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Activated Zinc Technology; Making Zinc-Rich Epoxies Work Better for the Applicator and the Owner

Activated Zinc Technology; Making Zinc-Rich Epoxies Work Better for the Applicator and the Owner
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Inorganic zinc-rich coatings (IOZ’s) are often considered the gold standard for corrosion protection in atmospheric environments. Frequently, zinc epoxy coatings are considered second best among the most effective coatings for corrosion protection. However, current zinc-rich coating technology is not exempt of limitations, such as poor mechanical properties of the film, rigid environmental application conditions, or the inefficient use of zinc particles for providing galvanic protection. Due to these limitations, a number of asset owners have made the decision not to use zinc-rich coatings to maintain coating systems in marine and offshore environments

Product Number: 41216-985-SG
Author: James McDonald, Pablo L. Bernad
Publication Date: 2016
Industries: Corrosion Monitoring and Control , Coatings
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 Inorganic zinc-rich coatings (IOZ’s) are often considered the gold standard for corrosion protection in atmospheric environments. Frequently, zinc epoxy coatings are considered second best among the most effective coatings for corrosion protection. However, current zinc-rich coating technology is not exempt of limitations, such as poor mechanical properties of the film, rigid environmental application conditions, or the inefficient use of zinc particles for providing galvanic protection. Due to these limitations, a number of asset owners have made the decision not to use zinc-rich coatings to maintain coating systems in marine and offshore environments. This has resulted in protective coating systems that last an average of 2-3 years before additional maintenance is required and 5-6 years before full recoating is needed. This paper presents a new generation of zinc-rich epoxy coatings that overcome the limitations of the current technology. Core to the technology is the efficient activation of the zinc content within the film and robust application and film characteristics. Here, we present the advantages to applicators and asset owners alike. Practical application characteristics have been designed into the material for use by applicators with varying degrees of experience and short application windows. Also presented is the experimental and test data that supports the proposed mechanisms for the activation of the zinc and improved film characteristics. Thus, the presented activated zinc technology combines galvanic, barrier and inhibition mechanisms in protection of steel by zinc rich coatings. Zinc rich epoxy primers based on this technology provide more zinc dust pigment for the electrochemical protection process and as such, it significantly reduces corrosion and maintenance. Also, mechanical properties are clearly improved, the application window is enlarged and process safety during painting works is improved. Finally, the durability of the whole coating system increases. Maintenance intervals can be extended, and new maintenance strategies can be developed.

 Inorganic zinc-rich coatings (IOZ’s) are often considered the gold standard for corrosion protection in atmospheric environments. Frequently, zinc epoxy coatings are considered second best among the most effective coatings for corrosion protection. However, current zinc-rich coating technology is not exempt of limitations, such as poor mechanical properties of the film, rigid environmental application conditions, or the inefficient use of zinc particles for providing galvanic protection. Due to these limitations, a number of asset owners have made the decision not to use zinc-rich coatings to maintain coating systems in marine and offshore environments. This has resulted in protective coating systems that last an average of 2-3 years before additional maintenance is required and 5-6 years before full recoating is needed. This paper presents a new generation of zinc-rich epoxy coatings that overcome the limitations of the current technology. Core to the technology is the efficient activation of the zinc content within the film and robust application and film characteristics. Here, we present the advantages to applicators and asset owners alike. Practical application characteristics have been designed into the material for use by applicators with varying degrees of experience and short application windows. Also presented is the experimental and test data that supports the proposed mechanisms for the activation of the zinc and improved film characteristics. Thus, the presented activated zinc technology combines galvanic, barrier and inhibition mechanisms in protection of steel by zinc rich coatings. Zinc rich epoxy primers based on this technology provide more zinc dust pigment for the electrochemical protection process and as such, it significantly reduces corrosion and maintenance. Also, mechanical properties are clearly improved, the application window is enlarged and process safety during painting works is improved. Finally, the durability of the whole coating system increases. Maintenance intervals can be extended, and new maintenance strategies can be developed.

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Zinc-rich primers, with zinc dust loadings of 80-85% by weight in the dry film, are often the preferred primer during new construction of assets placed in environments with high atmospheric corrosivity. Coating standards such as SSPC-Paint 20 and ISO 12944 demand that zinc-rich primers contain at least 65% and 80% zinc dust by weight in the final dry film, respectively. Traditional zinc rich primers need this high zinc loading to achieve galvanic protection of steel. New technology allows us to develop zinc primers with a lower content of zinc and/or different zinc morphology than dust to provide similar or better corrosion protection to the steel.
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