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Zinc-Rich Coatings
Coatings with greater than 65% zinc by weight
in the dried film are considered Zinc-Rich
Zinc content is important, SSPC Paint 20 defines 3
levels of zinc in the dried film
Level 1 equal to or greater than 85%
Level 2 equal to 77% to 85%
Level 3 equal to 65% to 77%
Inorganic Zinc
Powdered metallic zinc
Mixed with a reactive silicate solution
Ethyl Silicate
Potassium Silicate
Other Alkalai Silicates
Inorganic Zinc
Sandblasted
surface
Organic Zinc-Rich
Available as one, two- or three-package products
Two component epoxy with zinc dust
Moisture cure urethane with zinc dust
Application Considerations
Zinc Dispersion in Film
Proper mixing during
application
Weathering of Zinc
Primer prior to topcoating
Secondary surface
preparation
Degree of Cure
Especially for IOZ silicate
Resists chemicals, to a
degree (zinc is
amphoteric reacts with
acids and bases)
Pre-construction primer
Thin film build, lower zinc loads
Zinc-Rich
CARC
Epoxy/CARC
Control
Zinc-Rich
Only
18
Zinc Rich A
Zinc Rich B
Galvanized Sheet
1 year
Zinc-Rich
Epoxy/CARC
Zinc-Rich
CARC
Epoxy/CARC
Control
Zinc-Rich
Only
9 years
1 year
Zinc-Rich
Epoxy/CARC
Zinc-Rich
CARC
Epoxy/CARC
Control
Zinc-Rich
Only
9 years
22
Electrochemical Data
Perform a variety of
experiments
Polarization resistance
Open Circuit Corrosion
Potential
Electrochemical
Impedance Spectroscopy
Galvanic Current
(Interaction with steel)
23
Effect of Environment
Current - mA
Seawater
Tap Water
10
15
20
25
24
Effect of Environment
Tap Water Cell
1
0.8
0.7
E(off), zinc
0.6
0.5
0.4
0.9
0.3
0.8
10
15
20
Volts vs SCE
Volts vs SCE
0.9
Seawater Cell
E(off), steel
Couple Potential
25
0.7
E(off), zinc
0.6
0.5
E(off), steel
0.4
Couple Potential
0.3
0
10
15
20
25
25
Polarization Behavior
(9 days in seawater)
Potential vs SCE - Volts
0.000
-0.200
-0.400
Galvanized
-0.600
Zinc A
-0.800
Zinc B
Zinc C
-1.000
Zinc D
-1.200
1.E-07
1.E-06
1.E-05
1.E-04
1.E-03
1.E-02
1.E-01 1.E+00
Current - Amps
26
Potential, mV vs Ag/AgCl
-200
-400
-600
zinc
steel
1/100 zinc
-800
-1000
-1200
1.E-03
1.E-02
1.E-01
1.E+00
1.E+01
1.E+02
1.E+03
Current - mA
27
0.5
0.44%
0.44%
Steel Polarization - V
0.4
0.7%
1.8%
0.3
2.7%
7.1%
0.2
7.1%
0.1
11%
28%
44.4%
0
-0.1
10
15
20
25
30
35
100%
Time - Days
28
Binder type
Packing factor
Zinc content
Defect geometry
Zinc coating thickness
Electrolyte conductivity
Zinc particle purity
Zinc particle size
Surface chemistry
29
Electrochemical Observations
Lower resistivity electrolyte
Better sacrificial protection, shorter life
Summary/Conclusions
Zinc rich coatings can help increase coating
service life in marine atmosphere exposure
Zinc rich coatings have unique issues which
must be considered
Todays coating community is more sophisticated
than 30 years ago