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Zinc-rich Coatings –
Comparative Performance
Introduction
• 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
Zn2+
Electrolyte
• 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
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
• Conversely, Curragh Coal Mine was painted with IOZ primer only
in 1981 and largely remains untopcoated today 20 years later.
• Temperature
Zinc Silicate Galvanizing
Max. Service
540°C 400°C
Temperature
Comparison of Anti-corrosive Performance – Without Topcoat
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
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
• The direct cost of three coats system is 15% - 20% cheaper than
galvanizing
Track Record 1: Three coats system of BASF--IPS