickness. The final forming and placement often includes punching
continuous sheet galvanizing process has greater control holes, bending, cutting, etc., which creates uncoated
and preciseness when it comes to zinc thickness as the air areas. Like batch hot-dip galvanizing, the surrounding
knife used after galvanizing ensures a uniform thickness zinc of continuous sheet coatings will provide cathodic
across the steel sheet. The coating is mostly unalloyed protection to these uncoated areas; however, as there is
zinc, though minimal alloy layers are present, and is much less zinc present, best practice is to touch up any
ductile and able to withstand deep drawing or bending exposed areas after fabrication to extend service life.
without damage. This is important as the coating is
Applications/Exposure Conditions
applied prior to final fabrication such as punching,
bending, and cutting. As the name states, the continuous galvanizing process
is only applied to sheet steels. The most common
Because of the precise control of coating thickness, applications are in car bodies, appliances, corrugated
continuous sheet is stocked in a variety of coating weights. roofing and siding, duct work, and culvert pipe. The
One of the most common zinc coatings is Class G90, smooth coating does allow it to be treated for painting,
which has 0.9 oz/ft2 of zinc (total both sides) or about which will increase service life. Because of the relatively
0.80 mils (20 µm) per side. Table 1 (page 4) shows the thin coating, unpainted continuous sheet galvanizing
available coating grades of continuous sheet galvanizing. is recommended for interior applications or where
exposure to corrosive elements is mild.

CONTINUOUS SHEET
GALVANIZING SUMMARY
• Factory controlled
• Precise and consistent coating thickness
• Interior applications only
(unless painted over)
• Available in annealed condition
for formability
• Mostly pure zinc coating – softer than steel

5•
 ZINC PAINTING
Zinc Application Process is another reason constant agitation and homogenous
Zinc painting, often erroneously termed cold galvanizing, mixture is important during application. There is some
is the application by brush or spray of zinc dust mixed question as to whether cathodic protection is possible at
with organic or inorganic binders. Prior to application, all if the zinc particles are encapsulated in the binder and
the steel must be cleaned by sand blasting to near the binder is non-conductive.
white metal (SSPC–SP 10), commercial blast cleaning
Inorganic and organic zinc-rich paints vary somewhat
(SSPC-SP 6) or white metal (SSPC-SP 5). The zinc dust
in their performance. Inorganic zinc-rich paints, which
must be mixed with a polymeric-containing vehicle
adhere to the steel with mild chemical reactivity, have
and constantly agitated during application to produce
good solvent resistance and can withstand temperature
a homogenous mixture and proper adhesion. Zinc-rich
up to about 700 F (375 C). Inorganic zinc-rich paints do
paints typically contain 92-95% metallic zinc in dry film.
not chalk, peel, or blister readily, are easy to weld and
When spray applying, feed lines should be kept as short
provide simpler cleanup than organics. The density of
as possible to prevent settling of zinc dust and uneven
inorganic zinc-rich paints are about half the density of
film coats. Zinc painting can be applied in either the
zinc per mil of batch hot-dip galvanized coatings.
shop or the field.
The properties of organic zinc-rich paints depend on
Coating Characteristics and Performance the solvent system. Multiple coats may be applied within
Like all paint coatings, zinc-rich paint is a surface 24 hours without cracking. Organic zinc-rich paints do
coating, mechanically bonded to the steel at a few not have the same temperature resistance of inorganic
hundred pounds per square inch (psi). Zinc-rich paints zincs, as they are limited to 200-300 F. They are also
are either organic, consisting of epoxies, chlorinated subject to ultraviolet (sunlight) degradation, and are not
hydrocarbons, and other polymers, or inorganic based as effective as inorganics in corrosion protection.
on organic alkyl silicates. The organic or inorganic paints
are applied to a dry film thickness of 2.5 to 3.5 mils. If Applications
applied too thick, cracking may occur. Zinc-rich paint can be applied to steel of any size and
shape, though application is difficult on more complex
fabrications. Zinc-rich paints are widely used as primers
to high-performance two and three coat systems and
for touch-up and repair of batch hot-dip galvanized
coatings. In mild environments, inorganic zinc paint
may be used independently for corrosion protection, but
should be top coated in more severe environments to
extend service life.

ZINC PAINTING SUMMARY

• In-shop or field application
One commonality of all zinc coatings examined thus • Weak bond to steel
far is the cathodic protection afforded. Zinc-rich paint
• Thinner coating on corners and edges
coatings are different than the other coatings as there
• Coating thickness consistency depends on
is a binding material used to adhere the zinc particles.
skill of application
For cathodic protection to be possible, the zinc dust
• Durability depends on zinc content in dry
must be at a concentration high enough to provide for
film condition
conductivity between the zinc particles and the steel. This

•6 American Galvanizers Association

ZINC SPRAY METALLIZING
Zinc Application Process Applications/Exposure Conditions
Zinc spraying, or metallizing, is accomplished by feeding Zinc spray metallizing can be applied to materials
zinc powder or wire into a heated gun, where it is of any size, though complexity of the structure is
melted and sprayed onto the part using important. Metallizing is commonly
combustion gases and/or auxiliary used as an alternative to batch hot-dip
compressed air to provide the necessary galvanizing when the part is too large
velocity (Figure 6). Prior to metallizing, for immersion in the galvanizing kettle.
the steel must be abrasively cleaned. And though more often and easily
applied in the shop, metallizing in the
The 100% zinc coating can be applied
field is a great option for extending the
in the shop or field, but is more
life of already erected batch galvanized
commonly done in the shop where heat
structures. The biggest limitations to
for melting is more readily available.
metallizing applications are availability
The heat is supplied by combustion of
(skilled operator and equipment) and a
an oxygen-fuel gas flame or by electric
significant cost premium.
arc. Processes have been developed for
feeding molten zinc directly into the
spray nozzle, but only for in shop applications. Following
the zinc application, the coating is normally sealed with ZINC SPRAY METALLIZING
a low viscosity polyurethane, epoxy-phenolic, epoxy, or
vinyl resin. SUMMARY
• Factory controlled
Coating Characteristics and Performance
• Quality varies by skill of labor
The metallized zinc coating is rough and slightly porous,
with density about 80% that of batch hot-dip galvanizing. • Inconsistent coverage and coating thickness
As the metallized coating is exposed to the atmosphere, • Weak mechanical bond of zinc to steel
zinc corrosion products tend to fill the pores providing • Interior or exterior use
consistent cathodic protection. Metallizing covers welds, • Labor intensive
seams, ends, and rivets well and can be applied in excess
of 10 mils (254 µm). However, the mechanically-bonded
pure zinc coating can be inconsistent and requires a
skilled operator for best application. Coatings tend to be
thinner on corners and edges, and no coating is applied to
interior surfaces or difficult to access recesses and cavities.

Electric Arc
Power Supply
Zinc Wire Feeder

Zinc Wire Inside

or Insulated Flexible Conduit

Spray Gun
OXY. FUEL

Heat Control
Circuit
Source Compressed Air Source Cable
Figure 6: Zinc Spray Metallizing

7•
 MECHANICAL PLATING
Zinc Application Process
Mechanical zinc plating is accomplished by tumbling
small parts in a drum with zinc and proprietary
chemicals. Small iron and steel parts – usually limited in
size to about 8-9 inches (200-300 mm) and weighing less
than one pound (0.5 kg) – are cleaned and flash copper
coated before loading into a plating barrel. The barrel is
then loaded with proprietary chemicals, glass beads and
zinc powder and tumbled (Figure 7). During tumbling,
the glass beads peen zinc powder onto the part. Once
finished, the parts are dried and packaged, or post-
treated with a passivation film, dried, and packaged.
Because of the application process (tumbling and
GLASS peening), the coating thickness can vary throughout the
BEADS part. Complex designs with recesses or blind holes as
well as edges, corners and threads can have inconsistent
or non-existent coatings due to inaccessibility to the
PLATING peening action of the glass beads. It is also important
PLATING CHEMICALS the compaction agents (beads) are large enough to avoid
DRUM
being lodged in any cavities, recesses, or small threads in
the part. The coating is mechanically-bonded to the steel
METAL with a similar adhesion to zinc plating.
POWDER
Applications/Exposure Conditions
As mentioned, mechanical plating can only be applied
WATER to small parts limited to the capacity of the drum.
Furthermore, the materials must be simple in design to
CLEANED AND
COPPERED PARTS ensure peening to all surfaces. Mechanical zinc plating
is most commonly used on high-strength fasteners and
Figure 7: Mechanical Plating
other small parts not suitable for hot-dip galvanizing.
Coating Characteristics & Performance
Mechanical plating consists of a flash coating of
copper followed by the zinc coating. Coating thickness MECHANICAL PLATING
requirements specified in ASTM B695 range from SUMMARY
0.2 to 4.3 mils (5 to 110 µm). While thicker coatings
• Factory controlled
are possible, the common thickness on commercial
• Small parts only
fasteners is 2 mils (50 µm). Coating thickness is
regulated by the amount of zinc charged to the • Poor/no coverage in recesses
plating barrel and the duration of tumbling time. • Variable thickness of coating depending
The coating has a density of about 70% compared on tumbling time
to a batch hot-dip galvanized coating density. The • Inconsistent coating thickness
hot-dip coating has over 30% more zinc per unit • Thinner coating on edges and corners
volume than a mechanical coating.

•8 American Galvanizers Association

ELECTROGALVANIZING
Zinc Application Process
Electrogalvanized (electroplated) coatings are created
by applying zinc to steel sheet and strip by electro-
deposition. Similar to sheet galvanizing, the operation is
continuous and coating thickness is minimal. Applied in
a steel mill, sheet or strip is fed through entry equipment
into a series of washes and rinses then into the zinc
plating bath.
The most common zinc electrolyte-anode arrangement
uses lead-silver, or other insoluble anodes and electrolytes
of zinc sulfates. Soluble anodes of pure zinc are also used. Applications/Exposure Conditions
The coating develops as positively charged zinc ions in Electrogalvanized coatings are applied to sheet steels
the solution are electrically reduced to zinc metal and and wire, and therefore are used in similar applications
deposited on the positively charged cathode (sheet steel). to continuous sheet galvanizing or wire galvanizing.
Grain refiners may be added to help produce a smooth, The most common applications are in automobile and
tight-knit zinc coating on the steel. appliance bodies and fasteners. Furthermore, to extend
Coating Characteristics and Performance the service life, electrogalvanized coatings can be treated
This electro-deposited zinc coating consists of pure to make them suitable for painting, and this is often
zinc tightly adherent to the steel. The coating is highly recommended due to the extremely thin zinc coating.
ductile remaining intact even after severe deformation.
Produced on strip and sheet materials, the coating
weight ranges up to 0.2 oz/ft2 (60 g/m2), or thicknesses ELECTROGALVANIZING
up to 0.36 mils (9.1 µm) per side, while on wire, coating SUMMARY
weights may reach up to 3 oz/ft2 (915 g/m2). The coating
• Factory controlled
of pure zinc is thinner than continuous sheet galvanizing,
mechanically-bonded, and there are no alloy layers, but • Very thin/consistent coating
provides a smoother finish. Heat-treated and electro- • Interior use only
coated wire can be cold drawn to about 95% reduction • Ductile coating of pure zinc
in area, depending on the chemical composition of the • Exposed/bare steel edges when slit or
wire, heat treatment, and diameter. cut-to-length

9•
 ZINC PLATING
Zinc Application Process zinc coating is thin, up to a maximum thickness of 1 mil
Zinc plating is identical to electrogalvanizing in principle (25 µm), and mechanically bonded to the surface with a
because both are electro-deposition processes. However, hardness of about a third to a half that of most steels. The
zinc plating is used on small parts such as fasteners, governing specification, ASTM B633, lists four classes
crank handles, springs and other hardware items rather of zinc-plating: Fe/Zn 5, Fe/Zn 8, Fe/Zn 12 and Fe/Zn
than sheet metal. The zinc is applied as an expendable 25 where the number indicates the coating thickness in
electrode in a cyanide, alkaline non-cyanide, or acid microns (µm).
chloride salt solution. Cyanide baths are the most
Applications/Exposure Conditions
operationally efficient but can potentially create pollution
and are hazardous. Zinc plating is typically used for screws and other small
fasteners, light switch plates, and various small parts
After alkaline or electrolytic cleaning, pickling to remove that will be exposed in interior or mildly corrosive
surface oxides, and rinsing, the parts are loaded into conditions. For use in moderate or severe environments,
a barrel, rack, or drum and immersed in the plating the materials must be chromate-conversion coated for
solution. Various brightening agents may be added to additional corrosion protection.
the solution to add luster, but careful control is needed to
ensure a quality product. Post-plating treatments may be
used to passivate the zinc surface as well as impart various ZINC PLATING SUMMARY
translucent colors or to extend the life of the coating.
• Factory controlled
Coating Characteristics & Performance • Small parts only
Typical zinc-plated coatings are dull gray with a matte • Interior use only
finish, although whiter, more lustrous coatings can be • Very thin coating
produced, depending on the process or agents added to
the plating bath or through post-treatments. The pure

SELECTION OF ZINC COATINGS

Once the decision has been made to use a zinc coating Table 3 (page 12) provides a snapshot of each of the zinc
for corrosion protection, a few additional factors must be coatings based on several criteria.
considered to ensure the proper coating is selected for the
application and service environment. Each zinc coating Coating Thickness vs. Coating Weight
reviewed provides varying degrees of corrosion protection As has been stated several times throughout this guide,
and it is important to identify the corrosiveness of the the service life of zinc coatings is linear to zinc coating
exposure environment to ensure the coating selected will thickness. However, zinc coating thickness evaluated
provide adequate service life. Some zinc coatings will be alone can be deceiving when the zinc has been applied
eliminated by their nature alone, e.g. zinc coatings whose by different processes. In addition to thickness, the
processes are limited to small parts or sheet steels cannot amount of available zinc per unit volume, or density, is
be considered for the protective coating of structural steel also important. Keeping in mind various ASTM and/
members; while others may be ruled out based on cost, or other specifications require different weights or
appearance, availability, performance, etc. The following thicknesses, it is important to convert all coatings to a
information examines a few factors in more detail, while common denominator for comparison.

• 10 American Galvanizers Association

While coating densities for some types of zinc coatings Economic Considerations
are nearly identical, others differ considerably. One Initial cost will always be considered when specifying
logical common denominator for comparing zinc steel corrosion protection. However, in addition to
coatings would be to convert all coatings into an equal the initial cost, evaluating the performance of the zinc
weight per unit area of zinc; which in theory would coating in the intended environment also impacts the
provide equal service lives. Table 2 represents the coating economics of the protective system. Hidden costs,
thickness required by each zinc application method to such as accessibility of the site, production loss due to
equal 1 oz of zinc/ft2 of surface. Therefore, according maintenance recoating, and rising wages for labor-
to the conversions, 1.7 mils of hot-dip galvanized intensive coatings, such as metal spraying and painting
coating would give the same service life as 2.2 mils of must also be considered.
mechanical plating or 3 to 6 mils (depending on the
paint formulation) of zinc-rich paint. The choice of the most economical system is not
precise, because neither the timing nor the cost of
Hot-dip galvanizing 1.7 mils (43 μm) future maintenance can be accurately predicted. In
(batch or continuous) addition, depreciation of capital investment, tax relief for
electrogalvanizing, investment and maintenance cost and the time value of
zinc plating money must be considered and can change.
Zinc spraying (metallizing) 1.9 mils (48 μm)
However, to get the most realistic cost of the coating
Mechanical plating 2.2 mils (55 μm)
system throughout the project’s life, economic models
Zinc-rich paint 3-6 mils (75-150 μm) for comparing the life-cycle costs of different coatings
Table 2: Coating Densities have been developed. As the calculation of life-cycle
It is also important to remember for all continuous cost is complex and cumbersome, the American
galvanized sheet materials, including electrogalvanized, Galvanizers Association developed an automated online
the coating weight is given for the total zinc weight for both Life Cycle Cost Calculator to facilitate the process at
sides of the sheet. To obtain the amount of zinc per unit lcc.galvanizeit.org. The online life-cycle cost calculator
area of surface, the weight given must be divided in two, utilizes the same economic formula as the one
assuming equal distribution on both sides. For example, recommended in ASTM A1068, and the data is provided
an ASTM A653 Class G90 sheet contains 0.90 oz zinc/ft2 of by real-world field performance and published reports
zinc or about 0.45 oz/ft2 per side (see Table 1, page 4). (NACE Paper 8279, 2008).

CONCLUSION
Though all of the coatings in this publication are comprised of zinc and often lumped under the umbrella term
“galvanizing,” each is very different in its application, characteristics, and performance in various environments. It is
important to evaluate the exposure condition of each project before selecting the most effective zinc coating for that
particular application, because as this aid points out, not all zinc coatings are created equally.

11 •
 Zinc Co
APPLICATION COATING
CURE
METHOD VENUE/ SPECIFICATION THICKNESS SIZE
TIME
CONDITIONS MINIMUM/TYPICAL
In shop factory-
Batch Hot-Dip ASTM A123, A153, A767, 1.4 to 3.9 milsa/ Fasteners to
controlled; no special <1 hr
Galvanizing requirement
CSA G164, ISO 1461 2 to 8.0 mils 90’ beams

Sheet steel
In shop factory-
Continuous Sheet 0 to 3.2 milsb/ 0.010”-1.70”
controlled; no special ASTM A653 <1 hr
Galvanizing requirement
0 to 3.2 mils thick,
72” wide
In shop or field; SSPC-PS Guide 12.00,
conditions are 22.00; 0.6 to 5.0 mils/coat/ 24-72
Zinc Painting Unlimited
subjective and prone SSPC-PS Paint 20; 4.0 to 6.0 mils hrs
to human error SSPC-PS 12.01
Zinc Spray 3.3 mils/
In shop or field AWS C2.2 Unlimited <24 hrsd
Metallizing 4.0 to 6.0 mils
In shop factory- Small parts
Mechanical 0.2 to 4.2 milsc/
controlled; no special ASTM B695 8”-9” and <1 hr
Plating requirement
0.2 to 4.2 mils
under 1 lb
In shop factory-
0.28 milsb/
Electrogalvanizing controlled; no special ASTM A879 Sheet steel <1 hr
0 to 0.28 mils
requirement
In shop factory-
0.2 to 1.0 milsc/
Zinc Plating controlled; no special ASTM B633 Small parts <1 hr
0.2 to 1.0 mils
requirement
a
Range based on ASTM, ISO, and CSA minimum thicknesses for all grades, classes, etc., encompassed by the specifications.
b
Total for both sides of sheet.
c
Range based on ASTM minimum thicknesses for all grades, classes, etc., encompassed by the specifications.
d
Dependent on sealer top coat
Table 3: Zinc Coatings and Applications

• 12 American Galvanizers Association

oatings
BOND TO ABRASION
FINISH/ EXPOSURE
COVERAGE CONSISTENCY SUBSTRATE RESISTANCE/
APPEARANCE CONDITIONS
STEEL HARDNESS
Varies
100% edges, corners, and interior Metallurgical Intermetallic layers
Matte, gray, shiny, spangle, Interior/exterior
≥ flat surfaces ~3,600 psi 179-250 DPN
or combination

Controlled Interior or
Uniform thickness Metallurgical
~70 DPN Minimum to highly mildly corrosive
Controlled by air knife ~3,600 psi
spangled conditions

Inconsistent, based on operator skill

Mechanical Soft and not Smooth finish
Tends to thin at edges and corners Interior/exterior
400-600 psi abrasion resistant Color to suit specifier
Interior surfaces are uncoated

Mechanical Matte gray

Inconsistent based on operator skill ~70 DPN Interior/exterior
~1,500 psi Rough
Matte gray
Inconsistent Mechanical
75 DPN Rough compared to Interior/exterior
Thinner at edges, corners, and recesses 400-600 psi
electroplated

Mechanical Smooth finish

100% coverage ~70 DPN Interior
300-500 psi Shiny, unless passivated

Smooth finish
Mechanical
100% coverage 75 DPN Dull gray to shiny Interior
300-500 psi
Controlled by additives

ACKNOWLEDGEMENTS
We acknowledge the assistance of the following who supplied illustrations for use in this booklet:
Figure 2: Teck Metals Ltd.
Figure 3: Adapted from drawing courtesy Nordisk Förzinkningsförening, Stockholm, Sweden from
Rust Prevention by Hot Dip Galvanizing.
Figure 6: Xstrata Canada Corp.
Figure 7: Lester Coch, Tru-Plate Process, Inc., Jericho, New York from the Economics of Mechanical
Plating, April 1978.

13 •
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