Des:gnation:D6386-99(Reapproved 2005)

Standard Practice for

Preparation of Tinc (Hot-Dip Galvanized) Coated lron and

Stedl Product and HardwarC Surfaces for Paintingl
This standard is issued under the axed dcsignation D 6386: dle numttr inlmediately following the dcsignation indicates thc year o
On3mal adoption or,ln the cttc of re sion,thc ycar of l t rc sion A numbcr in ParCntteses indicates me year Of l tapprovai A
supcrsc pt epsilon te

indicatcs all cditodai changc shcc ttc iast rc

ision r rcappro
l

1, Scope

j
gs 5 l C

rP CrJ
`
`C
.ent
Cicanin3
"
n SrCt incatlon Nc i Sol
cc Prcptttr.lti
Sul

2 2 5

i t Thls practicc dcscribes illcthodb or prcpdiing surtaces or

Sudace PrepFation Specilication No 2 Hand Tool Clean

new and weadlered hot dip galvanized steel for p nting.

Hot dp galvanlzed steel is produced by the ttersion of
ib cated

lng

Surface Preparation Specincatlon No 3 Power Tool Clean

or unfab cated products h a bath of inolten zinc.as

mg

pecined m speciflcations A 123 or A 153/A153M.This

DfF Blast
Surface Preparation Speciflcation No.7 Brush

_practtce covers sttace preparaton on iron and steel products

d hardware dlat have not been painted prevbusly.Galva

Cleaning
Paint Spec catlon No. 27 Bast Zinc Chromate Vinyl

ized stt es may have bcen treated with protective coatings

Butyral Wash Primer

LO preVent the currence of wet storage staln.This practice

ortO the coil

does not apply to shect galvanized steel products

)adng or conunuous roner coating processes.
1.2 The values stated ln SI units are to be regarded as dle
_standardo The values given in parentheses are For infoll..atiOn
^ ly.

ss
0


1.32
s
`
`
`s
"

S,
o C
, SS
`
`.fr J
`'
`
`
sP :

S `sttb
o/
`
f tt

c`s r`
, sara

r"
S`
g

,
ira

ica

Jara

-2.Referenced Documents
2.l AStty srarlda r2

A123 Specincat10n for Zinc oIOt Dip Galvanized)COat_

ings on lron and Steel Products

A153/A1531 Speciflcatlon for Zinc Coatlng(HOt Dip)on

lron and Steel Hardware
A780 Pracice for Repnlr of I)amaged and Uncoated Areas

of Hot Dip Calvanlzed Coatmgs

B201 Pracdce for Tesdng Chromate Coatngs on Zinc and

Ca um Sraces

E376 Practice for Measu ng Coating Thickness by

Magnetic Field or Eddy Current C31eCtrOmagnetic)TeSt

3. Summary of Practice
3.l This practice describes the preparation methods that
provide clean and suitable galvanized surfaces for p^lnting,
speciflcauy sO that an applied coadng systern can develop ale
adhesion nccessa /for a satlsfactory service Lre.
3.2 The zinc coating is constandy in a state of change.From
dle time the steel part is removed iom the galvanizing ketac,

the exposed zinc coattng interacts widl the envlronment to

follll, arst ttc oxides, next ttnc hydroxides, and then zinc
cttbonates.4 The process of complete conversion of the outer
layer of zlnc carbonates can take up to two yearS of exposure
to dle envronment, depen g on the l al climatologlcal

condidons.Durlng the nrst stage,known as newly galvanlzed

steel,dle exposed srace cOnsists mainly of znc metal with a
small anlount of zinc oxide.Dunng e second stage,known as
partiany weathered g van17ed StCel, the exPoSed sJace
consists nlalnly of zlnc o des and z hydro des with some

carbonates.At dle flnal stage, known as weathered

galvanlzed steel, the exposed srace consists mainly of

water insoluble nc carbonatcs,some zllllc o deS,and rarely,

zinc hydroxldes. l e surface preparation for each of these

stages must be treated separately.

3.3 Variations in sCace preparation produce end conditions

Methods

dlat difet hence they do not necessarily yield identical results

when paints are subsequendy apphed.Service conditions win

rThis practice is under

the jurisdiction of ASTM

Corilnitte DOl on Paint and

I -iated Coatings, Materials, and Applications, and is the direct rcsponsibility of
Subcomminee DOl.tt5 on Indusrial Protctive Coatings.
Currcnt edition approved July I 2fi)5. Published August 2005. Originally

- :

rroved in 1999. Last previous edition approved in 1999 as D6386-99.

2
For rcfercnced ASTM standards, visit the ASTM website, wwv.astm.org, or
contact ASTM Customer Service at service@astm.org, For Annwl Book of ASTM
volume information, rcfer to the standard's Document Summary page on

-Standords
t ASTM

website.

dictate the type of srace preparation to be selected,although

t Available ftom Society for Protective Coatings (SSPC), 40 24th St., 6th Floor,
Piftsburgh, PA L52224656.
'This interaction is dcscribed in "Duplex Systems," van Eijnsbcrgcn, J.F.H.,
Elsevier Science, New York, IYY 1994, nd n Zinc Hatdbook, Portec F., Marcel
Dekker. Inc., New Yodq NY 1991.

Copynght o ASTM Intemational,100 3arr Harbor D"vo,PO Box C700,WOst Conshohockon,PA 19428

2959,Unlted Sta s

dff o s:l86 - ee (2oos)

the quality produced by any indi dual process may vary with
direrent cOmpositiollls of the zinc srace.

tank aned with the solution,sprayod,or brushed with a sof

brisde brush, usuauy ny10n and not stecl or coppe Whel

4.Signincance and Use

rttr m60

4.l This practice descHbes the procedures that can be used

to prepare new and weathered zinc coated surfaces on after

water or water under pressuFe.Allow to dry completely befon

procecdingo Whenever galvanized steel is rinsed,it is desrabll

fabrication stcel products for painting,and that can improve the

to usc heated drying to accelerate the complete removal o

watr from the surface.

dipplng or spraylng,the soludon woFkS beStin the temperatun

bond of pttnt to the zinc surface.

to 85C._Ater cleaning,nIIse thoroughly m ho

5.3.2 Sb

,
51 N` G

The category of newly galva

Surfacc Preparation Specincation l Proper rags or brushe

should be used to vipe the galvanized parts

11
rsi n toti[illg
.ls bccll givtinlzcd i ithiil thc
latc c n
previous 48 h There also should be no visible signs of zinc
oxlde or zlnc hydroxlde, which irst appear as a line u hite

N(

1- Caution:These rags or brushes should be cleaned or recycle

often shce oil can accumulate on thetr su aces and be transtrred back

dle galv zed palt. Sma parts may be dlpped or cleaned h ultrasoni

oowder
r/2:4g Hot dip galvanized suttaces gen
5.2S
`'
erally are relattvely smooth after g vanizing.There may be

baths of 3olvents Atter cleanlng,dnse thproughly in hot water or wate

under pressure Auow to dtt cOmpletely before pr eedlng

: gHand or power toc

5.3.3 Ha r P
`r b

some dick edges due to excess liquid zinc run ofF d ng the

cle ng

galvaluzlng,or hgh spots h ale coatmg due to included

iron zhc htemetallics(drosS)Or zinc oxide particles.hse

inay be used to clean light deposits of zinc reactton bl

products, suCh as wet storage stain, as specined in sSP(

sracc Preparation Sp incatiOn 2 or 3.

4-Hot dip galvanized sdaces ha
5.4S 2

line,must

be smoothed to avoid palnt alm gapS in dle areas of the high

`Prapara

a layer of zinc oxide and zinc hydroxide that must be remove(

spots.

before paint will adhere to the zinc coamlgo zinc coa ng

generally are relatively sm th and may be shghdy roughenel

5.2.l Zinc high spots,thosc that would cause pamtflhn gaps

such as dle rnetal p line,should be removed by cle g vith

por

hand or power tools as descHbed in SSPC Stlrfacc Preparation

SpecincatiOn 2 o

Typlca cleaning solvents,such a

and grease The procedure to be used is as specified in SSP(

nized steel reters to zinc coated steel that has no suracc

treatinent after galvanizing such as vater quenching or chro

hgh sPots and rough edges,such as the metal

CI` g

`
llash naphtha,can be used to remove oi
mineral spu ts or high

Processes for Newly Galvanized Steel

to palnmg.The fouowmg fOur methods may be used u

prepare the galvanlzed surface for painmg.

3 1he zinc should be removed until it is

: g Abrasive sweep or brush bltstlng

5.4.l Sw`` 31a

level with the surrounding ttea, t ndng care that tte base
coatlng is not removed by the cleaning IIlethods.After clean

wi ch

uses a rapid nozzle movement will roughen the galva

nized surface pronle. The abrasive mate al must be chosei

ing, thc srace shau be mspected for confo.1..ance to the

requlred zinc ckness in accordance with Speclflcauons

with care to provide a smpping action without removing exces

zinc layers.One of the mate als that has becn used success
fully is alumnumagnesiunl silicate_Particle size should b`
in the range of 200 to 500 (8 to 20 s).Other mate al

A123 or A 153/A153M umizmg a nlagnedc thckness insLu

ment h accordancc widl Pracdce E 376.Any item falling
below tte required zinc dlickness,before or after removal of

that can be used are soft nlmeral sands with a MOH hardnes
of ttve or less,organic lneda such as conl cobs or wah

any high spots, shau be repttd in accordance widl Practice

A780.

sheus,cOrundum,and lllnestone. Depending on the value o

g HOt dip galvanized surfaces must be

5.35
`Clea
clean and tree or oil alld grease before they are palnted.
Adhesion problems have been expenenced with newly galva
dzed attcles that have en water quenched or treated wiL l

hardness for the abrasive medium,bl

thg pressure may neel

to be detemlmcd for the approp ate nozzle to work piec.

distance, geomett of the component, and bl ting medium
For some an anOy COatings,even the relatively low pressurt

c omate conversion coatings. These o post galv zing

blast of O.15 to O.25 NIPa(20 to psi)can be t greal

causing cohesion probler .0 contamination of the com
presscd air win degrade p,lnt adhesion to sweep blastel

treaments are not reconlmended for galvanized articles that arc

to be panted.
:ag An alkaline solution,pH
: CJ
O s AJ
5.3.l A`
in the range of H to 12 dennitely not greater than 13,can be

hot dip

galvanized surfaces. Care is nceded in averting ali

Of COntamination.Care rnust be taken to leave zlnc layer

htact.The purpose of sweep blasting is to defom,not remov

the galvamzed lnetal.Any area fa ing below ale requred zin(
thickness,before or after sweep blasting,should be repaired il
accordance with Practice A 780.T E procedure for this proces

used to remove traces of oil,grease,or dirt.An alkaline cleaner

up of zlnc oxide or
wet storage stain(sce Ame can Galvanizers Publications,War
is unsuitable for rernoval of heavy build

srarag`SraFP15,for desc pdon of alese cOndidons),S 5.4 for

relnoval of zinc oxide layen Th alkaline solutton nolrunany is

can be found in SSPC Surfacc Preparat n Specincation 7

2 to 5%sodiunl compounds,widl small addi o s of emulsi

fying,chelatmg,or sequesteng agents,or a combination

Sweep blasting of zinc should be not less dlan l10 m2/h(120

ft2/h)uSing alesc abras e materials. e substrate should bl
maintained at a temPcrame greatcr than 3 C(5 D aboVC th`

thereof This solution can be apphed through illlmersion in a

dew point temperature.Fouowing abrasive blast cleaning

5 Ava

surfaces should be blown down with clean,compressed att ll

some atinospheric conditions,such as high hunudit Or higI

able from Amencan Calvanlzers Ass iadon,12200 E IliEAve.,No 204,

Aurora.C08001 5376

36

4ffi

o el46 - ee (2oos)

temperature, or both, the formation of zinc oxide on the blasted

surface will besn very quickly, so the paint coating should be
applied immediately, within 60 min, after sweep blasting. Zinc

oxide formation is not visible to the naked eye: therefore. in

any atmospherc, painting should be stated as soon ., po*ribl"

after surface prcparation.
5.4.2 Zinc-Phosphate Treatment-This convenion-soeting
process consists of rcacting the newly galvanized zinc surfaci
in an acidic zinc phosphate solution ssntaining sxidiziag
agents and other salts for accelerating the coating action. The
zinc surface is converted to a crystalline phosphate coating of
the proper texture to inhibit corrosion and increase the adherence and durability of the paint film. This process may be
applied by immersion, spray or soft bristle brush application.
After a time period of 3 to 6 min, the surface should be washed
with clean water and allowed to completely dry before appli_
cation of the paint system. painting should take place ioon
after treabnent to avoid pick up of surface contaminants.

5.4.3 Wgsh Primer Treannent-T\is process involves the

use of a metal conditioner to neutalize surface oxides and
hydroxides along with etching the surface. One example of a
wash primer is SSPC Paint Specification 27. The process is

ll.5

temperature) tr a pressrlle wash, then thoroughly

ryglg
dried. This tmatueat

is ap'plied in the ge!.,,anigrng plant or l-atjr

in the paint shop. When applied in the paint shop, the surface
must first be appropriately cleaned as just described to rcmove
contaminants picked up after galvaniz.ing.

5.4.5 Notifrcation

of Surface Treatment-T\e paint

shop

must be notified as to how the galvanized articles have been

processed and which surface treatment method, if any, is used
to prepare the surface.

6. Processes for Partially Weathercd Galvanized Steel

6. 1 Before preparing the surface of partially weathered
galvanized steel, the surface must be checked for the presence

of chromate conversion coating. The presence of a chromate

conversion coating can severcly impair the adhesion of some
paint coating sysoem. Chromate conversion coatings can be
applied at the galvanizing facility to protect the newly galvanized surface from excessive growth of zinc oxide and zinc
hy&oxide, commonly called wet storage siain. The presence of

outlined

in

Appendix

technique described

positive

Xl.

The removal

of the cbromate

5.4.4 should not be removed if it tests

cbrome. This process is not a

for the presence of

chromate conversion coaring. If the galvanized surface has

thick edges or high spots, these should be removd see 5.2.1.
when the high spots have been treated and the chromarc has
been removed completely by sanding tx swoep blasting in
accordance with 5.4.1, surfaces should be blowa down with
clean, comlncsscd air. In some amospheric conditions, such as
higb humidity ot high tempraturc, or both, the formation of
zinc oxide on the blasted surface will begn very quickly so the
paint coating should be applied within 30 min after sweep
blasting. Zinc oxide formation is not visible to the naked eye;
therefore, in any atmospherc, painting should be as soon as
possible after surface preparation.
6.2 Beforc preparing the surface of partially weathered
galvanized steel, the surface must be checked for the presence
of wet storage stein. Wet storage stein is the whitish zinc
corrosion product forned when galvanized parts arc exposed to
moist air without sufrcient air circulation between the parts
and is described in the American Galvanizen Association
hrblication, Wet Storage Srain. Wet storage srein consists
prinarily of beta zinc hydroxide and small percentages of zinc
oxide and zinc carbonate. Since wet storage 5tein is hygoscopic and has a larger volume than zinc metal, paint adhesion
can be afiected seriously when painting over wet storage srrin.
Careful bmshing with a mild zs6snia solution using a soft
bristle brush will rcmove mild cases of wet storage srrin.
Thorough water rinsing must immediately follow the bnrshing.
Morc severe cases of wet storage stain that have thick whirc
corrosiou products ou the zinc surface, or even black corrosion
products, can be cleaned using vigorous soft bristle brushing
with a mild acidic solution with a pH of 3.5 to 4.5, such as
acetic acid or citric aci4 but not hydrochloric or sulfuric acid

of

olution to the newly galvanized surface and then allowing it to

dry, forming 4 thin film coating. When applied, the solution
first reacts with the zinc surface forming a passivating converiion coating while simultaneously forming an acrylic coating
ruitable for painting on top of the passivation layer. The
undedying conversion coating provides strong adhesion to the
;alvanized surface while the thin fifm acrylic layer provides
rarrier protection, which inhibits corrosion and provides a
lighly compatible surface for the application of organic paint
films. There are versions of these solutions that cont in chrome
nd versions without chrome. The application methods for
hese water based heatuents arc dipping, flow coating, spray_
ing, or other approfriate means. Following application the
rcating is dried in an oven or in air. In some instances, the

is applied to hot-galvanized articles, in which

atkatine degreasing solution (pH

conversion coating also is outlines in Appendix Xl. The

surface preparation method described in 5.4.4 could test
positive for the prcsence of chrome. The surface p'rcparation

5.4.4 Acrylic Passivation/Pretrcatment-T\e passivation/

rtrament process consists of applying an acidic acrylic

:oating

6ild

max) followed by a thorough rinse with hot watei 160"C

chromate conversion coatings can be detccted by the procedure

based on three prinary components: a hydroxyl+ontaining

resin: a pigment capable of reacting with re.sin and acid: an{
an acid capable sf malcing the resin insoluble by reacting with
the rcsin, the pigment, and the zinc surface. The result is a film
rf approximately 8 to 13 pm (0.3 to e.J mits). Failures can
rcur if the film exceeds 13 pm (0.5 nils). The film usually is
applied by spray but may be applied by soft bristle bmsh, diF,
rr loller coater. Using these lattcr coating methods, it may be
':fFcult to control fts fitm thickness. For drying tine prior
to
copcoating, follow the manufacoret's instnrctions. This wash
primer treatment may be better suited !o certain types of paint
iystems. See SSPC Paint SpecificationZl for the best match
his treaEnent to a paint system.

removed with a

case

separale drying is not necessary. Rinsing is not required. The

coating is approximarcly l-pm (0.0+mils) thick. painting is

rossible any time during a period of four months after
pplication, as long as the surface is free of visible zinc oxides
or zinc hydroxides; however, if harmful gsaraminants, such as
'lust, dirt, oils, grease or deposits are present, they must be
37

{ff o dn6 - ee (2oos)

solutions. Thorough waterrinsing must immediately follow
the
bru$ing. After the part has completely dried, the surface
profile should be applied in accordance with 5.4, and, then
the
surfaces shouiri be biown down wrth clean, comp,ressed air.
If
no protective treatnent" such as those describe d n 5.4.2_5.4.4

is

applied, in some atnospheric conditions, such as high

humidity, or high temperature, or both, the formation of zinc
oxide on the surface will begin very quickly so the paint
coating should be applied within 30 min.
prot".tiu"
treaEnent is applied, it is not necessary to paint immediately.
Zinc oxide formation is not visible to the nated eye; therefori,
in any atmosphere, painting should be as soon as possible after

if

surface preparation.
6.3 If there is no indication

"

of either chromate conversion

:ouqF or wet storage strin, the surface can be prepared

detailed in Section 5.

7.

as

for lVeathered Galvanized Steel

Processes

surface cleaning in accordance with 5.3 should be performec

before any other cleaning is done.
7.2 The natrrra! corrosion of the zinc netal pioduccs

roughened surface

film consisting primarily of basic

zinc

carbonate. The surface preparation that is needed is a powel

wash with warm water to remove loose particles from the

surface. The power wash should use water

of less than l0 Mpa

(1450 psi) so

j;$

with

a, not to

a pressure

damage the

protective film. This film is nanrrally roughened in its growth

process, so no extra surface profiling is needed. Allow
the
surface to completely dry before application
system.

of the paint

7.3 Fully-weathered galvamzed steel can be painted suc_

9es;t1ftf with the application of appropriate paint systems
including primers and top coat paints. The use of pietrear
ments, such as those described in 5.4, can enhanie paint

adhesion and extend long term performance.

7.1 Fully weathered galvanizsd steel, as described rn 3.2,

has developed a stable and finely etched surface that is verv

suited for paint coating adhesion. If there are organic contami_

nants, such as oil, grease, or soot on the surface of the part,

E. Keywords
8.1 galvanized steel; galvanizing; hot-dipped galvanizing.
painting; paint preparation; surfacing pr"paritiou zinc coatin!

APPENDU
(Nonmnndatory Information)

xl'

IDEMIT"nNG TIIE PRESENCE OFAI\D REMOVING CEROMATE TREATMENTS

USEDAS WET STORAGE (ALSO
CALLED IIT'MID.STORAGE) STAIN IIYHIBITORS

Xl'l

oneof theinhibitorsusedbyproducersof

zinc-coated x1.3.1 weathering the surfaces for six months, or

prexI.3.2 Abrading ile surfaces by sanding, or
of many paint coatings to zinc coated steel
x1.3.3 Sweep b'iast clean in accordance with 5.4.1.

stel is a hexavalent chromium solution. This treatment

vents adhesion
surfaces.

XI.z [f zinc-coated

to be painted is galvanized to
order, the order should prohibit the use of hexavalent cbrosteel

mium humid-storage strain treatuents.

X1.4 The presence of hexavalent chromium on galvanized

surfaces can be determined by spot tesring used practice B 20 l.

Xl.5

Conduct the spot test on several representative spots

on each individual piece of galvanized steel.

Xl'3 Hexavalent chromium treatment can be removed from Xl.6 Test, in accordance with practice B 201,
every piece
galvanized surfaces by one of the following three methods:
of galvanized steel that is to be teated for painting.
ASTM lntamatbnal bkg tro ,prgt'drlt tf4rr,dng tha vattdty of any patent rtghg
aslxlfted in @nnrr;ton with any ltem mdntioned
ln this shnclard' use6 ol this stadad.arc ixprasay aaua-na aitdrmnaaoi
ot w ralay a
y srd,
tigttF., an(t 0B risk
of brtringcnwtt d str/t dglfr, an ennyh6no6
"t
'nltent

rrgraa&nttq.

This

'

siandadissttir,tb revis*n atanydne bytt.F r6qr,nsiuefrd',//,k*il @'7'nittfF aN mulf

be reviawdewryfueyeaB etfr
rnwrovd or withdnwr'

it not Evised, either

Your Cr,nmet# arc invited eihar tor reviskm ol this staded ot for a&itional
stattr,aftls
a&lressd to Asru htemattona! Heia,&uarten Your rrlmments witt r*llive caraful
@nsihntion at a neeting ot the
tas@nslae tadvftal amnittee, wlt*lt
rou maf anea. tyou ta natyou@mton9
it,iriiri,rg-y*
mako yo,r,eyrsro.ow,to theAsfU Connitt*' on Sl',.da*, athez&rcss

aN slpuld

ii *t iani

*rcnr wtiw.

",-rb

is qyrighted by asTM tntematic//,al, I oo Baft Hatuot

Ddve, po Bo( c7N, west hnstphe*en, pA t g428-2g5g,
lydaqhdffiial
r$,r, (W q yultple qies) of iltis stan.#li
may a a"na by urffihg ASTM at the atuve
e&ress or at 6lo-(,2-9sas 6none1, a1/.&8fiz-es*;
t6rl, n servi(F/lastm.oq (e4nait); or hrough the ASru website
.

!hi?

united states'

(w*w.estn.or0.

"r

.1' :.JTftt.FllrrF inrf,r.Tl$}T'; r