Surface Preparation
GALVANIZED & NON-FERROUS
Galvanized steel used in the construction industry (Wolverhampton Abrasives), garnet, or olivine is
is manufactured by a hot dip process in accordance the preferred method. New low pressure wet
with BS 729. The process deposits a minimum abrasive blasting techniques are particularly
weight of zinc of 610 gms/m2 equal to 85 microns effective.
thickness on each face.
Nozzle pressures should be kept as low as
The thickness of zinc may be increased to 140 possible, typically 30 p.s.i. to avoid excessive
microns or more by the use of special steels or by disruption to the galvanized surfaces. Average
blast cleaning the steel prior to galvanizing. profile of 25 ± 5 microns is ideal for receiving paint
coatings.
For many service conditions galvanized steel
provides adequate corrosion protection without Metallic abrasives should not be used for
further treatment using surface coatings. preparation of galvanizing.
However, there are instances in which the exposure Abrasive blast cleaning is the only method
conditions require application of a coating system to recommended for immersed or buried galvanized
protect the galvanizing and give increased steelwork, that is to be painted subsequently.
durability, or for cosmetic appearance.
Duplex systems which comprise galvanizing plus a
high performance coating system give much
Use of T-Wash
improved durability either to unpainted galvanizing (Leigh’s L703 Mordant Wash)
or paint systems applied directly to steel.
This method is a wet process which if correctly used
is an indicative method for determining if surfaces
Surface Preparation - New have been correctly degreased.
Galvanizing Surfaces should be degreased using an aqueous
detergent solution and rinsed with fresh water prior
Newly manufactured galvanized steel has a smooth to application of T-Wash.
bright spangled appearance which is difficult to Detailed instructions for the use of Leigh’s L703
paint successfully without further surface Mordant Wash Solution are laid down in the Product
preparation. Technical Data Sheet and the brochure entitled
Adhesion failures were frequent occurrences in the ‘Guidance Notes on the use of L703’.
past due to inadequate surface preparation or Use of mordant wash is particularly useful for
choice of wrong specification. Several years ago, pretreatment of components of complex shape
Leigh’s sponsored independent research to which are difficult to blast clean.
investigate these parameters for treatment of
galvanized steel.
Two projects, the Trent Project (1986) was Preparation of Weathered
commissioned by W & J Leigh and the R508 Galvanized Surfaces
Project (1992) in conjunction with the Galvanizers
Association and Zinc Development Association to Degrease and scrub with freshwater to remove zinc
investigate these areas. This research identified salts. More tenacious deposits of zinc salts may be
two means of surface preparation as the preferred removed by abrading if necessary. If the bright
methods for galvanizing. spangled appearance has tarnished sufficiently
during exposure, no further pretreatment is
necessary prior to painting. If only minor tarnishing
Abrasive Blast Cleaning or oxidation of the surface has occurred,
pretreatment using abrasive blast cleaning or the
Abrasive blast cleaning using a fine grade of non- use of mordant wash solution may need to be
metallic abrasive such as Stonegrit Extrafine considered.
6 - Apr. 98
Surface Preparation
GALVANIZED & NON-FERROUS
Choice of Coating Specification ‘Galvatite’ - Introduction
Coating of galvanized steel should be carried out Galvatite is the trade name for British Steel plc cold
using specifications utilising high performance rolled sheet which is zinc coated using a hot dip
coatings of a non-saponifiable type. process. It is produced at steel thicknesses of 0.4
Saponifiable coatings such as alkyd based to 3.25mms. Galvatite is coated with a metallic zinc
materials should not be applied directly to thickness of 14 to 83 microns, to give a bright
galvanized surfaces. appearance which is spangled at higher
thicknesses. Galvatite is used for more aggressive
Dry film thickness of paint systems applied can be conditions than Zintec where better corrosion
significantly reduced compared with similar resistance is required.
systems applied to steel. A typical thickness of 150
microns d.f.t. over the galvanizing is adequate for Fabricated products in which it is used include
external exposure service conditions to give a life to rolled, formed or pressed items including roof
first maintenance of 20 years. purlins, cladding, HVAC units etc.
Paint film thicknesses of up to 150 microns give
best performance. The use of higher dry film
‘Zintec’ - Introduction thicknesses are unnecessary.
Zintec is the trade name for British Steel plc cold
rolled sheet and coil that has been electrolytically ‘Galvatite’ - Surface Preparation
coated with a thin layer of zinc. It is produced at
steel thicknesses of 0.4 to 2.0mm and contains a Galvatite is produced in grades which incorporate a
thickness of zinc from 1.0 to 1.75 microns. chromate or an oil pretreatment as standard to
Zintec can be recognised by its matt grey prevent the formation of anti-white rust.
appearance significantly different to the bright Galvatite treated with the chromate pretreatment
spangled surface produced by hot dip processes of reduces the effectiveness of T-Wash which fails to
galvanizing and Galvatite. convert to a dark grey colour when applied.
Zintec is not used for aggressive external Satisfactory paint adhesion may only be achieved
environments. It is used in the manufacture of by degreasing and abrading surfaces. Fine grade
sheet steel pressed products such as washing emery or aluminium oxide abrasive paper or pads
machines, air conditioning plant and car bodies. should be used. Care should be taken to avoid
excessive removal or damage to the protective zinc
layer. T-Wash should not be used.
‘Zintec’ -Surface Preparation
Conversely British Steel will supply Galvatite which
Zintec is produced in grades which incorporate has been treated with an iron/zinc alloy to assist
either a chromate or an oil treatment to inhibit the paint adhesion. Coating systems may be applied
formation of zinc oxide - white rust. directly without further pretreatment other than
degreasing. Degrease thoroughly using aqueous
Sound coating adhesion is achieved by thorough detergent solution followed by a copious hot water
degreasing. Coating failures which occasionally rinse.
have occurred have been attributed to inadequate
cleanliness prior to painting. No further Solvent wiping with clean cotton cloth and xylene
pretreatment is necessary after degreasing. (Leigh’s Cleanser/Thinner No 2) can be satisfactory
for small areas, as long as the cloth is changed
Degreasing should be carried out using aqueous frequently. Dirty cloths will redeposit oil on the
detergent solution and rinsed with hot water. surface as the solvent evaporates.
The use of strongly alkaline degreasants should be Solvent wiping must be carried out in line with
avoided since they can adversely affect the zinc Health and Safety requirements, ensuring good
coating.
7 - Apr. 98
Surface Preparation
GALVANIZED & NON-FERROUS
ventilation and avoidance of skin contact. Zinc and Aluminium Sprayed
Strong alkaline de-greasers with a pH value of
greater than 10 may dissolve the zinc coating and Metal Surfaces
should be avoided.
After sweeping down, vacuuming or blowing down
to remove residual dust following application of the
Sheet Aluminium and Aluminium metal spray, surfaces should be primed as soon as
possible. Experience has shown that metal sprayed
Alloys surfaces absorb atmospheric moisture easily and
quickly.
Degrease and abrade using a suitable hand or
mechanical method. Aluminium surfaces may be This absorbed moisture can create problems,
primed using either etch primer or a suitable epoxy particularly in the case of aluminium sprayed metal
primer according to the subsequent service which may subsequently operate under high
condition to which the coating will be subjected. temperature conditions. Typical specifications for
the treatment of metal sprayed surfaces are
Heavy gauge sections may be blast cleaned. Use included in the Manual.
of aluminium oxide/bauxite abrasive is
recommended, such as Stonegrit Fine as supplied
by Wolverhampton Abrasives.
Austenitic Stainless Steel
Austenitic and duplex stainless steels are playing
an increasing part in the construction of
petrochemical and chemical plants due to their
extremely high levels of corrosion resistance. The
use of protective coating systems is not normally
considered necessary for protection of stainless
steel alloys due to the presence of a passive film of
chromium oxide.
However, under severe exposure conditions,
particularly where chloride attack is possible and
especially at elevated temperatures, stress
cracking corrosion may be a serious problem.
W & J Leigh have developed a specialist primer for
the treatment of stainless steel surfaces which has
a proven track record in resisting the effects of
stress cracking corrosion.
Normal surface preparation after degreasing
involves light abrasive blast cleaning using garnet
or aluminium oxide abrasive. A blast profile of fine
grade equal to segment 1 of the ISO Grit
Comparator is suitable for this purpose. Austenitic
stainless steel should not be primed using heavy
metal primers, including zinc or lead.
8 - Apr. 98