HDG DATASHEET: 15
Painting and Powder Coating on Hot Dip Galvanizing
Duplex Coating The other key benefit of a duplex system is the synergistic effect
A duplex coating is defined as a combination of two different that is achieved whereby the galvanized coating causes the organic
coating systems which often complement one another. Typically system to perform better than it would do if applied directly on
this means a metallic coating overcoated by an organic system. to a steel surface. If paint is applied on to a steel surface, over
Examples of such systems are hot dip galvanizing surfaces which a period of time moisture permeates through microcracks in
have been painted or powder coated. the coating leading to red rust which creates stresses within the
organic layer leading to coating failure. Conversely when applied
Typically a galvanized coating on its own will provide adequate on to a galvanized coating, moisture may penetrate through to
corrosion protection. However, an organic may be applied over the galvanized substrate leading to the formation of zinc corrosion
the galvanized finish for a number of reasons such as to add products. These have a much smaller volume than the red rust that
colour for improved aesthetics, to try and blend the structure into would be otherwise formed and consequently create much lower
its surroundings, to try and make the structure stand out from its stresses within the organic coating. The corrosion products so
surroundings or to provide additional corrosion protection in a very formed may even backfill any porosity within the paint system so
severe environment. preventing further moisture penetration.
As a result of this process the life of a duplex system is more than
the sum of its two component parts as illustrated by the equation
below.
LDuplex = K (LHDG + LOrganic)
Where: LDuplex is the life of the duplex system
LHDG is the expected life of the hot dip galvanized
coating
LOrganic is the life of the organic system applied
K is a constant
The value of ‘K’ may vary but typically lies in the range 1.2-2.5
dependent upon the make-up of the duplex system applied.
Specification
Standards are available to allow specification of the different
components of a duplex system as summarised below.
Hot dip galvanizing will normally be specified by BS EN ISO 1461
: 2009 ‘Hot Dip galvanized Coatings on Fabrictaed Iron and Steel
Articles – Specifications and Test Methods’. This standard contains
coating thickness and surface smoothness requirements although
where aesthetics are of particular importance, consideration may
be given to conducting a trial dip so as to produce reference
samples from which a supply standard can be agreed.
Information on suitable paint specifications and their application
may be found within BS EN ISO 12944 Parts 4 & 5 ‘Paints and
Varnishes – Corrosion Protection of Steel Structures by Protective
Paint Systems’. Part 4 covers types of surface and surface
Benefits of a Duplex System preparation while Part 5 gives guidance on protective systems.
A duplex system offers a number of advantages over utilising just Powder coating over hot dip galvanizing may be specified by
one of the chosen coatings. Firstly if a structure is required to be BS EN 13438 ‘Paints and Varnishes – Powder Organic Coatings
a specific colour, painting or powder coating is required. However, for Galvanized or Sherardised Steel Products for Corrosion
by applying the product over a galvanized coating, a high level Purposes’. In addition BS EN 15773 ‘Industrial Application of
of underlying corrosion protection is provided such that if the Powder Organic Coatings to Hot Dip Galvanized or Sherardised
organic system becomes damaged there is no urgency to conduct Steel Articles (Duplex System) – Specifications, Recommendations
immediate remedial work as the galvanized coating will prevent the and Guidelines’ which sets out guidelines for communication and
formation of red rust which would otherwise undercut the organic agreements that should take place in order to achieve the best
system if applied directly on to a steel substrate. possible finish may also be referenced.
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Surface Preparation for Duplex Coatings
Where an organic is to be applied, it is important that
consideration is given to preparation of the galvanized surface so
as to ensure good adhesion of the organic application. Examples
of preparation procedures which have been successful following
removal of oil, grease and other surface contaminants include:
Chemical Pretreatment – This typically involves application
of T-wash (sometimes known as mordant wash or mordant
solution) or a suitable etch primer to the galvanized surface prior
to overcoating. Typically T-wash tends to be used on newly
galvanized steelwork while etch primers are used on weathered
surfaces. It is important that adequate time is permitted for the
pretreatment solution to fully dry out and react prior to overcoating
and where a powder coating is to be applied this might be
achieved by heating to at least 40°C above the final curing
temperature for about 10 minutes. It should be noted though that
the galvanized product should not be subject to a temperature of
200°C or above for more than a few minutes as this may lead to
peeling of the outer layer of pure zinc.
Mechanical Pretreatment – This involves lightly sweep blasting
the galvanized surface at low pressure (0.3 MPa or 40 psi
maximum) with a soft blast media such as fine copper slag, J
blast or carborundum powder. When conducted, it is important
to control both the blast distance and blast angle as the aim is to
produce a slight profile on the galvanized surface to act as a key
for subsequent organic application. Excessive blasting may lead
to coating damage and should be avoided.
In addition to the above pretreatments there are now a number of
direct application paints which may be applied without the need
for preparation after thorough washing down and degreasing.
A number of different organic systems are available for application
over a galvanized finish offering a full range of RAL colours.
This sheet is part of the series ‘HDG Datasheets’ and can be requested from
Galvanizers Association. Published August 2015.
