The

Inspection
INSPECTION
of Hot-Dip
Galvanized
Steel
Products
REPAIR
TOUCH-UP
SPECIFICATION
PASSIVATION
METHODS
SAMPLING
TESTING
INSPECTION
IN
SPEC
TESTING
HOT-DIP
GALVANIZED

TION
REPAIR
PASSIVATION
CONSIDERATIONS
SAMPLING
APPEARANCE
© 2008 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

VISUAL
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.
 TABLE
table
OF
CONTENTS
Purpose of Inspection 3
Coating Measurements 5
Coating Thickness
Coating Weight
Appearance 6
Visual Observation
Reasons for Different Appearances
Visual Inspection 7-10
Bare Spots 7
Chain and Wire Marks
Clogged Holes/ Clogged Threads
Distortion 8
Dross Inclusions
Excessive Aluminum in Galvanizing Bath
Flux Inclusions
Products in Contact
Rough Surface Condition 9
Runs
Sand Embedded in Casting
Striations
Surface Contamination 10
Weeping Weld
Wet Storage Stain
Zinc Skimmings
Additional Inspection Testing 11
Adherence Test
Embrittlement Test
Bending Test
Sampling Methods 11
Passivation Testing 11
Repair Method Selection and Considerations 12
Touch-Up and Repair Methods 12
Zinc-Based Solders
Zinc-Rich Paints
Zinc Spray
Related Specifications and Materials 13
 PURPOSE
OF
INSPECTION
Hot-dip galvanizing is one of the most economical, maintenance-free corrosion protection systems available. Like any other manufacturing
process, hot-dip galvanized steel requires an inspection of the finished product to ensure compliance with applicable specifications. The
inspection process requires a clear understanding of both specification requirements and compliance measurement techniques to make
an accurate assessment.

For hot-dip galvanized products, a key feature is durability The requirements for hot-dip galvanized coatings are found in
and decades of maintenance-free performance. However, three ASTM specifications; A 123/A 123M, A 153/A 153M, and
to plan for the extension of a product’s service life and A 767/A 767M. The difference between these specifications
facilitate long-term budget planning, the estimated time to is the type of steel product covered by each. A 123/A 123M
first maintenance in atmospheric exposures can be seen in covers structural steel, pipe and tubing, flat bar, and wire.
the chart below. A 153/A 153M includes small castings, nails, nuts, bolts,
washers, and small parts centrifuged after galvanizing to
For any environment, the service life of hot-dip galvanized remove excess zinc. And A 767/A 767M covers reinforcing
steel is directly proportional to the thickness of the zinc steel bars. In Canada, the specification CSA G 164 covers
coating. Thus, coating thickness is an important requirement the requirements for all hot-dip galvanized articles, and
in the specification and effectiveness of hot-dip galvanizing ISO 1461 is the standard used in Europe. In all cases, the
as a corrosion protection system. inspection of hot-dip galvanized products is conducted at
the galvanizing plant prior to shipment of the article.
Measuring coating thickness is only one of the many
specification requirements in the inspection process. Other
requirements include adherence, appearance, and finish.

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
Average Thickness of Zinc (mils)
1 mil = 25.4µm = 0.56oz/ft2
*Time to first maintenance is defined as the time to 5% rusting of the substrate steel surface.

Time to First Maintenance for Hot-Dip Galvanized Coatings

AMERICAN GALVANIZERS ASSOCIATION

Table 1: Minimum Coating Thickness from ASTM A 123/A 123M. (See Table 1a for information on Coating Thickness Grade)

Minimum Average Coating Thickness Grade by Material Category - ASTM A 123/A 123M
(rolled, pressed and forged shapes, castings, plates, bars and strips)

Material Category All Specimens Tested

Steel Thickness Range (Measured), in. (mm)

<1/16 (<1.6) /16 to <1/8 (1.6 to < 3.2)

1 1
/8 to 3/16 (3.2 to 4.8) >3/16 to <1/4 (>4.8 to <6.4) >1/4 (>6.4)

Structural Shapes 45 65 75 85 100

Strip and Bar 45 65 75 85 100
Pipe and Tubing 45 45 75 75 75
Wire 35 50 60 65 80
Reinforcing Bar — — — — 100

Table 2: Minimum Coating Thickness from ASTM A 153/A 153M.

Minimum Average Coating Thickness by Material Class - ASTM A 153/A 153M

(iron and steel hardware)

Class of Material Minimum Weight of Zinc Coating, oz/ft2 (g/m2) of SurfaceA

Average of Specimens Tested Any Individual Specimen

Class A - Castings, Malleable Iron, Steel 2.00 (610) 1.80 (550)

Class B -  olled, pressed and forged articles (except
R
those which would be included under Class C or D)
B-1 -  /16 in. (4.76 mm) and over in thickness and over
3

15 in. (381 mm) in length 2.00 (610) 1.80 (550)

B-2 - Under 3/16 in. (4.76 mm) in thickness and over 15 in.
(381 mm) in length 1.50 (458) 1.25 (381)
B-3 - Any thickness and 15 in. (4.76 mm) and under in length 1.30 (397) 1.10 (336)
Class C - Fasteners over 3/8 in. (9.52 mm) in diameter and similar
articles. Washers 3/16 in. and 1/4 in. (4.76 and 6.35 mm)
in thickness 1.25 (381) 1.00 (305)
Class D - Fasteners 3/8 in. (9.52 mm) and under in diameter, rivets,
nails and similar articles. Washers under 3/16 in. (4.76 mm)
in thickness 1.00 (305) 0.85 (259)

A
In the case of long pieces, such as anchor rods and similar articles over 5 ft (1.52 mm) in length, the weight of coating shall be determined at each end and
the middle of the article. In no case shall individual measurements be below the minimum shown in the “Any Individual Specimen” column.

Table 1a: Coating Thickness Grades from ASTM A 123/A 123M Table 3: Minimum Coating Thickness from ASTM A 767/A 767M

Coating Thickness Grade Minimum Coating Thickness by Class - ASTM A

767/A 767M (reinforcing bars)
Coating Grade mils oz/ft2 um g/m2
Mass of Zinc Coating
Coating Class min., g/m2 of Surface
35 1.4 0.8 35 245
45 1.8 1.0 45 320 Class I
55 2.2 1.3 55 390 Bar Designation Size No. 10 [3] 915
65 2.6 1.5 65 460 Bar Designation Size No. 13 [4] and larger 1070
75 3.0 1.7 75 530 Class II
85 3.3 2.0 85 600 Bar Designation Size No. 10 [3] and larger 610
100 3.9 2.3 100 705
Coating Class Weight of Zinc Coating
min., oz/ft2 of Surface

Class I
Bar designation size no. 3 3.00
Bar designation size no. 4 and larger 3.50
Class II
Bar designation size no. 3 and larger 2.00

AMERICAN GALVANIZERS ASSOCIATION

 COATING
MEASUREMENTS
The specifications give requirements concerning the amount of coating applied to the steel part during the hot-dip galvanizing process.
The amount of coating can be specified by thickness or weight. The specifications include tables providing specific requirements for
thickness or weight based upon the steel part type and the measured steel thickness.

The minimum coating requirements specified by ASTM for different classes of work are summarized in Table 1 for ASTM A 123/A 123M,
Table 2 for ASTM A 153/A 153M, and Table 3 for ASTM A 767/A 767M located on the previous page.

COATING THICKNESS The other method to

Coating thickness refers to the
thickness of the final hot-dip
galvanized coating. Two different
methods are used to measure
the coating thickness of hot-dip
galvanized steel; a magnetic
thickness gauge and microscopy.
Utilizing a magnetic thickness
gauge is a non-destructive, simple
way to measure coating thickness.
There are three different types of
magnetic thickness gauges.
Figure 1: Pencil-Style
Magnetic Thickness Gauge
The first type of magnetic
thickness gauge is pocket-size
and employs a spring-loaded magnet encased in a pencil-
like container, as seen in Figure 1 (above). The accuracy of
the pencil-style gauge depends on the skill of the inspector,
thus the measurement should be made multiple times.
A banana gauge, as seen
in Figure 2 (left) is another
tool used to measure coating
thickness. Banana gauges can
measure coating thickness in any
position, without recalibration or
interference from gravity.
The most accurate gauge, and
easiest to use, is the electronic
Figure 2: The Banana Gauge
or digital thickness gauge, as
seen in Figure 3 (below). Electronic gauges can also store
data and perform averaging calculations.
The specification ASTM E 376
contains information on measuring
coating thickness using a magnet
or electromagnetic current to make
coating thickness measurements
as accurate as possible.
Figure 3: Electronic or Digital
Thickness Gauge
measure coating thickness
is a destructive technique
that exposes the edge of
a coating under an optical
microscope as shown in
Figure 4 (right). The sample
must be sectioned then
mounted and polished to
show the exposed edge
of the hot-dip galvanized
coating. The calibrated Figure 4: Microscopy
eyepiece of an optical microscope can then determine the
thickness of the coating. Since this technique destroys the
part being measured, it is only used as a reference method
for resolving measurement disputes.
COATING WEIGHT
Coating weight refers to the mass of hot-dip galvanized
coating applied to a product for a given surface area. Two
different methods can be used to measure the coating
weight of hot-dip galvanized steel. The first method
uses a process called weigh-galvanize-weigh, and is
only appropriate for single specimen samples. Weigh-
galvanize-weigh measures the weight of a steel part after
it has been cleaned and, then, again after it has been
galvanized. This technique only measures the zinc metal
added to the steel and will underestimate the total coating
weight by up to 10 percent.
The second method is a destructive technique called
weigh-strip-weigh, and again, is only appropriate for
single specimen samples. Weigh-strip-weigh measures
the weight immediately after a galvanized part is cooled
and, then, again after the coating has been stripped off
the part using an acid solution. The weigh-strip-weigh
renders the part unusable as the coating is removed. The
weights must then be divided by the surface area of the
steel part to determine a value that can be compared to
the specification requirements.

AMERICAN GALVANIZERS ASSOCIATION

 Finish & APPEARANCE
finish
Several factors can affect the finish and appearance of hot-dip galvanized coatings. Some of these factors can be controlled by the
galvanizers, others cannot. The inspection of finish and appearance is done with an unmagnified visual inspection, which is performed
by fully observing all parts and pieces of a hot-dip galvanized product to ensure all specification requirements have been met. Visual
inspection is done in order to observe surface conditions (both inside and out) and to check all contact points, welds, junctions, and bend
areas. The visual inspection should be completed at the galvanizing facility before the part is shipped.

VISUAL OBSERVATIONS REASONS FOR DIFFERENT APPEARANCES

Figure 5 (right), shows The amount of silicon
products with connected added during the steel-
galvanized pieces that making process can
have different appearances. create differences in
The appearances of these the appearance of
pieces differ greatly from galvanized products.
one another due to the The Sandelin Curve,
steel chemistry of the as seen in Figure 8
different sections of the (right), compares zinc
Figure 5: Shiny vs. Dull (Acceptable)
parts; however, all of these coating thickness to Figure 8: Sandelin Curve
products continue to have an equal amount of corrosion the mass percentage
resistance throughout and meet the specification. of silicon in the steel. The recommended silicon composition
is either less than 0.04% or between 0.15% and 0.25%.
A visually dull and shiny coating on a product can also be the Any steels not within these ranges are considered reactive
result of a different cooling rate. In Figure 6 (left), the outer steels and can be expected to form thicker than average
edges of the product were zinc coatings.
cooled rapidly, allowing
a free zinc layer to form Reactive steels tend
on top of the intermetallic to produce thicker
layers. As the product galvanized coatings with
weathers, the differences a matte gray appearance
in appearance will become instead of the typical
less noticeable and the shiny appearance. This
Figure 6: Gray Coating Due to overall color will turn a difference in appearance
Temperature Differences (Acceptable) uniform, dull gray. is a result of the rapid
zinc-iron intermetallic
The fabrication and processing of the steel can also create Figure 9: Recommended Silicon vs growth that consumes
a bright or dull appearance in galvanized products. The Reactive Zinc/ Alloy Layers all of the pure zinc layer
top rail in Figure 7 (below) has a winding pattern of dull (the growth of the intermetallic layer is out of the galvanizer’s
gray areas corresponding control). In Figure 9 (above), the micrograph on the left shows
to the process used during a recommended silicon steel zinc-iron alloy formation, while the
the making of the tube. micrograph on the right shows reactive silicon steel zinc-iron
The stresses in the steel alloy formation. The micrographs clearly show the differences
from processing affect the in coating structure that can occur due to the amount of silicon
intermetallic formation and in the steel.
can result in this striped look.
The corrosion protection is In addition to silicon, the
not affected and these parts Figure 7: Gray Coating Due to presence of phosphorus
meet the specification. Processing (Acceptable) influences the reaction
between molten zinc
and steel. Figure 10
(right) shows steel with
phosphorus levels over
0.04% which produce Figure 10: Rough Coating Due to
dull coating areas and Phosphorous Levels Over 0.04%
ridges of thicker coating (Acceptable unless used for handrail)
where there is increased intermetallic growth. The end result is
a rough surface with a ridged appearance.

AMERICAN GALVANIZERS ASSOCIATION


INSPECTION
The hot-dip galvanized coating can have various surface defects that may or may not lower the long-term corrosion performance.
Some of these surface defects are rejectable, as they can decrease the corrosion protection, while others will have little effect on the
corrosion performance and are not cause for rejection.
BARE SPOTS
Bare spots, defined as an uncoated area on the steel
surface, are a surface defect that can occur because of
inadequate surface preparation. Bare spots may be caused
by welding slag, sand embedded in castings, excess
aluminum in the galvanizing kettle, or lifting devices that
prevent the coating from forming in a small area. In order to
avoid bare spots, like those seen in Figure 11 (below), the
galvanizer must ensure the surfaces are clean and without
rust after pretreatment. Small bare spots can be repaired in
the galvanizing shop.
If the size of the bare
spot or total number of
spots causes rejection,
the parts may be
stripped, regalvanized,
and then re-inspected
for compliance to the
Figure 11: Bare Spots (Rejectable) specifications.
CHAIN AND WIRE MARKS
Another type of surface defect occurs when steel is lifted and
transported using chains and wires attached to overhead
cranes. Lifting devices can leave uncoated areas on the
finished product that will need to be renovated. Superficial
marks, like those seen in Figure 12 (below), left on the
galvanized coating from the lifting attachments are not
grounds for rejection unless the marks expose bare steel;
in such a case, the galvanizer must repair the bare areas
before the part is acceptable.
Figure 12: Chain and Wire
Marks (Acceptable unless
bare steel is exposed)
AMERICAN GALVANIZERS ASSOCIATION
VISUAL
CLOGGED HOLES/CLOGGED THREADS
Clogged holes are a defect caused by molten zinc metal not
draining adequately and partially or completely filling holes
with excess zinc. Molten zinc will not drain easily from holes
less than 3/10" (8mm) in diameter due to the viscosity of
zinc metal. A good example is the screen shown in Figure
13a (below). Clogged holes can be minimized by making
all holes as large as
possible; regardless,
clogged holes less
than 1/2” in diameter
are not a cause for
rejection, unless it
prevents the part from
being used for its
intended purpose.
Figure 13a: Clogged Holes (Acceptable)
Clogged threads are caused by poor drainage of a threaded
section after the product is withdrawn from the galvanizing
kettle. Clogged threads, as seen in Figure 13b (below), can
be cleaned by using post-galvanizing cleaning operations
such as a centrifuge or by heating them with a torch to
approximately 500 F (260 C) and then brushing them off with
a wire brush to remove the excess zinc. The clogged threads
must be cleaned before the part will meet the specification.
Figure 13b: Clogged Threads (Acceptable
after threads are cleaned)
DISTORTION Excess Aluminum in Galvanizing Bath
Distortion, as seen in Figure 14 (below), is the buckling Another type of surface
of a thin, flat steel plate or other flat material such as wire defect, shown in Figure
mesh. Distortion occurs when the steel tries to move to 16 (left), is caused by an
accommodate the thermal expansion. Since the steel is excess amount of aluminum
welded in place it cannot move. This creates a high stress in the galvanizing bath. This
level often relieved by distortion of the part. Distortion is creates bare spots, seen as
acceptable, unless black marks, on the surface
it prevents the part of the steel. The part may be
from fulfilling its Figure 16: Excess Aluminum in repaired only if small areas
intended use. Many Galvanizing Bath (Rejectable) of bare spots are evident. If
distorted parts on thin this condition occurs over the entire part, the part must be
steel sheets can be rejected, stripped, and regalvanized.
bent after galvanizing
to bring the part to
an acceptable final
Flux Inclusions
Flux inclusions can be
Figure 14: Distortion (Acceptable) condition.
created by the failure of
the flux to release during
Dross Inclusions the hot-dip galvanizing
Dross inclusions are a distinct particle of zinc-iron process. If this occurs, the
intermetallic alloy that can become entrapped or entrained galvanized coating will not
in the zinc coating. Dross inclusions, as seen in Figure form under the flux spot. If
Figure 17: Flux Inclusions from
15 (below), sometimes may be avoided by changing the area is small enough, Interior of Pipe (Rejectable)
the lifting orientation or redesigning the product to allow it can be cleaned and
for more effective drainage. If the dross particles are repaired. If the flux inclusion covers a large area, then the
small and completely covered by zinc metal, they will not part must be rejected. Flux deposits on the interior of a
affect the corrosion protection, and are acceptable. If the hollow part, such as a pipe or tube, as seen in Figure 17
dross particles are large, called a gross dross particle in (above), cannot be repaired, and the part must be rejected.
the specification, and prevent the full galvanized coating Parts rejected for flux deposits may be stripped of their zinc
from forming on the steel, then the dross particle must be coating and then regalvanized.
removed and the area repaired.
Products in Contact/touch marks
Another type of surface defect is caused when steel parts
come in contact with one another or are stuck together
during the galvanizing process. This usually occurs when
many small products are hung on the same fixture, creating
the chance products may become connected or overlapped
during the galvanizing process, as illustrated in Figure 18
(below). The galvanizer is responsible for proper handling of
Figure 15: Dross Inclusions (Acceptable unless large,
and if removed, a bare spot is exposed) all steel parts in order to avoid defects from products in contact.

A similar type of surface defect

is known as a touch mark, which
is a damaged or uncoated area
on the surface of the product.
Touch marks are caused by
galvanized products resting on

VISUAL one another or by the material

handling equipment used during

INSPECTION
the galvanizing operation. Touch
marks, shown in Figure 18 (left),

(CONT.)
Figure 18: Products in Contact/
Touch Marks (Rejectable)
are cause for rejection, but may
be repaired if the size meets the
specification requirement for
repairable areas.

AMERICAN GALVANIZERS ASSOCIATION

Rough Surface Condition
Rough surface condition or appearance is a uniformly rough
coating with a textured appearance over the entire product.
The cause for rough surface condition could be the steel
chemistry or the preparation of the surface by mechanical
cleaning, such as blasting before the part reaches the
galvanizer. Rough surface condition, as seen in Figure 19
(below), can actually have a positive effect on corrosion
performance because a thicker zinc coating is produced.
One of the few situations where rough coating is cause for
rejection is if it occurs on handrails.
Figure 19: Rough
Surface Condition/
Steel Surface
Condition
(Acceptable)
Runs
Runs are localized thick areas of zinc on the surface. Runs
occur when zinc freezes on the surface of the product during
removal from the zinc bath, as seen in Figure 20 (below).
If runs are unavoidable and will interfere with the intended
application, they can be buffed. Runs are not cause for
rejection unless they affect the intended use of the steel part.
Figure 20: Runs
(Acceptable)
AMERICAN GALVANIZERS ASSOCIATION
Sand Embedded in Castings
Sand inclusion defects occur when sand becomes embedded
in the castings and creates rough or bare spots on the
surface of the galvanized steel. Sand inclusions are not
removed by conventional acid pickling, therefore abrasive
cleaning should be done before the products are sent to
the galvanizer. This type of defect leaves bare spots and
must be cleaned and repaired, or the part must be rejected,
stripped, and regalvanized. Sand embedded in a casting is
shown in Figure 21 (below).
Figure 21: Sand
Embedded in Casting
(Rejectable)
Striations
Striations are characterized by raised parallel ridges in the
galvanized coating, which can be caused by the chemical
composition of the steel. Striations, as seen in Figure
22 (below, left), are related to the type of steel that was
galvanized, and while the appearance is affected, the
performance of the corrosion protection is not– striations are
acceptable. Fish-boning, seen in Figure 22 (below, right),
similar to striations, is an irregular pattern over the entire
surface of the steel part, which is caused by differences in
the surface chemistry of a large diameter steel piece and
variations in the reaction rate between the steel and molten
zinc. These surface conditions do not affect the corrosion
performance and are acceptable.
Figure 22: Striations/ Fish Boning (Acceptable)
Surface Contaminant
Surface contaminants will create an ungalvanized area
where the contaminant was originally located, and a
surface defect may occur. This can be caused by paint,
oil, wax, or lacquer not removed during the pretreatment
cleaning steps. Surface contaminants, as seen in Figure
23 (below), should be mechanically removed prior to the
galvanizing process. If they result in bare areas, then the
repair requirements apply and small areas may be repaired,
but a large area is grounds for rejection, and the entire part
must be regalvanized.
Figure 23: Surface
Contaminant (Rejectable)
Weeping Weld
Weeping welds stain the zinc surface at the welded connections
on the steel. Caused by entrapped cleaning solutions that
penetrate the space between the two pieces, weeping welds
can be avoided by providing a 3/32" (2.4mm) or larger gap
between the two pieces when welding them. This will allow
the zinc to penetrate the gap. The weld must then be made
with gaps instead of continuous weld bead, actually making a
stronger joint when the process is complete. Weeping welds,
as seen in Figure 24 (below), are not the responsibility of the
galvanizer and are not cause for rejection.
Figure 24: Weeping Weld
(Acceptable)
VISUAL
INSPECTION
AMERICAN GALVANIZERS ASSOCIATION
Wet Storage Stain
Wet storage stain is a white, powdery surface deposit on
freshly galvanized surfaces. Wet storage stain is caused by
the newly galvanized surfaces being covered by moisture,
such as rain, dew, or condensation, and having no air flow
over the surface. Water reacts with the zinc metal on the
surface to form zinc oxide and zinc hydroxide. Wet storage
stain is most often found on stacked and bundled items, such
as galvanized sheets, plates, angles, and bars. It can have
the appearance of light, medium, or heavy white powder on
the galvanized steel product. Each of these appearances
can be seen in Figure 25 (below).
1. Light 2. Medium
3. Heavy Figure 25: Wet Storage Stain
(Light (1) or Medium (2) is Acceptable,
Heavy (3) is Rejectable)
Zinc Skimmings
Zinc skimming deposits are usually caused when there
is no access to remove the zinc skimmings during the
withdrawal of the steel from the galvanizing kettle. Zinc
skimmings on the molten zinc surface are then trapped
on the zinc coating. Zinc skimming deposits, as seen in
Figure 26 (below), are not grounds for rejection. The zinc
coating underneath is not harmed during their removal
and it meets the necessary specifications.
Figure 26: Zinc Skimmings
(Acceptable)
 additional
inspection testing
Adherence Test
Testing of the zinc coating adherence to the steel is achieved using a stout knife, as stated in A 123/A
123M and A 153/A 153M.

Embrittlement Test
When there is suspicion of potential embrittlement of a product, it may be necessary to test a small
group of the products to measure the ductility. Products suspected of embrittlement shall be tested
according to the specification A 143/A 143M.

Bending Test
The hot-dip galvanized coating on a steel bar must withstand bending without flaking or peeling
when the bending test is preformed in accordance with the procedure in A 143/A 143M.

Rebar is commonly bent prior to the hot-dip galvanizing process. Steel reinforcing bars bent cold
prior to hot-dip galvanizing should be fabricated to a bend diameter equal to or greater than the
specified value in A 767/A 767M.

sampling methods
A sampling protocol has been adopted by ASTM to ensure high quality products because the
inspection of the coating thickness for every piece of material galvanized in a project would not
be practical. To properly evaluate hot-dip galvanized coatings, randomly chosen specimens are
selected to represent the lot. The inspection quantities are determined by the lot sizes and are
detailed in the ASTM specifications A 123/A 123M, A 153/A 153M, and A 767/A 767M.

For large articles such as plates, bars and angle sections, tests should be conducted on the galvanized
article according to the procedure described in A 123/A 123M. The measurement of coating thickness
should be taken at widely dispersed points to represent a true sampling of the whole part. Extremely
large parts should be tested in sections to properly represent the entire product. For small objects such
as nuts, bolts, and washers, an entire article should be the test specimen as stated in A 153/A 153M.

The minimum average coating thickness for a lot is the average of the specimen values and must
meet the minimum for the material category as stated in the appropriate specification.

passivation testing
The specification to determine the presence of chromate on zinc surfaces is ASTM B 201. This test
involves placing drops of a lead acetate solution on the surface of the product, waiting 5 seconds, and
then blotting it gently. If this solution creates a dark deposit or black stain, then there is unpassivated
zinc present. A clear result indicates the presence of a chromate passivation coating.
repair METHOD selections
Selections
AND CONSIDERATIONS
If the galvanized product does not meet all of the requirements of the specification, it must be repaired
or rejected along with the lot it represents. When repair of the product is allowed by the specification,
the galvanizer is responsible for the repair unless directed otherwise by the purchaser. The coating
thickness of the repaired area must match the coating thickness of the surrounding area. The maximum
sizes for allowable areas that can be repaired during in-plant production are defined in the specifications.

AND
TOUCH-UP and
REPAIR METHODS
The repair methods for hot-dip galvanizing are listed in ASTM A 780 and include three accepted
methods: zinc-based solders, zinc-rich paints, and zinc spray/ metallizing.

Zinc-Based Solders
Soldering with zinc-based alloys is achieved by applying zinc alloy in either a stick or powder form. The
area being repaired needs to be preheated to approximately 600 F (315 C). The acceptable material
compositions of solders used for repair are included in the specification.

The final coating thickness for this repair shall meet the specification requirement for the material
category of the steel part being repaired. The thickness shall be measured by any of the methods in
A 123/A 123M that are non-destructive. Zinc-based solder products closely match the surrounding zinc
and blend in well with the existing coating appearance.

Zinc-Rich Paints
Zinc-rich paint is applied to a clean, dry steel surface by either a brush or spray. Zinc-rich paints
must contain either between 65% to 69% metallic zinc by weight or greater than 92% metallic zinc by
weight in the dry film. Paints containing zinc dust are classified as organic or inorganic, depending
on the binder they contain. Inorganic binders are particularly suitable for paints applied in touch-up
applications of undamaged hot-dip galvanized areas.

The coating thickness for the paint must be 50% higher than the surrounding coating thickness, but not
greater than 4.0 mils, and measurements should be taken with either a magnetic, electromagnetic or
eddy current gauge.

Zinc Spray
Zinc spray, which is also referred to as metallizing, is done by melting zinc powder or zinc wire in a
flame or electric arc and projecting the molten zinc droplets by air or gas onto the surface to be coated.
The zinc used is nominally 99.5% pure or better and the corrosion resistance of the coating produced
by this technique is approximately equal to the hot-dip galvanized coating.

The renovated area shall have a zinc coating thickness at least as thick as that specified in
A 123/A 123M for the thickness grade required for the appropriate material category. For best results,
thickness measurements for the metallized coating should be taken with either a magnetic or an
electromagnetic gauge.
 related ASTM
RELATED
SPECIFICATIONS
• ASTM A 123/A 123M – Standard Specification for Zinc
(Hot-Dip Galvanized) Coatings on Iron and Steel Products

• ASTM A 153/A 153M – Standard Specification for Zinc

Coating (Hot-Dip) on Iron and Hardware

• ASTM A 767/A 767M – Standard Specification for Zinc-Coated

(Galvanized) Steel Bars for Concrete Reinforcement

• ASTM A 780 – Standard Practice for Repair of Damaged

and Uncoated Areas of Hot-Dip Galvanized Coatings

• ASTM A 143/A 143M – Standard Practice for Safeguarding

Against Embrittlement of Hot-Dip Galvanized Structural
Steel Products and Procedure for Detecting Embrittlement

• ASTM A 384/A 384M – Standard Practice for Safeguarding

Against Warpage and Distortion During Hot-Dip Galvanizing
of Steel Assemblies

• ASTM A 385 – Standard Practice for Providing High-Quality

Zinc Coatings (Hot-Dip)

• ASTM B 6 – Standard Specification for Zinc

• ASTM D 6386 – Standard Practice for Preparation of Zinc

(Hot-Dip Galvanized) Coated Iron and Steel Product and
Hardware Surfaces for Paint

• ASTM E 376 – Standard Practice for Measuring

Coating Thickness by Magnetic-Field or Eddy-Current
(Electromagnetic) Examination Methods

AMERICAN GALVANIZERS ASSOCIATION

American Galvanizers Association
www.galvanizeit.org