How much Zinc is needed for galvanic protection?

Mike Winter Technical Manager International Paint

For internal use only not to be circulated outside AkzoNobel

Traditional Wisdom

Zinc silicates are all the same they only differ in zinc content The only important consideration is how much is in the coating The more Zinc the better

Zinc Levels how much is needed?

Most standards use % Zn dust by weight in dry film:

BS5493 >90% SSPC Paint 20 Level 1 >85% ISO12944 >80% SSPC Paint 20 Level 2 77% - 85% SSPC Paint 20 Level 3 65% - 77% SSPC Paint 29 >65%
Some use % Zinc metal:

BS5462 > 85% UNE48293 (Spain) > 80% Caltrans > 78%

Laboratory Test Protocols Commonly Used

ASTM B117 continuous hot salt spray

e.g SSPC Paint 20/29 3,000 hr test requirement

ISO 20340 - 4,200 hrs cyclic salt spray/QUV (3 days/3 days) with 1 day freeze cycle @ -20C
e.g. Norsok M501

ASTM D5894 cyclic prohesion/QUV (7 days/7 days)

e.g. AASHTO R31-04 5,000 hrs test requirement

Outdoor exposure

ASTM B 117 Salt Spray 3,000 hrs

85% zinc in dry film

77% zinc in dry film

80% zinc in dry film

65% zinc in dry film

ISO 20340 4,200 hours

85% zinc

80% zinc

77% zinc

ISO 20340 creep data 4,200 hours Single coat IOZ system
85% Similar formula types

% Zn vs creep 1 coat

Zinc epoxy

100 90

77% 65% 50%

80

% Zn in dry film

70 60 50 40 30 20 10 0 0 2 4 6 8 10 ISO20340 creep (mm) % Zn

ISO 20340 Creep data 4,200 hours Zinc silicate/epoxy/polyurethane systems

Similar formula types

% Zn vs creep 3 coat system

85%

Zinc epoxy

100 90 80
77%

% zn in dry film

70 60 50 40 30 20 10 0 0 2 4 6 8 10 12 ISO20340 creep (mm) % Zn

65%

50%

Mechanism of Zinc Silicate Protection

Untopcoated Zinc silicates in corrosive environments protect galvanically for approx 3 months Over time, the open porous film of a zinc silicate coating becomes plugged with reaction products of zinc metal and oxygen, carbon dioxide, sulfur dioxide, sodium chloride etc

The porous zinc silicate film becomes a tight, dense, passive barrier coating
This mechanism does not occur with topcoated zinc silicates

Single Coat Zinc Rich Epoxy Systems

Paint A

3,000 hrs ASTM B117

Paint B

Note: both paints have 80% Zn/dry film

3,024 hrs ASTM D5894

Three Coat Zinc Epoxy/Epoxy/PU Systems

A B A B

3,000 hrs ASTM B117

Scribe cleaned using ISO 20340 method

A and B both have 80% Zn in dry film

Scribe cleaned using ASTM D1654 method

3,024 hrs ASTM D5894

Outdoor Exposure (ISO12944 C3 environment)

65% Zn

85% Zn

77% Zn

85% Zn

16 Mth exposure

50% Zn

Outdoor exposure (ISO12944 C3 environment)

65% Zn 85% Zn

77% Zn

85% Zn

3 coat system: Zinc sil/epoxy/pu 16 mths exposure

50% Zn

Zinc Rich Performance Trends

Single coat Zinc Silicate systems always give less scribe creep than 3 coat systems Single coat zinc epoxy systems usually give less scribe creep than 3 coat systems Different formulations at same zinc level perform differently Within similar formula types, higher zinc loads usually give less scribe creep Testing with an acidic spray (e.g. ASTM D5894 type tests), always gives higher creep values than testing with neutral (e.g. ASTM B117) spray

Other Factors Affecting Performance of Zinc Silicate Systems

Cure conditions
Zinc silicates typically require >50% RH, and some require >65% RH Application at low %RH gives poor curing and poor performance

Cure time prior to topcoating

most zinc silicates require 24 hrs, but fast recoating is a benefit

for the applicator

Quality of application dry spray, film roughness, film porosity, bubbling of topcoats

Type of zinc dust high lead contents may improve anticorrosive performance, but..its lead. Particle size distribution may also affect performance.

Overcoating of Zinc Rich Systems

Zinc silicates must be well cured prior to overcoating

Typically 16-24 hrs at 77F/60% RH Require a sealer or mist coat to prevent pinholing of topcoats

Zinc epoxies may be overcoated in as little as 3 hours under similar conditions

Time to complete a 3 coat zinc/epoxy/polyurethane system (actual data from a job*)

Zinc silicate movable in 100 hrs Zinc epoxy movable in 36 hrs

Faster curing zinc silicates can reduce the time gap between zinc epoxy and zinc silicate system application

* See Inorganic Zinc Primer vs Organic Zinc primer, M.Cornago, ENI Exploration & Production, presented at Corrrosion 2007

Flaking due to overcoating before full cure

Pinholing of topcoats over IOZ

Conclusions

% Zinc is not sole determining factor in IOZ or OZ performance Generally, in equivalent type formulations, % Zinc will affect performance, depending on the system/exposure environment Selection of % Zn required (or even if zinc rich is appropriate) should be based on application and exposure environment Topcoated IOZ systems perform poorer in lab testing than single coat IOZ systems Performance of a Zinc rich coating should be considered as a blend of anticorrosive and application related properties (cure speed, application tolerance, ease of application etc)

Traditional Wisdom?

Zinc silicates are all the same they only differ in zinc content (wrong) The only important consideration is how much is in the coating (no, theres more to it than that)

The more Zinc the better (maybe, but depends on what youre doing with it)