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http://www.materialsperformance.com/articles/coating-linings/2016/06/what-do-you-know-about-inorganic-zinc-coatings 1/14
9/6/2018 What Do You Know about Inorganic Zinc Coatings?
S
ingle-coat inorganic zinc (IOZ) silicate coatings can provide long-term protection to
steel, especially in marine atmospheric environments. As a single coat, they allow rapid
coating work. As a relatively thin coating, they are also very economical. Some problems
can arise when using these coatings, however, which have led to their avoidance, misuse,
or failure.
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For the solvent-borne product, the rst stage is evaporation of the solvent, which readily occurs
even under very cold conditions. After evaporation of the solvent, alkyl (typically ethyl) silicate
reacts with water (a hydrolysis reaction) to form a silanol and ethanol. The silanol molecules cross-
link in a condensation reaction to form a silicate polymer and water. The zinc ions, produced by the
addition of zinc dust to the silicate binder, serve to catalyze both the hydrolysis and condensation
reactions.
Although commonly believed to react with atmospheric moisture, Eccleston1 has shown by gas
chromatography that water for the hydrolysis reaction is, in fact, the water released from the
condensation reaction. This is con rmed by practical observations. One manufacturer has recently
introduced a humectant additive (the opposite of a desiccant) for dry conditions, which holds the
condensation reaction moisture within the coating lm while it cures. Moreover, some
manufacturers allow application of their products down to 0 °F (–18 °C), even though there is no
liquid water available in the atmosphere. Below the freezing point of water, the silicate liquid acts as
an antifreeze so the two reactions can still proceed, albeit at a slow rate. Above 32 °F (0 °C),
however, a humid environment is required to ensure that water remains within the uncured coating
so the practical effect is the same as if the reaction occurred with atmospheric moisture.
Ideal conditions for application of a solvent-borne IOZ silicate coating are a surface temperature of
68 to 77 °F (20 to 25 °C), with a relative humidity (RH) between 70 and 90%. Curing times increase
as actual conditions move further away from these ideal conditions. Under conditions of low
humidity, the coating “dries” but a soft, friable, uncured coating results. Water misting or steaming
must be carried out if the RH drops below 50% during curing (60% if overcoated), but such actions
will not cure a coating that has dried. The coating also will cure under very high humidity
conditions, but evaporation of the solvent will be slowed and there is greater risk of damage from
rain or condensation. There are a number of tests that have been suggested for checking the cure of
solvent-borne IOZ silicate coatings, but an investigation by Starr2 found that the methyl ethyl
ketone (MEK) solvent rub test (ASTM D47523) was the only reliable eld method.
For the water-borne product, the rst curing stage is evaporation of the water, so warm, dry
conditions are required. After the water evaporates, one of the rst reaction products during the
cure is an alkaline hydroxide (OH–) (typically potassium hydroxide [KOH]). Unlike the ethanol that
forms during cure of the solvent-borne product, the hydroxide remains on the surface. Under
normal conditions, this will neutralize through a reaction with atmospheric carbon dioxide (CO2)
and moisture. However, heavy dew or water ponding can cause this hydroxide to attack the zinc or
unreacted silicate and cause spot rusting, blistering, or a soft, uncured lm (Figure 1).4 Heavy rain
will usually wash the hydroxide out of the lm, so this damage might not arise. Depending on the
weather conditions, it may be weeks or months before the hydroxide is reacted or removed from the
coating and a neutral surface is achieved.
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9/6/2018 What Do You Know about Inorganic Zinc Coatings?
Figure 1: Spot rusting and blistering on a water-borne IOZ silicate coating due to alkali production from condensation during
curing.
Ideal conditions for the application of water-borne IOZ silicate coatings are a surface temperature of
68 to 77 °F (20 to 25 °C) and an RH between 40 and 50%. Under these conditions, curing to water
resistance can be achieved in 2 or 3 h, although high-ratio types can reach water insolubility within
an hour. Moving further away from the ideal conditions lengthens the coatings’ curing time. Water-
borne products should not be applied below 40 °F (5 °C), and high temperatures may result in dry
spray. The coating must be protected from rain or heavy dew during the curing period. Although not
often indicated, moving air is also important for drying any water-borne coating; and use of fans to
avoid stagnant air conditions is strongly recommended.5
To prevent an applicator from being forced to apply an IOZ silicate coating under climatic
conditions where it is not likely to achieve a satisfactory cure, provisions should be made by
speci ers to allow either a solvent- or water-borne silicate coating to be used depending on
prevailing conditions.
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9/6/2018 What Do You Know about Inorganic Zinc Coatings?
concrete will often self-heal. A thorough visual inspection should be carried out to ensure there is
no severe mudcracking, which requires repair. Minor mudcracking that is adherent usually can be
left without serious consequences.
Szokolik7 notes that excessive thickness can adversely affect the cure of high-ratio, water-based IOZ
silicate coatings applied in less than favorable ambient conditions and suggests a maximum
thickness of 6 mils (150 µm) for these materials. This would probably be a reasonable upper limit for
any IOZ coating. It is more critical, however, to ensure there is suf cient coating covering every part
of the structure. To achieve this, the target lm thickness should eliminate the chance there will be
regions with less than 3 mils (~75 µm) of coating. To achieve this, skilled applicators should aim for
a minimum of <~4 mils (100 µm). This should ensure there is suf cient coating over the entire
surface to minimize the risk of premature breakdown in regions with low dry lm thickness (DFT).
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9/6/2018 What Do You Know about Inorganic Zinc Coatings?
The porous nature of the zinc can cause bubbling (gassing) or pinholing of the topcoat, which
usually results in a cratered appearance when dry (Figure 4). There are a number of techniques used
to minimize this risk, including use of a low DFT mist coat, application of an extra topcoat that is
thinned down considerably, or use of a compatible tie coat.11 Ideally, the topcoat should be applied
after the IOZ has been exposed to the weather for several weeks, and these problems are rare when
topcoating shop-primed steel on site after construction.
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9/6/2018 What Do You Know about Inorganic Zinc Coatings?
Figure 4: Bubbling can result from overcoating an IOZ coating if proper procedures are not carried out.
Water-borne IOZ coatings normally should not be topcoated because of the additional problem of
possible residual alkalinity, which can destroy any applied coating. However, a water-borne IOZ
silicate coating topcoated with acrylic latex is a unique system that combines excellent durability
with low or no volatile organic compounds (VOCs), and can be used as a “green” coating system
where color and good durability are required. This system was used when the iconic Golden Gate
Bridge that crosses the San Francisco Bay was repainted in the 1980s.
If this system is speci ed, it is essential that there is no residual alkalinity on the primer surface in
addition to all the other concerns regarding drying, curing, and topcoating. Investigations by the
U.S. Department of Transportation12 showed acrylic topcoats over water-borne IOZ coatings
inevitably blistered within 60 days unless the primer was neutralized. These researchers
recommended testing the pH of the surface if it is to be overcoated, to ensure it is between 4 and 7.
Conclusions
IOZ silicate coatings, whether solvent-borne or water-borne, provide a number of unique challenges
for the speci er and applicator. However, the excellent protection, rapid application, and good
economy provided by these systems suggest it is worth learning to apply them properly and
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9/6/2018 What Do You Know about Inorganic Zinc Coatings?
understanding their limits and idiosyncrasies. Successful application will reward the asset owner
with a unique and powerful product in the ght against corrosion.
References
1 G. Eccleston, “Effect of Cure Temperature and Humidity on the Properties of Solvent-Borne Zinc
Silicate Coatings,” JPCL-PMC Jan (1998): pp. 36-45.
2 T.L. Starr, “Improving the Reliability of Zinc- Rich Paint Systems,” JPCL Vol. 3 (3) (1986): pp. 22-
31.
3 ASTM D4752–10 (2015), “Standard Practice for Measuring MEK Resistance of Ethyl Silicate
(Inorganic) Zinc-Rich Primers by Solvent Rub” (West Conshohocken, PA: ASTM, 2015).
7 A. Szokolik, “Field Testing of Inorganic Zinc Silicates,” JPCL May (1995): pp. 56-67.
8 “Problem Solving Forum,” JPCL Nov (1998): p. 11.
9 W.J. Paton, “Performance Characteristics of Zinc-Rich Coatings Applied to Carbon Steel,” NASA
Technical Note, D-7336, July 1973.
10 G.R. Ruschau, et al., “Speci cations vs. Reality for Selection of Protective Coatings,” CORROSION
2008, paper no. 017 (Houston, TX: NACE International, 2008).
11 SSPC-PS Guide 8.00, “Guide to Topcoating Zinc-Rich Primers” (Pittsburgh, PA: SSPC, 2002).
12 J.P. Ault, C.L. Farschon, “Adhesion Criteria Between Water-Based Inorganic Zinc Coatings and
Their Topcoats for Steel,” Federal Highway Administration, FHWA-RD-98-170, March 1999.
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