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Inorganic Zinc Primers vs. Galvanizing… the age old debate

Inorganic Zinc versus Galvanizing

There is an age old debate regarding galvanizing steel versus using inorganic zinc primers for protection against corrosion in exterior environments.  Below is a selection from a NACE (National Association of Corrosion Engineers) publication discussing the subject. The text is widely accepted as the most comprehensive guide to corrosion engineering.

Excerpt from: NACE Publication; “Corrosion Prevention by Protective Coatings” by Charles Munger; p: 153

“Although inorganic zinc coatings are made with metallic zinc, they should not be considered a metallic coating, e.g., galvanizing. There has been considerable discussion and controversy with regard to inorganic zinc coatings and galvanizing, with most of the proponents of either material taking a rather strong stand in favor of their particular product. Actually, inorganic zinc coatings and galvanizing should not be considered competitive. Rather, they should be considered complementary, since both of them provide an excellent corrosion-resistant application under the conditions where each one operates best.

They are two entirely different concepts of coating, even though they both rely on metallic zinc for the basis of their corrosion resistance. Both are chemically bonded to the metal surface, the galvanizing by an amalgam of zinc and iron, while the inorganic coating is bonded by a chemical compound of iron and silica. Actually galvanizing can be considered an inorganic zinc coating, and in many ways, it will do the same things that an inorganic zinc-rich coating will do.

There are also some basic differences. The zinc in an inorganic zinc coating is not continuous as it is with galvanizing. It is made up of individual zinc particles which are surrounded by and reactive with an inert zinc-silicate matrix. This matrix is very chemically inert and except for strong acids or alkalies, is unreactive with most environmental conditions where coatings would be used. This does not mean that in an acid atmosphere the zinc in the inorganic zinc coating might not be dissolved. However, because it is in a chemical-resistant matrix as discrete particles completely surrounded by the matrix, the solution of the zinc is slowed down in a major way. On the other hand, zinc in galvanizing is pure zinc, and any acid in the atmosphere reacts directly with it with no inhibition of the reaction, as in the case in the inorganic zinc coating. This is an important difference between the two materials and is the reason why, under many difficult corrosion conditions, the inorganic zinc coating will have a much longer life than the galvanizing under the same conditions. This has proven to be the case not only in laboratory testing over a number of years, but also in both industrial and marine atmospheres.

… (3 oz/ft2 hot dip galvanized panels) exposed to two years of tidal conditions (immersed and non-immersed) showed almost complete breakdown by pinpoint rusting; compared to (3 mils) of inorganic zinc coated panels with no appreciable corrosion.

Inasmuch as the zinc in a zinc coating is surrounded and interlocked into an inert matrix, the coating has controlled reactivity and controlled conductivity. (Testing) has shown that the metallic zinc was considerably more reactive than the zinc which was protected by the inorganic zinc matrix.

While galvanized surfaces provided a malleable zinc surface, the inorganic zinc coating, because of the hard, rock-like character of the zinc silicate matrix, results in a much harder and more abrasion resistant coating than metallic zinc. All the above differences generally indicate, on an exposure-for-exposure basis, that the inorganic zinc will tend to have a longer life span under more conditions than will the normally galvanized steel surface.”

SUMMARY

So what does this all mean for my project? An inorganic zinc coating offers both chemical and galvanic protection with that a 1 mil layer pure zinc used in the galvanizing process cannot and does not offer the abrasion and chemical protection of an inorganic zinc primers.

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Inorganic Zinc Primers vs. Galvanizing… the age old debate

Comparing and testing generic topcoats for exterior use

One of the important factors a buyer considers during the paint buying process is how well topcoats perform during their service.

Also known as weathering finishes, these coatings are designed for ultraviolet (UV) exposure during exterior use. They’re common in any industry that requires equipment or structures to be used or kept outdoors. Topcoats are the first line of defense against the elements, providing protection to intermediate coats which are designed to protect primers.

And it’s important to note right away that there’s no such thing as a coating that doesn’t weather. All coatings fade and break down eventually. With a greater understanding of topcoat formulations and quality testing methods, you’re empowered to make the choice that offers the best protection for your critical assets.

Accelerated weathering testing

In these tests, UV and moisture exposure is simulated in controlled settings over abbreviated time frames to judge how well coatings stand up to the elements. This is a preferred method for testing and comparing weathering finishes because it’s impractical to rely on real-time field tests that would take years to complete.

However, accelerated weathering testing is an imperfect method that requires strict controls and an understanding that actual results may vary in the field. Consider these practical issues:

  • The UV lamps used to simulate sunlight in these tests emit radiation only in a very narrow bandwidth compared to the broad-spectrum UV radiation produced by the sun.
  • Proper testing in controlled conditions cannot replicate or predict the diversity of ever-changing operating conditions in the field.
  • There’s no accurate way to translate results from accelerated weathering testing to actual useful service lives for coatings in the field. The testing should only be used to compare coatings against one another in similar conditions.

Comparing coating formulations

Tests conducted on weathering finishes are designed to shed light on a few different things, such as:

  • Resin quality – Resins are key components in coatings because they form the matrices that hold color pigments in place. When testing coatings to judge the quality of their resins, it’s best to use white or light-colored formulas that lack color pigments. That’s because differing color pigments degrade at differing rates, and that could skew the results of tests targeting resins.
  • Color fastness – Not all pigments are created equal—even like-colored pigments. For example, the red pigments used to color a muscle car are of far higher quality than those used in other, shorter-term applications. When testing for color fastness, choose formulations with similar resin quality so that resin degradation doesn’t interfere with pigments.
  • Gloss retention – When comparing the rate at which gloss loss occurs in a coating, it’s critical that the angles to which lamps are set remain constant. Differing angles alter the way light impacts a painted surface, and results will not be reliable.

It’s important to maintain other constants in tests, too, like film thickness, application method, curing conditions, testing exposure cycles and testing surface preparation. Ignoring experimental controls allows too many variables to interfere with test results.

Performance benchmarks

The Society for Protective Coatings’ (SSPC) standard for two-component weatherable aliphatic polyurethane coatings (SSPC Paint 36) defines three performance levels for weathering finishes.

Level 1 finishes are rated based on 500-hour exposures during accelerated weathering tests. Level 2 finishes are rated based on 1,000-hour tests. Level 3 finishes are rated based on 2,000-hour tests.

Alkyds or oil-based coatings are typically tested in the 250 – 1,000 hour range; most of these coatings sustain significant gloss loss at the high end of this range.

Epoxies lose gloss quickly and begin to chalk after a couple hundred hours of exposure.

Acrylic formulations can vary widely, but they typically hold gloss for between 1,000 and 2,000 hours.

Polyurethanes are even more variable in formulation than acrylics and are commonly tested for several thousand hours. Polyurethane clear coats care often tested into the 5,000 hour range.

Siloxanes and fluorourethanes known as “ultra-weatherables” have shown impressive gloss retention even after 9,000 hours of accelerated weathering testing.

Comparing US Coatings finishes

US Coatings offers many weathering finishes. Buyers need to carefully consider all aspects of an asset or structure prior to choosing a weathering finish, including:

  • The intended use of the asset and whether such a finish is even appropriate.
  • Whether the aesthetic appeal of an asset is important to its end use.
  • Whether a such a finish is being used in conjunction with other coatings or asset protection systems.
  • How frequently you expect to re-coat the asset.

Use the chart below to determine which US Coatings product is the best match for your exposed assets:

We’re here to help you answer any questions you may have. If you want to talk through your options further, let’s talk. You can also explore our products in greater detail by downloading our product data sheets here.

Choosing the right weathering finish is just one step in assuring your next painting project goes off smoothly. In this guide, we take you through all the elements of a productive —and painless— industrial painting program.

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Inorganic Zinc Primers vs. Galvanizing… the age old debate

Recoating aged and weathered coatings when proper prep is not always an option.

MasticGrip 2500 is a surface tolerant, aluminum flake filled, mastic epoxy which can act as primer or finish.

MasticGrip 2500  is an aluminum pigmented, low-stress, high-solids mastic with outstanding performance properties and offers . It has unique properties over conventional coatings because it wets out existing rust down to the steel substrate. MasticGrip 2500 coating in a number of industrial markets. Today it continues to provide unmatched levels of barrier protection and corrosion resistance over existing finishes and rusted steel; or is suitable for hand or power tool cleaned surfaces.

MasticGrip 2500: What is the Labyrinth Effect?

The Labyrinth effect essentially creates complex maze for moisture to not easily penetrate the coating. This is important because the rate of osmosis is a critical component to premature coating failure. MasticGrip 2500 utilizes aluminum flakes of various sizes which acts similar to a coat of armor for your substrate. The protection is effective against everyday abuse from UV, water, and chemicals.

Why use MasticGrip 2500 as a “everywhere” primer?

The low viscosity formulation enables it to wet out and penetrate rust down to the substrate, yet it’s high solids allows it to bond to a variety of aged coatings without crazing or lifting. In short, MasticGrip 2500 is the most dependable, robust protection for maintenance painting available. It’s the best primer choice for aged, weathered coatings that can’t be mechanically abraded. This primer/finish is the perfect solution for owner you would like to get five to ten more years out of an asset before a complete repaint down to bare steel.

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Inorganic Zinc Primers vs. Galvanizing… the age old debate

RustGrip 2300 is designed to minimize prep when time and resources are limited

RUSTGRIP 2300 is a highly cross-linked penetrating primer/sealer with superior wetting properties. Its a 100% solids epoxy, and will not lift existing coatings yet, allows any topcoat to be overcoated. It is highly flexible with good chemical and solvent resistance, and accepts a variety of topcoats. Recommended use as primer/sealer for marginally prepared steel and over aged coatings. Its excellent wetting properties allows it to penetrate rust and discontinuities in existing coatings and provides a firm anchorage for a variety of topcoats.

RustGrip 2300: The primer that breaks all the rules…

Do you have tightly adhered, aged coating, or weathered steel with tight rust?

Scrape it, clean it, and prime with RustGrip 2300. Its low viscosity formulation enables it to bond to surfaces that heavier pigmented coatings cannot. Even an hour after it is applied it continues to wetout and seal down light surface chalking and tight rust.

It’s the only primer choice for aged, weathered coatings that can’t be mechanically abraded. This primer is the perfect solution for owner you would like to get five to ten more years out of an asset before a complete repaint down to bare steel.

Rusting storage tank at a chemicle plant. 

RustGrip 2300 Flyer

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Inorganic Zinc Primers vs. Galvanizing… the age old debate

US Coatings offers prefabricated hazardous material storage buildings

US Coatings is enhancing customers’ ability to comply with hazardous material storage and containment requirements by offering prefabricated hazardous material storage buildings.

Industrial firms rely on these structures to safely store dangerous corrosive, flammable, combustible or other hazardous materials that they must keep in or near their facilities.

US Coatings offers a wide range of free-standing, relocatable prefabricated hazardous material storage buildings to meet any facility’s need. Structures available include:

  • Non-combustible steel construction – Designed to store flammable or combustible liquids and other hazardous materials, these structures feature exterior weatherproof unitized non-combustible steel construction made with welded structural and heavy-gauge steel sheets.
  • Two-hour fire-rated uni-directional – These structures are designed to store flammable, combustible, corrosive and poisonous materials and incorporate weatherproof two-hour fire-rated non-combustible heavy-gauge steel construction. The design includes layers of UL-Classified fire-resistant gypsum wallboard between the exterior steel and interior galvannealed steel sheets.
  • Two-hour fire-rated bi-directional – This model safely contains drums, compressed gas cylinders, bottles and other hazardous material containers. It features weatherproof bi-directional two-hour fire-rated non-combustible heavy-gauge steel construction and includes layers of fire-resistant gypsum wallboard, insulation and galvannealed interior and exterior steel sheets. The structure meets UL Fire Resistance Rating U425.
  • Four-hour fire-rated bi-directional – This structure is designed to contain drums, totes, compressed gas cylinders, bottles or other hazardous material containers when they must be stored very close to other buildings or within a larger structure. It meets UL Fire Resistance Rating U490 and features bi-directional four-hour fire-rated non-combustible heavy-gauge steel construction with insulation and two layers of UL-Classified Ultracode fire-resistant gypsum wallboard. Exterior surfaces are made of corrosion-resistant galvannealed steel sheets.

Additional standard features

All prefabricated hazardous material storage buildings we offer also come with the following features:

  • Screened air inlet vents with UL-Classified three-hour fire-rated dampers.
  • Open channel building base to allow for under-building inspections and for forklift and crane sling transit.
  • Internal spill containment capacity of 30 percent of the total storage capacity.
  • Hold-down brackets to bolt structures to foundations to resist seismic and wind loads.
  • Static ground system including an exterior grounding connection, grounding rod, copper conductor and grounding lugs.
  • DOT hazard placard.

All buildings are Factory Mutual-approved and labeled and meet all state and municipal building code requirements.

Customize your prefabricated hazardous material storage building

We know one size doesn’t fit all. That’s why we offer customization options for customers whose unique hazardous material storage needs require individual solutions.

Using modular construction, we build units up to ten feet tall and offer widths of 6 – 14 feet in two-foot increments. We can also vary the lengths of your structure, starting at 8 feet long and topping out at 52 feet, also in two-foot increments.

Optional temperature control systems and explosion relief vents that comply with NFPA 68 are also available on all US Coatings prefabricated hazardous material storage buildings.

Request a consultation

If you’re facing a hazardous material storage requirement, we want to guide you to the solution that best fits your need. Let’s talk — together, we’ll identify the building and accessories that ensure your hazardous materials are kept secure and your personnel and assets are protected.

 

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Inorganic Zinc Primers vs. Galvanizing… the age old debate

Our free Building Product Specifications have been written by CSI experts and are available in the CSI 3-part and the Canadian CSC formats for building and construction professionals. Our 09 67 00 Fluid-Applied Flooring specifications are available to download in DOC, or PDF format and come complete technical data profiles, applicable ASTM standards, performance features and product attributes.

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Inorganic Zinc Primers vs. Galvanizing… the age old debate

Apellix, the safety partner for the technological revolution, is proud to announce that its Smart Bee™ aerial robot was named an Innovation of the Year award winner at the Materials Performance annual Readers’ Choice Corrosion Innovation of the Year Awards. A software-controlled quadcopter (drone) that tests paint thickness on structures at heights up to 150’, the Smart Bee was selected by corrosion control professionals worldwide as the winner of the Computer Assisted DFT Measurement Drone in the testing category.

Recognizing the most timely and useful innovations in the field of corrosion control worldwide, the awards, sponsored by NACE International, are judged by a distinguished panel of corrosion experts who reviewed innovations developed by individuals, companies, and organizations from around the world.

The Smart Bee is the first commercial application from Apellix based on its patented software-controlled aerial robotics platform. It takes dry film thickness (DFT) measurements consistent with SSPC-PA2 standards featuring the Fischer Technology, Inc. DUALSCOPE FMP 40C system. The Smart Bee can record DFT measurements on surfaces up to 150’ above the ground, eliminating the need for scaffolding and cranes, keeping workers safely on the ground, and increasing productivity by 15x, all while automatically recording every measurement with the time, date, photo confirmation, and additional project data.

The Smart Bee is currently available on a limited basis to industry partners who will participate in development of future enhancements, including DFT Measurement on non-ferrous surfaces.

 

Apellix expects to release a beta version of its Worker Bee™ solution – a spray painting drone that can coat between 5,000 and 12,000 square feet per hour on elevated structures up to 100’ – to industry partners in Q4 2017. The company is also working with several construction engineering firms to develop additional applications of the aerial robotics platform.

About Apellix

Apellix, an early-stage software company based in Jacksonville, Florida, develops software and other tools to precisely control and allow its custom-built aerial robots to perform tasks that are otherwise dangerous or difficult for humans to perform.

Please contact US Coatings for more information or if you have possible use cases.

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Inorganic Zinc Primers vs. Galvanizing… the age old debate

Gripcrete 9000 PA Release 2-23

New Product Bulletin

PRODUCT RELEASE DATE: 2/23/2017

GripCrete 9000 PA OVERVIEW:

GripCrete 9000 PA is a high-solids polyaspartic developed for direct to concrete and primed concrete surfaces. This unique polyaspartic material has exceptional adhesion to marginally prepared surfaces because of unique viscosity and adhesion promoters. Its features epoxy type chemical resistance and tenacious adhesion while offering aliphatic polyurethane type protection to UV radiation. This new technology combines the work of three coatings; epoxy primer/ epoxy intermediate/polyurethane topcoat into one coat. This polyaspartic formulation will also have the unique ability to be tinted in the field to enable fast turn projects with unlimited color options. GripCrete 9000 PA will provide a high gloss finish. The material is VOC compliant and offer extended working times (up to one hour in low humidity environments) which is a vast increase from traditional polyaspartic offerings.

WHY WE DEVELOPED IT

GripCrete 9000 PA was developed to offer an alternative to polyurea and traditional polyaspartic floor coating. These coatings offer less than desirable results as working times and adhesion to prepped concrete has left the applicator with few options for fast turn projects. This material has superior application characteristics over competitor products while still providing excellent UV protection, chemical resistance, and same day return-to-service times.

KEY FEATURES

• Smooth, gloss finish

• 75% solids, VOC compliant

• SSPC Level 3 Paint 36 UV resistance performance

• Long working time (40-45 minutes)

• Resists forklift traffic

• Superior chemical and hot tire resistance

• Compliant for USDA applications

• Versatile usage for color quartz, vinyl flake, and metallic pigment applications

• Super fast return to service (2-4 hours for foot traffic)

WHERE DO I APPLY?

GripCrete 9000 PA is perfect for flooring applicators and owners who desire for a material with color matching capabilities and excellent adhesion to bare concrete or other hard to coat surfaces. It is excellent for commercial facilities seeking a solution for a low VOC, quick return to service floor coating that can hold up to consistent abuse from pedestrian traffic and forklift wear and tear.

Additionally, it can be used in most markets where a quick return to service (foot traffic) floor coating is desired. Combined with ease of application, adhesion to marginal prepared substrates, and fast return to service,

GripCrete 9000 is a product you can stand on.

TARGET MARKETS

• Industrial Facilities: Manufacturing, Food & Beverage, Oil and Gas, Marine, Conventional Power Plants, Waste Water

• Commercial buildings: Warehouses, Garages, Churches, Schools, Commercial Building, Breweries, Restaurants

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Inorganic Zinc Primers vs. Galvanizing… the age old debate

 

To protect the equipment that drives your business, you need a partner with experience developing protective coatings for a wide variety of assets and industries.

At US Coatings, we build relationships that last the duration of a job and then some.

Floor Coatings Brochure

 

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Inorganic Zinc Primers vs. Galvanizing… the age old debate

Why warehouse floor coatings are more than just paint

Compared to other equipment and capabilities necessary in productive warehouses or other industrial settings, the paint chosen to coat a concrete floor never tops anyone’s list.

But warehouse floor coatings are critical to safe, efficient operations because they can reduce slip and trip hazards, protect concrete from harmful spills and heavy abuse and increase an operation’s efficiency.

At best, underestimating the necessity of the right warehouse floor coating can hold an operation back from running at peak efficiency. At worst, it puts employees and assets at risk and firms on the hook.

Enhance safety, efficiency and aesthetics with warehouse floor coatings

In settings where heavy shelves and forklifts are used, the right warehouse floor coating can protect concrete from cracking and chipping as well as the harmful effects of spilled chemicals. Coatings also protect people. Workers can move more safely on floor coatings engineered to resist slips and trips.

While it may seem frivolous to labor over what color to paint a floor, the right color does more for a space than meets the eye:

  • Spilled chemicals can be located and cleaned more easily when they contrast with the color of a floor coating. Differing floor coating colors can also separate sectors of a warehouse. This increases efficiency and reduces the risk of confusion and accidents.
  • Utility bills in warehouses add up. But the right warehouse floor coating can reflect light, keeping spaces more brightly lit. High-gloss coatings can reduce the cost to light a space or lead to the reduction in amount of lights used.
  • Aesthetics do matter. While a floor’s coating can add value in terms of safety, efficiency and asset protection, they’re also more pleasing to look at. Certain colors can even improve workers’ moods.

Comparing coating systems

The advantages and disadvantages of the many available coating systems mean decision makers must assess the work done in their spaces, the safety concerns present in those settings, their project budget and time constraints. Here’s a quick roundup of warehouse floor coating systems:

  • MMA – Low-glare Methyl Methacrylate (MMA) systems are resistant to some acids, alkalis and solvents and boast a fast cure time—you can walk on an MMA-coated surface in less than two hours. MMA can be applied at lower temperatures, can withstand elevated temperatures and has a much higher dry film thickness (DFT) than other systems, making it resistant to scratching. But floor preparation cannot be overlooked as MMA systems don’t bond as well to substrates compared to other options. Good ventilation is required when applying odorous MMA coats. MMA systems require as many as four coats and are costlier compared to other systems.
  • Epoxy and urethaneThese systems also resist chemicals well and boast high hardness. Their dry film thickness is on par with other coatings systems, require three coats and are among the less costly alternatives. But these systems do not cure quickly. The walk-on time of 24 hours is among the longest of the available systems; because each coat takes longer to cure, the total project time takes nearly two days.
  • 100% solids epoxy – These systems stand up to abrasion and chemical spills and can be applied to floors as part of a multi-part system or on their own. Because these coatings are 100% solids, their wet film thickness and dry film thickness are identical. That means no thickness is lost due to evaporation of harmful volatile organic compounds (VOCs). For this reason, 100% solids epoxy coatings are safer to use. They’re also the cheapest option, but they do not cure quickly —walk-on time is up to 24 hours.
  • Polyaspartic – This hybrid system is an offshoot of epoxy and urethane systems that offers the advantages in a single coating what two coatings of epoxy and urethane systems can muster. Polyaspartic formulations can be manipulated to allow for curing times that suit individual projects and can be applied at temperatures well below freezing. Walk-on time is just four hours and polyaspartics are safer to use due to only moderate odors. These systems are costlier than epoxy / urethane and 100% solids systems but offer better flexibility compared to the other options.

US Coatings systems suit various needs

No industrial setting is identical, so one coating type certainly doesn’t fit all settings. That’s why US Coatings offers a range of floor coating options made to suit your individual needs.

GripCrete 200 SL – This 100% solids flooring epoxy is recommended in interior spaces where abrasion resistance or chemical protection is desired, including warehouses, service centers and commercial buildings. It can be used alone or in a multi-coat system.

GripCrete 200 SL can be applied directly to concrete but the risk outgassing / pinholing is reduced if the surface is primed. See additional GripCrete 200 SL specs here.

GripCrete 1750 MVE – MVE stands for moisture vapor emission. This low-odor, low-VOC, 100% solids concrete primer / sealer minimizes outgassing and moisture vapor transmission. GripCrete 1750 MVE is suitable for use as a primer in confined spaces and in underground or above-ground concrete coating applications. It can be applied to damp concrete.

GripCrete 1750 MVE is prone to chalking and ambering under sunlight in humid conditions; urethane or polyaspartic topcoats (such as GripCrete 200 SL or GripCrete 9000 PA) are recommended to prevent epoxy erosion and to retain color.

GripCrete 9000 PA – PA stands for polyaspartic. This next-generation coating is designed for a wide range of interior and exterior applications, including in warehouses, factories, chemical processing plants, stadiums and institutional buildings like hospitals and schools. It can also serve as a topcoat over other US Coatings floor systems. GripCrete 9000 PA is fast curing and UV-stable.

Polyaspartic coatings add greater value because they achieve in a single application the benefits of an epoxy and urethane system. As project timelines and budgets constrict, a polyaspartic warehouse floor coating could be the option that returns industrial spaces to service faster while keeping workers safe.

Thinking strategically about your warehouse floor coating can raise many questions, so contact us and we’ll help guide you through choosing the coating that best suits your space and developing a coatings maintenance plan. To get additional information about the products we offer, consult our product catalog.

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