Designation: D6386 − 10

Standard Practice for

Preparation of Zinc (Hot-Dip Galvanized) Coated Iron and
Steel Product and Hardware Surfaces for Painting1
This standard is issued under the fixed designation D6386; the number immediately following the designation indicates the year of
original adoption or, in the case of revision, the year of last revision. A number in parentheses indicates the year of last reapproval. A
superscript epsilon (´) indicates an editorial change since the last revision or reapproval.
This standard has been approved for use by agencies of the Department of Defense.

1. Scope* B201 Practice for Testing Chromate Coatings on Zinc and

1.1 This practice describes methods of preparing surfaces of Cadmium Surfaces
new and weathered hot-dip galvanized steel for painting. D7396 Guide for Preparation of New, Continuous Zinc-
Hot-dip galvanized steel is produced by the immersion of Coated (Galvanized) Steel Surfaces for Painting
fabricated or unfabricated products in a bath of molten zinc, as E376 Practice for Measuring Coating Thickness by
specified in Specifications A123/A123M or A153/A153M. Magnetic-Field or Eddy-Current (Electromagnetic) Test-
This practice covers surface preparation on iron and steel ing Methods
products and hardware that have not been painted previously. 2.2 Society for Protective Coatings Specifications:3
Galvanized surfaces may have been treated with protective Surface Preparation Specification No. 1 Solvent Cleaning
coatings to prevent the occurrence of wet storage stain. This Surface Preparation Specification No. 2 Hand Tool Cleaning
practice does not apply to sheet galvanized steel products nor Surface Preparation Specification No. 3 Power Tool Clean-
to the coil coating or continuous roller coating processes. Sheet ing
and coil surface preparation can be done in accordance with Surface Preparation Specification No. 7 Brush-Off Blast
Practice D7396. Cleaning
Surface Preparation Specification No. 11 Power Tool Clean-
1.2 The values stated in SI units are to be regarded as the
ing to Bare Metal
standard. The values given in parentheses are for information
Paint Specification No. 27 Basic Zinc Chromate-Vinyl
only.
Butyral Wash Primer
1.3 This standard does not purport to address all of the
safety concerns, if any, associated with its use. It is the 3. Summary of Practice
responsibility of the user of this standard to establish appro- 3.1 This practice describes the preparation methods that
priate safety and health practices and to determine the provide clean and suitable galvanized surfaces for painting,
application of regulatory limitations prior to use. specifically so that an applied coating system can develop the
2. Referenced Documents adhesion necessary for a satisfactory service life.
2.1 ASTM Standards:2 3.2 The zinc coating is constantly in a state of change. From
A123/A123M Specification for Zinc (Hot-Dip Galvanized) the time the steel part is removed from the galvanizing kettle,
Coatings on Iron and Steel Products the exposed zinc coating interacts with the environment to
A153/A153M Specification for Zinc Coating (Hot-Dip) on form, first zinc oxides, next zinc hydroxides, and then zinc
Iron and Steel Hardware carbonates.4 The process of complete conversion of the outer
A780 Practice for Repair of Damaged and Uncoated Areas layer of zinc carbonates can take up to two years of exposure
of Hot-Dip Galvanized Coatings to the environment, depending on the local climatological
conditions. During the first stage, known as newly galvanized
steel, the exposed surface consists mainly of zinc metal with a
1
This practice is under the jurisdiction of ASTM Committee D01 on Paint and small amount of zinc oxide. During the second stage, known as
Related Coatings, Materials, and Applications and is the direct responsibility of partially weathered galvanized steel, the exposed surface
Subcommittee D01.46 on Industrial Protective Coatings.
Current edition approved July 1, 2010. Published July 2010. Originally approved
in 1999. Last previous edition approved in 2005 as D6386 – 99 (2005). DOI:
3
10.1520/D6386-10. Available from Society for Protective Coatings (SSPC), 40 24th St., 6th Floor,
2
For referenced ASTM standards, visit the ASTM website, www.astm.org, or Pittsburgh, PA 15222-4656, http://www.sspc.org.
4
contact ASTM Customer Service at [email protected]. For Annual Book of ASTM This interaction is described in “Duplex Systems,” van Eijnsbergen, J.F.H.,
Standards volume information, refer to the standard’s Document Summary page on Elsevier Science, New York, NY 1994, and in Zinc Handbook, Porter, F., Marcel
the ASTM website. Dekker, Inc., New York, NY 1991.

*A Summary of Changes section appears at the end of this standard

Copyright © ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959. United States

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 D6386 − 10
consists mainly of zinc oxides and zinc hydroxides with some is unsuitable for removal of heavy build-up of zinc oxide or
zinc carbonates. At the final stage, known as weathered wet storage stain (see American Galvanizers Publications, Wet
galvanized steel, the exposed surface consists mainly of Storage Stain5, for description of these conditions). See 5.4 for
water-insoluble zinc carbonates, some zinc oxides, and rarely, removal of zinc oxide layer. The alkaline solution nominally is
zinc hydroxides. The surface preparation for each of these 2 to 5 % sodium compounds, with small additions of
stages must be treated separately. emulsifying, chelating, or sequestering agents, or a combina-
3.3 Variations in surface preparation produce end conditions tion thereof. This solution can be applied through immersion in
that differ, hence they do not necessarily yield identical results a tank filled with the solution, sprayed, or brushed with a soft
when paints are subsequently applied. Service conditions will bristle brush, usually nylon and not steel or copper. When
dictate the type of surface preparation to be selected, although dipping or spraying, the solution works best in the temperature
the quality produced by any individual process may vary with range from 60 to 85°C. After cleaning, rinse thoroughly in hot
different compositions of the zinc surface. water or water under pressure. Allow to dry completely before
proceeding. Whenever galvanized steel is rinsed, it is desirable
4. Significance and Use to use heated drying to accelerate the complete removal of
4.1 This practice describes the procedures that can be used water from the surface.
to prepare new and weathered zinc-coated surfaces on after- 5.3.2 Solvent Cleaning—Typical cleaning solvents, such as
fabrication steel products for painting, and that can improve the mineral spirits or high-flash naphtha, can be used to remove oil
bond of paint to the zinc surface. and grease. The procedure to be used is as specified in SSPC
Surface Preparation Specification No. 1. Proper rags or brushes
5. Processes for Newly Galvanized Steel should be used to wipe the galvanized parts. (Warning—These
5.1 Newly Galvanized Steel—The category of newly galva- rags or brushes should be cleaned or recycled often since oil
nized steel refers to zinc-coated steel that has no surface can accumulate on their surfaces and be transferred back to the
treatment after galvanizing, such as water quenching or chro- galvanized part. Small parts may be dipped or cleaned in
mate conversion coating, and has been galvanized within the ultrasonic baths of solvents. After cleaning, rinse thoroughly in
previous 48 h. There also should be no visible signs of zinc hot water or water under pressure. Allow to dry completely
oxide or zinc hydroxide, which first appear as a fine white before proceeding.)
powder. 5.3.3 Hand or Power Tool Cleaning—Hand or power tool
cleaning may be used to clean light deposits of zinc reaction by
5.2 Surface Smoothing—Hot-dip galvanized surfaces gener-
products, such as wet-storage stain, as specified in SSPC
ally are relatively smooth after galvanizing. There may be
Surface Preparation Specification No. 2 or No. 3.
some thick edges due to excess liquid zinc run-off during the
galvanizing, or high spots in the coating due to included 5.4 Surface Preparation—Hot-dip galvanized surfaces have
iron-zinc intermetallics (dross) or zinc oxide particles. These a layer of zinc oxide and zinc hydroxide that must be removed
high spots and rough edges, such as the metal drip line, must before paint will adhere to the zinc coating. Zinc coatings
be smoothed to avoid paint film gaps in the areas of the high generally are relatively smooth and may be slightly roughened
spots. prior to painting. The following four methods may be used to
5.2.1 Zinc high spots, those that would cause paint film gaps prepare the galvanized surface for painting.
such as the metal drip line, should be removed by cleaning with 5.4.1 Sweep Blasting—Abrasive sweep or brush blasting,
hand or power tools as described in SSPC Surface Preparation which uses a rapid nozzle movement will roughen the galva-
Specification No. 2 or No. 3. The zinc should be removed until nized surface profile. The abrasive material must be chosen
it is level with the surrounding area, taking care that the base with care to provide a stripping action without removing excess
coating is not removed by the cleaning methods. After zinc layers, removal of up to 25 microns (1 mil) is acceptable.
cleaning, the surface shall be inspected for conformance to the One of the materials that has been used successfully is
required zinc thickness in accordance with Specifications aluminum/magnesium silicate. Particle size should be in the
A123/A123M or A153/A153M utilizing a magnetic thickness range of 200 to 500 µm (8 to 20 mils). Other materials that can
instrument in accordance with Practice E376. Any item falling be used are soft mineral sands with a MOH hardness of five or
below the required zinc thickness, before or after removal of less, organic media, such as corn cobs or walnut shells,
any high spots, shall be repaired in accordance with Practice corundum, and limestone. Depending on the value of hardness
A780. for the abrasive medium, blasting pressure may need to be
determined for the appropriate nozzle to work-piece distance,
5.3 Surface Cleaning—Hot-dip galvanized surfaces must be
geometry of the component, and blasting medium. For some
clean and free of oil and grease before they are painted.
all-alloy coatings, even the relatively low-pressure blast of 0.15
Adhesion problems have been experienced with newly galva-
to 0.25 MPa (20 to 40 psi) can be too great, causing cohesion
nized articles that have been water quenched or treated with
problems. Oil contamination of the compressed air will de-
chromate conversion coatings. These two post-galvanizing
grade paint adhesion to sweep-blasted hot-dip galvanized
treatments are not recommended for galvanized articles that are
surfaces. Care is needed in averting this type of contamination.
to be painted.
5.3.1 Aqueous Alkaline Cleaning—An alkaline solution, pH
in the range of 11 to 12 definitely not greater than 13, can be 5
Available from American Galvanizers Association (AGA), 6881 South Holly
used to remove traces of oil, grease, or dirt. An alkaline cleaner Circle, Suite 108 Centennial, CO 80112, http://www.galvanizeit.org.

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 D6386 − 10
Care must be taken to leave zinc layers intact. The purpose of applied by spray but may be applied by soft bristle brush, dip,
sweep blasting is to deform, not remove the galvanized metal. or roller coater. Using these latter coating methods, it may be
Any area falling below the required zinc thickness, before or difficult to control the film thickness. For drying time prior to
after sweep blasting, should be repaired in accordance with top coating, follow the manufacturer’s instructions. This wash
Practice A780. The procedure for this process can be found in primer treatment may be better suited to certain types of paint
SSPC Surface Preparation Specification No. 7. Sweep blasting systems. See SSPC Paint Specification No. 27 for the best
of zinc should be not less than 110 m2/h (1200 ft2/h) using match of this treatment to a paint system.
these abrasive materials. The substrate should be maintained at 5.4.5 Acrylic Passivation/Pretreatment—The passivation/
a temperature greater than 3°C (5°F) above the dew point pretreatment process consists of applying an acidic acrylic
temperature. Following abrasive blast cleaning, surfaces solution to the newly galvanized surface and then allowing it to
should be blown down with clean, compressed air. In some dry, forming a thin film coating. When applied, the solution
atmospheric conditions, such as high humidity, or high first reacts with the zinc surface forming a passivating conver-
temperature, or both, the formation of zinc oxide on the blasted sion coating while simultaneously forming an acrylic coating
surface will begin very quickly, so the paint coating should be suitable for painting on top of the passivation layer. The
applied immediately, within an hour, after sweep blasting. Zinc underlying conversion coating provides strong adhesion to the
oxide formation is not visible to the unaided eye; therefore, in galvanized surface while the thin film acrylic layer provides
any atmosphere, painting should be stated as soon as possible barrier protection, which inhibits corrosion and provides a
after surface preparation. highly compatible surface for the application of organic paint
5.4.2 Surface Grinding—Power tools such as grinders or films. There are versions of these solutions that contain chrome
sanders will roughen the surface of galvanized steel and and versions without chrome. The application methods for
produce a surface profile suitable for paint adhesion as per these water based treatments are dipping, flow coating,
SSPC Surface Preparation Specification No. 11. The grinder or spraying, or other appropriate means. Following application
sander shall not be applied with sufficient force to remove all the coating is dried in an oven or in air. In some instances, the
of the zinc coating rather a removal of up to 25 microns (1.0 coating is applied to hot-galvanized articles, in which case
mil) is acceptable. Following grinding or sanding, surfaces separate drying is not necessary. Rinsing is not required. The
should be blown down with clean, compressed air. In some coating is approximately 1-µm (0.04-mils) thick. Painting is
atmospheric conditions, such as high humidity, or high possible any time during a period of four months after
temperature, or both, the formation of zinc oxide on the ground application, as long as the surface is free of visible zinc oxides
or sanded surface will begin very quickly, so the paint coating or zinc hydroxides; however, if harmful contaminants, such as
should be applied immediately, within an hour, after grinding dust, dirt, oils, grease or deposits are present, they must be
or sanding. Zinc oxide formation is not visible to the unaided removed with a mild alkaline degreasing solution (pH 11.5
eye; therefore, in any atmosphere, painting should be started as max) followed by a thorough rinse with hot water (60°C
soon as possible after surface preparation. maximum temperature) or a pressure wash, then thoroughly
dried. This treatment is applied in the galvanizing plant or later
NOTE 1—This grinding or sanding process may produce a sharper
surface profile if the galvanized steel is over 50°C (122°F) as the zinc in the paint shop. When applied in the paint shop, the surface
metal is softer at elevated temperatures. must first be appropriately cleaned as just described to remove
contaminants picked up after galvanizing.
5.4.3 Zinc-Phosphate Treatment—This conversion-coating
process consists of reacting the newly galvanized zinc surface 5.4.6 Notification of Surface Treatment—The paint shop
in an acidic zinc phosphate solution containing oxidizing must be notified as to how the galvanized articles have been
agents and other salts for accelerating the coating action. The processed and which surface treatment method, if any, is used
zinc surface is converted to a crystalline phosphate coating of to prepare the surface. The method and extent of surface
the proper texture to inhibit corrosion and increase the adher- preparation shall be mutually agreeable to the purchaser and
ence and durability of the paint film. This process may be the supplier.
applied by immersion, spray or soft bristle brush application.
After a time period of 3 to 6 min, the surface should be washed 6. Processes for Partially Weathered Galvanized Steel
with clean water and allowed to completely dry before appli- 6.1 Before preparing the surface of partially weathered
cation of the paint system. Painting should take place soon galvanized steel, the surface must be checked for the presence
after treatment to avoid pick up of surface contaminants. of chromate conversion coating. The presence of a chromate
5.4.4 Wash Primer Treatment—This process involves the conversion coating can severely impair the adhesion of some
use of a metal conditioner to neutralize surface oxides and paint coating system. Chromate conversion coatings can be
hydroxides along with etching the surface. One example of a applied at the galvanizing facility to protect the newly galva-
wash primer is SSPC Paint Specification No. 27. The process nized surface from excessive growth of zinc oxide and zinc
is based on three primary components: a hydroxyl-containing hydroxide, commonly called wet storage stain. The presence of
resin: a pigment capable of reacting with resin and acid: and, chromate conversion coatings can be detected by the procedure
an acid capable of making the resin insoluble by reacting with outlined in Appendix X1. The removal of the chromate
the resin, the pigment, and the zinc surface. The result is a film conversion coating also is outlined in Appendix X1. The
of approximately 8 to 13 µm (0.3 to 0.5 mils). Failures can surface preparation method described in 5.4.5 could test
occur if the film exceeds 13 µm (0.5 mils). The film usually is positive for the presence of chrome. The surface preparation

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 D6386 − 10
technique described in 5.4.5 should not be removed if it tests is applied, in some atmospheric conditions, such as high
positive for the presence of chrome. This process is not a humidity, or high temperature, or both, the formation of zinc
chromate conversion coating. If the galvanized surface has oxide on the surface will begin very quickly so the paint
thick edges or high spots, these should be removed, see 5.2.1. coating should be applied within 30 min. If a protective
When the high spots have been treated and the chromate has treatment is applied, it is not necessary to paint immediately.
been removed completely by sanding or sweep blasting in Zinc oxide formation is not visible to the naked eye; therefore,
accordance with 5.4.1, surfaces should be blown down with in any atmosphere, painting should be started as soon as
clean, compressed air. In some atmospheric conditions, such as possible after surface preparation.
high humidity or high temperature, or both, the formation of 6.3 If there is no indication of either chromate conversion
zinc oxide on the blasted surface will begin very quickly so the coating or wet storage stain, the surface can be prepared as
paint coating should be applied within 30 min after sweep detailed in Section 5.
blasting. Zinc oxide formation is not visible to the naked eye;
therefore, in any atmosphere, painting should be as soon as 7. Processes for Weathered Galvanized Steel
possible after surface preparation. 7.1 Fully weathered galvanized steel, as described in 3.2,
has developed a stable and finely etched surface that is very
6.2 Before preparing the surface of partially weathered
suited for paint coating adhesion. If there are organic
galvanized steel, the surface must be checked for the presence
contaminants, such as oil, grease, or soot on the surface of the
of wet storage stain. Wet storage stain is the whitish zinc
part, surface cleaning in accordance with 5.3 should be
corrosion product formed when galvanized parts are exposed to
performed before any other cleaning is done.
moist air without sufficient air circulation between the parts
and is described in the American Galvanizers Association 7.2 The natural corrosion of the zinc metal produces a
Publication, Wet Storage Stain. Wet storage stain consists roughened surface film consisting primarily of basic zinc
primarily of beta zinc hydroxide and small percentages of zinc carbonate. The surface preparation that is needed is a power
oxide and zinc carbonate. Since wet storage stain is hygro- wash with warm water to remove loose particles from the
scopic and has a larger volume than zinc metal, paint adhesion surface. The power wash should use water jets with a pressure
can be affected seriously when painting over wet storage stain. of less than 10 MPa (1450 psi) so as not to damage the
Careful brushing with a mild ammonia solution using a soft protective film. This film is naturally roughened in its growth
bristle brush will remove mild cases of wet storage stain. process, so no extra surface profiling is needed. Allow the
Thorough water rinsing must immediately follow the brushing. surface to completely dry before application of the paint
More severe cases of wet storage stain that have thick white system.
corrosion products on the zinc surface, or even black corrosion 7.3 Fully-weathered galvanized steel can be painted suc-
products, can be cleaned using vigorous soft bristle brushing cessfully with the application of appropriate paint systems
with a mild acidic solution with a pH of 3.5 to 4.5, such as including primers and top coat paints. The use of
acetic acid or citric acid, but not hydrochloric or sulfuric acid pretreatments, such as those described in 5.4, can enhance
solutions. Thorough water rinsing must immediately follow the paint adhesion and extend long term performance.
brushing. After the part has completely dried, the surface
profile should be applied in accordance with 5.4, and, then the 8. Keywords
surfaces should be blown down with clean, compressed air. If 8.1 galvanized steel; galvanizing; hot-dipped galvanizing;
no protective treatment, such as those described in 5.4.3 – 5.4.5 painting; paint preparation; surfacing preparation; zinc coating

APPENDIX

(Nonmandatory Information)

X1. IDENTIFYING THE PRESENCE OF AND REMOVING CHROMATE TREATMENTS USED AS WET STORAGE (ALSO
CALLED HUMID-STORAGE) STAIN INHIBITORS

X1.1 One of the inhibitors used by producers of zinc-coated X1.3.1 Weathering the surfaces for six months, or
steel is a hexavalent chromium solution. This treatment pre-
X1.3.2 Abrading the surfaces by sanding, or
vents adhesion of many paint coatings to zinc coated steel
surfaces. X1.3.3 Sweep blast clean in accordance with 5.4.1.
X1.2 If zinc-coated steel to be painted is galvanized to X1.4 The presence of hexavalent chromium on galvanized
order, the order should prohibit the use of hexavalent chro-
surfaces can be determined by spot testing used Practice B201.
mium humid-storage strain treatments.
X1.3 Hexavalent chromium treatment can be removed from X1.5 Conduct the spot test on several representative spots
galvanized surfaces by one of the following three methods: on each individual piece of galvanized steel.

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 D6386 − 10
X1.6 Test, in accordance with Practice B201, every piece of
galvanized steel that is to be treated for painting.

SUMMARY OF CHANGES

Committee D01 has identified the location of selected changes to this standard since the last issue
(D6386 - 99 (2005)) that may impact the use of this standard. (Approved July 1, 2010.)

(1) Added section 5.4.2 and renumbered subsequent sections.

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