with galvanised coatings is white rust or wet storage stain. It is manifested as a bulky, white, powdery deposit that forms rapidly on the surface of the galvanised coating under certain specific conditions
Wet storage stain is the voluminous white
or gray deposit formed by accelerated corrosion of zinc coating when closely/tightly packed, newly galvanised articles are stored or shipped under damp conditions
White Rust Formation
Rainwater , even though does not contains dissolved salts or minerals, zinc react with water to form zinc hydroxide, a bulky white and relatively unstable oxide of zinc. Where freshly galvanised steel is exposed to pure water (rain, dew or condensation), in an oxygen deficient environment, the water will continue to react with the zinc and progressively consume the coating. The most common condition in which white rust occurs is with galvanised products that are nested together, tightly packed, or when water can penetrate between the items and remain for extended periods.
Presence of Salty atmosphere
with high humidity in coastal areas aggrevates white rust formation
Zinc corbonate layer
When this surface has access to freely moving air in normal atmospheric exposure ,it reacts with rainfall or dew condensation to form a porous ,gelatinous zinc hydroxide substance.During natural drying process this reacts with corbon dioxide in the atmosphore and converts into a thin film ,compact and tightly adherent layer,called basic Zinc corbonate layer. This protective layer is weather resistant and prevents corrosion.
Avoiding White Rust
Formation Outdoor stacking The articles should be raised from the ground and seperated with strip spacers to provide free access of air to all parts. They also to be inclined in a manner which will give maximum drainage . Should not be stored on wet soil or decaying vegetation.
Treating Galvanised Surfaces Affected
by White Rust
Light White Rusting
It is particularly evident on areas that have been
buffed or filed during quality assurance operations. It can be brushed off if required but will generally wash off in service with normal weather. No remedial treatment is generally required for this level.However zinc coating thichness shall be checked
Treating Galvanised Surfaces Affected
by White Rust
Moderate White Rusting
This is characterized by a noticeable darkening and
apparent etching of the galvanised coating under the affected area, with the white rust formation appearing bulky. The galvanised coating thickness should be checked to determine the extent of attack on the coating. Wire brush the affected area to remove all white corrosion products if the coating thickness is acceptable ,dichromating shall be done .
Treating Galvanised Surfaces Affected
by White Rust
Severe White Rusting
This is characterized by very heavy oxide deposits. Areas under the oxidized area may be almost black and show signs of red rust. A coating thickness check will determine the extent to which the galvanised coating has been damaged. Remedial treatment to reinstate the coating should be undertaken as follows: Wire brush or buff the affected area to remove all oxidation products and rust if any. Apply two or more coats of approved Zinc spray/epoxy zinc-rich paint to achieve required dry film thickness of 100 microns minimum. Where the affected area is extensive or where the wet storage stain would impair the use of the article for its intended service ,regalvanising is necessary.
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