What are the significant differences in performance between an

inorganic zinc primer (ethyl silicate) and an organic zinc primer

(epoxy), given the same application and exposure conditions?
Selected Answers
From Vyacheslav Volosiuk of Polymerprotection Ltd. on March 10, 2011:
The Michigan DOT has been the most influential proponent of multi-coat shop systems.
In the early 1980s, the Michigan DOT began requiring their three-coat system of inorganic
zinc/epoxy/polyurethane to be applied in a controlled shop environment. This lead to
handling-damage problems associated with fabricators, haulers and erectors unfamiliarity
with handling finish-painted steel and topcoated inorganic zinc that could be dry to the touch
but not necessarily cured hard. The remedy for excessive handling damage selected by
Michigan was to change the paint system to epoxy zinc rich/ epoxy/polyurethane. This
system is more resistant to handling damage and is not likely to be applied too quickly.
Michigans decision to change from the inorganic zinc primer to the organic zinc primer was
based on similar results of accelerated laboratorycorrosion testing of both systems. The
fallacy here is that the inorganic zinc-primed steel provides substantially improved corrosion
resistance when it is allowed to weather two months or more before topcoating. This
condition was not present for the accelerated test panels where each coat was applied backto-back in the laboratory. This difference in inorganic zinc system performance is well
documented by NASA and some coating suppliers. This change in coating procedure has
had profound effects on costs of fabricated steel. In order to achieve a Class B surface for
slip-critical connections, faying surfaces are primed with inorganic zinc. These surfaces must
dry and then be masked from application of the coating system. This effectively adds a
fourth coat in the shop and then requires additional field coating of the connection plates and
fasteners, normally done during final paint touch-up. Field touch- up should not require spot
blasting and full system application but rather, a spot prime of epoxy mastic or similar highperformance surface-tolerant product, followed by a spot application of the finish coat.
A glossy polyurethane finish can be difficult to tie in uniformly and invariably will not look
as good as its full-coat application. The quality of the field-applied topcoats over the
inorganic zinc has little bearing on the long-term corrosion resistance of the system.
Providing for their application in a better painting environment while eliminating the
weathering of the inorganic zinc primer, or replacing it with an organic zinc primer, results in
lower corrosion resistance. The most important coating, the inorganic zinc primer is still best
applied in a controlled shop environment. It is damage- resistant, has a Class B surface
rating for slip-critical connections, maintains its corrosion protection for many years and does
not have a finite recoat window. Many states have adopted the Michigan system in their
new bridge construction specifications. This is understandable because Michigan had, and
perhaps still has, the most comprehensive testing program for evaluating performance of
coating systems in the development of their qualified systems list. The Michigan DOT
materials laboratory has done a great service to our industry with its technical findings.
Invariably, there are circumstances where finish coating in the fabrication shop is prudent. It
is important, however, to balance the costs and benefits of this approach and understand the
history of this practice before making a wholesale policy decision. In summary, with a multicoat shop system, corrosion resistance is reduced from that of a shop-applied inorganic
zinc/field-applied topcoat system; fabrication costs are increased substantially; field coating
costs are not completely eliminated because of the need for touch-up; and aesthetics may
be compromised because of the difficulty in blending and matching glossy topcoats during
field touch-up.
From richard d souza of stoncor middle east llc on August 24, 2010:
The greatest difference between IOZ and epoxy zinc is that the former protects the

underlying surface by galvanic protection, whereas the zinc in the epoxy gets encapsulated
with epoxy binder and hence to an extent behaves like a barrier coating sacrificing the allimportant properties of zinc metal. Also, epoxy zinc requires higher dosage of pigment in the
dry film to afford close to the protection offered by IOZ primer. In essence, they are not an
apple to apple comparison of products, but when overcoated, both perform almost identically
in many ways.
From Marco Antonio Alvarado Meneses of Consultant Lima - Per on August 23, 2010:
According to SSPC Paint 20, zinc rich coatings can be classified in two groups: Type I (IOZ Inorganic) and Type II (OZ - Organic). These coatings form a film that provides galvanic
protection of the underlying steel. A high concentration of zinc particles in the film will provide
the necessary conductivity for galvanic protection. This high zinc loading contributes to the
films porosity and its poor internal cohesion. Inorganic zinc-rich silicate coatings frequently
do not bond well to each other, and it is safest to repair them using an organic zinc-rich
coating. When topcoating inorganic zinc-rich films, small bubbles may form in the wet
topcoat from the escape of air or solvent vapors trapped in the porous binder. Many painters
attempt to minimize this problem by applying a mistcoat (a thin, quick coat) and allowing it to
dry before applying a full topcoat. Because of topcoating problems and good performances
without topcoating in a variety of services, it is often best not to topcoat inorganic zinc-rich
coatings. IOZ are brittle and may crack if applied too thick; thus, they are generally applied at
less than 5 mils [125 m] dry film thickness, although some products can successfully be
applied at greater thicknesses. IOZ are normally specified for new building because, within
the parameters of zinc silicates, the solvent-borne ethyl silicates have been found to be more
generally tolerant than the waterborne alkali metal zinc silicates. Zinc silicates give the best
corrosion protection (especially alone),and demonstrate adhesion to SSPC SP 10, chemical
resistance, heat resistance, abrasion resistance, welding, and cutting properties. While zinc
silicate is a typical new building coating, organic zinc rich (OZ) is more of a maintenance
primer. The epoxy is easier to apply in higher film thickness without cracking and can be
applied with conventional airless spray, while alkali silicates normally need special
equipment. Organic zinc-rich coatings are not as electrically conductive as inorganic zincrich coatings; and thus, they have a lower level of galvanic protection. Organic zinc-rich
coatings do not require as high a level of blast-cleaned steel surface as do inorganic zinc
coatings, and they are easier to topcoat. The zinc in both generic types is attacked by acid or
alkali. See some advantages/Limitations of IOZ & OZ. Inorganic Zinc Rich - IOZ: Advantages
Can be low in VOCs Excellent abrasion resistance Excellent heat resistance Good
atmospheric durability Useful as shop primer Fast-drying Can be used untopcoated
Limitations Needs very clean, blasted surface Requires skilled applicator, agitated coating
Difficult to topcoat Attacked by acid and alkali High initial cost Organic Zinc Rich - OZ:
Advantages Can be low in VOCs Good atmospheric durability Relatively easily
topcoated Moderate surface preparation Limitations Requires skilled applicator Constant
agitation necessary Unsuitable for acid or alkali High initial cost Requires a topcoat
From Adam Backhaut of Diamond Vogel Paints on August 18, 2010:
Epoxies, by nature, have a slower (cross-link) cure time. Both systems offer good corrosion
resistance, but epoxy seems to be the most proven vehicle for corrosion control due to
excellent adhesion to bare metal. Inorganic zinc-rich coatings are corrosion-resistant primers
for iron and steel incorporating zinc dust pigment in an inorganic silicate vehicle. Inorganic
zinc-rich coatings require very good surface preparation; are highly abrasion-resistant; have
good dry heat resistance; have good resistance to immersion in hydrocarbon products,
solvents, fresh water, and pH-neutral aqueous solutions. These coatings are also resistant to
exposure in atmospheric environments, damp, humid environments, and chemical
environments where the pH ranges between 5 and 9. Organic zinc-rich coatings are
corrosion-resistant organic coating materials formulated by combining finely-divided zinc
metal and organic resin. Organic zinc-rich coatings often are used for touch-up and repair of
defects and damaged areas in inorganic zinc-rich coatings because the organic binder
provides better adhesion to bare metal than another coat of inorganic zinc-rich. Organic zinc-

rich coatings are more tolerant of surface preparation deficiencies than inorganic zinc-rich
coatings.