Designation: D7803 − 12

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Standard Practice for

Preparation of Zinc (Hot-Dip Galvanized) Coated Iron and
Steel Product and Hardware Surfaces for Powder Coating1
This standard is issued under the fixed designation D7803; 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.

1. Scope A123/A123M Specification for Zinc (Hot-Dip Galvanized)

1.1 This practice describes methods of preparing surfaces of Coatings on Iron and Steel Products
hot-dip galvanized iron and steel for powder coating and the A153/A153M Specification for Zinc Coating (Hot-Dip) on
application of powder coating materials. Iron and Steel Hardware
1.1.1 Powder coating is a dry finishing process which uses A780 Practice for Repair of Damaged and Uncoated Areas
finely ground particles of pigment and resin, electrostatically of Hot-Dip Galvanized Coatings
charged, and sprayed onto a part to be coated. The parts are B201 Practice for Testing Chromate Coatings on Zinc and
electrically grounded so that the charged particles projected at Cadmium Surfaces
them adhere to the surface and are held there until melted and D4285 Test Method for Indicating Oil or Water in Com-
fused into a smooth coating in the curing oven. pressed Air
1.1.2 Hot-dip galvanized iron or steel is produced by the D6386 Practice for Preparation of Zinc (Hot-Dip Galva-
immersion of fabricated or un-fabricated products in a bath of nized) Coated Iron and Steel Product and Hardware
molten zinc, as specified in Specification A123/A123M or Surfaces for Painting
A153/A153M. This practice covers surface preparation and D7091 Practice for Nondestructive Measurement of Dry
thermal pretreatment of iron and steel products and hardware Film Thickness of Nonmagnetic Coatings Applied to
which have not been painted or powder coated previously Ferrous Metals and Nonmagnetic, Nonconductive Coat-
(Practice D6386). Galvanized surfaces may have been treated ings Applied to Non-Ferrous Metals
with protective coatings to prevent the occurrence of wet E376 Practice for Measuring Coating Thickness by
storage stain. This practice neither applies to sheet galvanized Magnetic-Field or Eddy-Current (Electromagnetic) Test-
steel products nor to the coil coating or continuous roller ing Methods
coating processes. F21 Test Method for Hydrophobic Surface Films by the
Atomizer Test
1.2 The values stated in SI units are to be regarded as the
2.2 Society for Protective Coatings Specifications:3
standard. The values given in parentheses are for information
Surface Preparation Specification No. 1 Solvent Cleaning
only.
Surface Preparation Specification No. 2 Hand Tool Cleaning
1.3 This standard does not purport to address all of the Surface Preparation Specification No. 3 Power Tool Clean-
safety concerns, if any, associated with its use. It is the ing
responsibility of the user of this standard to establish appro- Surface Preparation Specification No. 12 Surface Prepara-
priate safety and health practices and determine the applica- tion and Cleaning of Metals by Water-Jetting Prior to
bility of regulatory limitations prior to use. Recoating
Surface Preparation Specification No. 16 Brush-Off Blast
2. Referenced Documents Cleaning of Coated and Uncoated Galvanized Steel,
2.1 ASTM Standards:2 Stainless Steels, and Non-Ferrous Metals

3. Summary of Practice
1
This practice is under the jurisdiction of ASTM Committee D01 on Paint and
3.1 This practice describes the procedures that can be used
Related Coatings, Materials, and Applications and is the direct responsibility of to prepare surfaces for powder coating application on new,
Subcommittee D01.46 on Industrial Protective Coatings. partially weathered, and fully weathered zinc-coated surfaces
Current edition approved June 1, 2012. Published June 2012. DOI: 10.1520/ on after-fabrication iron and steel products. These procedures
D7803-12.
2
For referenced ASTM standards, visit the ASTM website, www.astm.org, or
contact ASTM Customer Service at [email protected]. For Annual Book of ASTM
3
Standards volume information, refer to the standard’s Document Summary page on Available from Society for Protective Coatings (SSPC), 40 24th St., 6th Floor,
the ASTM website. Pittsburgh, PA 15222-4656, http://www.sspc.org.

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

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D7803 − 12
improve the bond of the powder coating to the zinc surface hence they do not necessarily yield identical results when
providing for long life. powder coatings are subsequently applied. The age of the zinc
3.2 The proper preparation of galvanized surfaces prior to corrosion products on the galvanized coating will dictate the
application of powder coating is dependent on cleaning, type of surface preparation to be selected.
profiling, and thermal pretreatment.
5. Processes for Cleaning and Preparing Hot Dipped
4. Significance and Use Galvanized Iron and Steel Surfaces for Powder Coating
4.1 This practice describes the methods of preparation of 5.1 Newly Galvanized Metal—The category of newly gal-
hot-dip galvanized surfaces prior to the application of powder vanized metal refers to zinc-coated metal that has no surface
coating. The key to achieving proper adhesion between powder treatment after galvanizing, such as water quenching or chro-
coatings and galvanized steel is surface preparation. The mate conversion coating, and has been galvanized within the
surface must be entirely free from metal oxides prior to powder previous 48 h. There also shall be no visible signs of zinc oxide
coating. Any metal oxides that remain on the surface of the or zinc hydroxide, which first appear as a fine white powder.
galvanized steel can potentially retain air or moisture. Upon 5.1.1 Surface Smoothing—Hot-dip galvanized surfaces, in
heating during the curing stages of the powder application, the general, are relatively smooth after galvanizing. There may be
oxides may release water vapor or air, which can expand and some thick/rough edges at the drip line due to excess liquid
penetrate the powder coating, causing blisters or voids. zinc run-off during the galvanization process, or high spots in
4.2 The zinc coating is constantly in a state of change. From the coating from included iron-zinc intermetallics (dross) or
the time the steel part is removed from the galvanizing kettle, zinc oxide particles. These high spots and rough edges must be
the exposed zinc coating interacts with the environment to smoothed to avoid powder coat film gaps in the areas of the
form, first zinc oxides and zinc hydroxides, and then zinc high spots. Zinc high spots shall be removed by cleaning with
carbonates.4 The process of complete conversion of the outer hand or power tools as described in SSPC Surface Preparation
layer of zinc carbonates can take up to two years of exposure Specification 2 or 3 until they are level with the surrounding
to the environment, depending on the local weather and zinc area, taking care that the base coating is not removed by
moisture conditions. the cleaning methods. After smoothing, the surface shall be
inspected for conformance to the required zinc thickness in
4.3 The zinc surface after full weathering is very resistant to accordance with Specification A123/A123M or A153/A153M
atmospheric corrosion because the tight patina that is formed utilizing a magnetic thickness instrument in accordance with
(zinc oxide, zinc hydroxide and zinc carbonate) is dense and Practice E376 and/or D7091. Any area falling below the
tenacious. However, during the formative stages of patina required zinc thickness, before or after removal of any high
development, the oxide/hydroxide layer is poorly adhered and spots, shall be repaired in accordance with Practice A780 using
must be removed in order for the powder coating to adhere an appropriate method that is compatible with the curing
properly to the galvanized coating. The second is pinholing/ temperature and time of the powder coating.
blistering of the coating which can severely limit its potential
5.1.2 Surface Cleaning—Hot-dip galvanized surfaces must
performance, especially in aggressive chloride environments.
be clean and free of oil and grease before they are powder
Entrapped gasses developed during the galvanizing process
coated. Adhesion problems have been experienced with newly
escape the surface through the coating as it cures at high
galvanized articles that have been water quenched or treated
temperatures. If these volatile materials are not removed
with chromate conversion coatings. These two post-
through an outgassing process prior to the baking of the
galvanizing treatments are not recommended for galvanized
powder, then pinholing or blistering can occur. The presence of
articles that are to be coated. Test Method F21 can determine
pinholes gives chlorides and other corrosive agents access to
if contamination is on the galvanized surface prior to powder
the zinc substrate consequently producing zinc corrosion
coating.
products which may leach out through the coatings. While the
5.1.2.1 Checking for Chromate Conversion Coating—
presence of these corrosion products may not result in associ-
Before preparing the surface of any state of the galvanized steel
ated delamination of the coating, unsightly white staining of
for powder coating, if the galvanizer has not indicated if he
the coating can occur. Blisters are defects that are not adhered
avoided the chromate bath, the surface of a sample group from
to the surface and may easily be broken into or off during
each shipment must be checked for the presence of a chromate
handling, which creates performance and aesthetic issues. The
conversion coating. The presence of a chromate conversion
proper preparation of the galvanized coating surface can
coating can severely impair the adhesion of powder coating.
increase the adhesion and coverage necessary to overcome
The presence of chromate conversion coatings can be detected
these problems and results in a satisfactory service life of the
by the procedure outlined in Practice B201. Chromate conver-
powder coating and the galvanized coating together.
sion coating can be removed completely by weathering galva-
4.4 Variations in surface preparation produce end conditions nized metal for six months outdoors, sanding in accordance
that differ as far as surface roughness and zinc composition, with 5.1.3.3, or sweep blasting in accordance with 5.1.3.1.
5.1.2.2 Aqueous Alkaline Cleaning—An alkaline solution,
4
pH in the range of 11 to 12, definitely not greater than 13, can
This interaction is described in “Duplex Systems,” van Eijnsbergen, J. F. H.,
Elsevier Science, New York, NY 1994, and in Zinc Handbook, Porter, F., Marcel be used to remove traces of oil, grease, or dirt. The alkaline
Dekker, Inc., New York, NY 1991. solution nominally is 2 to 5 % sodium compounds, with small

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D7803 − 12
additions of emulsifying, chelating, or sequestering agents, or (Test Method D4285). Care is needed in averting this type of
a combination thereof. This solution can be applied through contamination. The purpose of sweep blasting is to deform, not
immersion in a tank filled with the solution, sprayed, or remove the galvanized metal. Any area falling below the
brushed with a soft bristle brush, usually nylon and not steel or required zinc thickness, before or after sweep blasting, shall be
copper. When dipping or spraying, the solution works best in repaired in accordance with Practice A780. Sweep blasting of
the temperature range from 60 to 85°C (140 to 185°F). After zinc shall be not less than 110 m2/h (1200 ft2/h) using these
cleaning, rinse thoroughly in hot water or water under pressure. abrasive materials. The substrate shall be maintained at a
Allow to dry completely before proceeding. Whenever galva- temperature of at least 3°C (5°F) above the dew point tem-
nized steel is rinsed, it is desirable to use heated drying to perature. Following abrasive blast cleaning, surfaces shall be
accelerate the complete removal of water from the surface. blown down with clean, compressed air. In some atmospheric
NOTE 1—An alkaline cleaner is unsuitable for removal of heavy conditions, such as high humidity, high temperature, or both,
build-up of zinc oxide or wet storage stain (see American Galvanizers the formation of zinc oxide on the blasted surface will begin
Publication, Wet Storage Stain,5 for description of these conditions). See very quickly. Because newly formed zinc oxide is not visible to
5.1.3 for removal of zinc oxide layer. the naked eye, powder coating shall be applied as soon as
5.1.2.3 Solvent Cleaning—Typical cleaning solvents, such possible after surface preparation.
as mineral spirits or high-flash naphtha, can be used to remove 5.1.3.2 Phosphate Treatment—This conversion-coating pro-
oil and grease. The procedure to be used is as specified in SSPC cess consists of reacting the newly galvanized zinc surface in
SP 1. Proper rags or brushes shall be used to wipe the phosphate solution which contains oxidizing agents and other
galvanized parts. After cleaning, rinse thoroughly in hot water salts for accelerating the coating action. The zinc surface is
or water under pressure. Allow to dry completely before converted to a crystalline phosphate coating of the proper
proceeding. Whenever galvanized steel is rinsed, it is desirable texture to inhibit corrosion and increase the adherence and
to use heated drying to accelerate the complete removal of durability of the powder coating. This process can be applied
water from the surface. (Warning—These rags or brushes by immersion, spray or soft bristle brush application. After a
should be cleaned or recycled often since oil can accumulate on time period of 3 to 6 min, the surface shall be washed with
their surfaces and be transferred back to the galvanized part. clean water and allowed to completely dry before application
Small parts may be dipped or cleaned in ultrasonic baths of of the powder coating system. Whenever galvanized steel is
solvents.) rinsed, it is desirable to use heated drying to accelerate the
5.1.3 Surface Preparation—Hot-dip galvanized surfaces complete removal of water from the surface. Powder coating
have a layer of zinc oxide and zinc hydroxide that must be shall take place soon after treatment to avoid pick up of surface
removed before powder coating will adhere to the zinc coating. contaminants.
Zinc coatings are generally smooth and must be slightly 5.1.3.3 Surface Grinding—Power tools such as grinders or
roughened prior to powder coating. One of the following three sanders will roughen the surface of galvanized metal and
methods shall be used to prepare the galvanized surface for produce a surface profile suitable for powder coating adhesion.
powder coating. The grinder or sander shall not be applied with sufficient force
5.1.3.1 Sweep Blasting—Abrasive sweep or brush blasting to remove all of the zinc coating rather a removal of up to 25
in accordance with SSPC SP 16, which uses a rapid nozzle microns (1.0 mil) is acceptable. This grinding or sanding
movement, will roughen the galvanized surface profile. The process produces a sharper surface profile if the galvanized
abrasive material must be chosen carefully to provide a metal is over 50°C (122°F) as the zinc metal is softer at
stripping action that removes the oxide reaction products elevated temperatures. Following grinding or sanding, surfaces
without excessive removal of the zinc. One of the materials shall be blown down with clean, compressed air. In some
that has been used successfully is aluminum/magnesium sili- atmospheric conditions, such as high humidity, high
cate with a particle size in the range of 200 to 500 µm (8 to 20 temperature, or both, the formation of zinc oxide on the ground
mils.). Other materials that can be used are soft mineral sands surface will begin very quickly. Because newly formed zinc
with a Mohs hardness of five or less, organic media, such as oxide is not visible to the naked eye, powder coating shall be
corn cobs or walnut shells, corundum, or limestone. Depending applied as soon as possible after surface preparation.
on the value of hardness for the abrasive medium, blasting
pressure may need to be adjusted for the appropriate nozzle to 5.1.3.4 Notification of Surface Treatment—The powder
work-piece distance, geometry of the component, and blasting coating shop must be notified as to how the galvanized articles
medium. For reactive steel with all-alloy coatings which may have been processed and which surface preparation method, if
have compromised adhesion, even the relatively low-pressure any, was used to prepare the surface.
blast of 0.15 to 0.25 MPa (20 to 40 psi) can be too great, 5.2 Partially Weathered Galvanized Metal—The category of
causing adhesion problems. Care must be taken to leave zinc partially weathered galvanized metal refers to zinc-coated iron
layers intact. Oil contamination of the compressed air will or steel that has been galvanized for over 48 h and may have
degrade adhesion to sweep-blasted hot-dip galvanized surfaces had surface treatment after galvanizing, such as water quench-
ing or chromate conversion coating. There also may be visible
5
Available from American Galvanizers Association, 6881 South Holly Circle, signs of zinc oxide or zinc hydroxide, which appears as a fine
Suite 108, Centennial, CO, 80112, www.galvanizeit.org. white powder.

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5.2.1 Checking for Chromate Conversion Coating— 5.3.2 Power Washing—The natural corrosion of the zinc
Perform check and removal as described in 5.1.2.1. After the metal produces a roughened surface film consisting primarily
chromate conversion coating is removed proceed with surface of basic zinc carbonate. The surface preparation that can be
preparation in accordance with 5.1.3. used is a power wash with warm water to remove loose
5.2.2 Checking for Wet Storage Stain—Before preparing the particles from the surface as described in SSPC SP 12. The
surface of partially weathered galvanized metal for powder power wash shall use water jets with a pressure of less than 10
coating, the surface must be checked for the presence of wet MPa (1450 psi) so as not to damage the protective film. This
storage stain. Wet storage stain is the whitish zinc corrosion film is naturally roughened in its growth process, so no extra
product formed when galvanized parts are exposed to moist air surface profiling is needed. Allow the surface to completely dry
without sufficient air circulation between the parts and is before application of the powder coating system. Whenever
described in the American Galvanizers Publication, Wet Stor- galvanized steel is rinsed, it is desirable to use heated drying to
age Stain.5 Wet storage stain consists primarily of zinc hydrox- accelerate the complete removal of water from the surface.
ide and small percentages of zinc oxide and zinc carbonate. 6. Process for Thermal Pretreatment of Hot Dipped
Because wet storage stain is hygroscopic and has a larger Galvanized Iron and Steel Prior to Powder Coating
volume than zinc metal, powder coating adhesion can be
6.1 Newly Galvanized, Partially Weathered and Fully
affected seriously when coating over wet storage stain. Careful
Weathered Galvanized Metal Outgassing—Following cleaning
brushing with a mild ammonia solution using a soft bristle
and surface preparation, the work shall be thermally treated
brush will remove mild cases of wet storage stain. Thorough
through a dry-off/oven facility to remove residual moisture
water rinsing must immediately follow the brushing. Whenever
from the work prior to powder application to reduce pinholing
galvanized steel is rinsed, it is desirable to use heated drying to
and blistering.
accelerate the complete removal of water from the surface.
6.1.1 Thermal Treatment—Pre-baking in a drying oven can
More severe cases of wet storage stain have thick white reduce the potential for the galvanized coating to outgas. This
corrosion products on the zinc surface, or even black corrosion process will aid in the expulsion of any trapped air or water in
products, can be cleaned using vigorous soft bristle brushing the coating as well as ensure that the surface of the metal is free
with a mild acidic solution with a pH of 3.5 to 4.5, such as from any moisture. The pre-baking oven shall be operated at a
acetic acid or citric acid, but not hydrochloric or sulfuric acid higher temperature than the powder coating curing oven.
solutions. Thorough water rinsing must immediately follow the 6.1.2 Baking Requirements—The temperature of the pre-
brushing. Whenever galvanized steel is rinsed, it is desirable to bake oven shall be capable of heating the work to 30°C (65°F)
use heated drying to accelerate the complete removal of water higher than the curing oven. If the galvanized metal is run
from the surface. After the part has completely dried, the through a phosphate wash prior to powder coating, it is
surface profile shall be applied in accordance with 5.1.3. If no recommended that the pre-bake temperature of the work not
protective treatment, such as those described in 5.1.3.2 is exceed 280°C (535°F). Higher temperatures will deteriorate
applied, in some atmospheric conditions, such as high the thin phosphate coating, converting it into a powdery
humidity, or high temperature, or both, the formation of zinc substance that could affect adhesion.
oxide on the surface will begin very quickly. Because newly 6.1.3 Baking Procedure—The galvanized work piece shall
formed zinc oxide is not visible to the naked eye, powder be kept in the prebake oven for a sufficient time for the
coating shall be applied as soon as possible after surface galvanized surface to reach the temperature of the prebake
preparation. oven. Typically, this is one hour to assure all moisture and
5.2.3 Surface Preparation—If there is no indication of entrapped gasses are expelled. After the prebaking cycle is
either chromate conversion coating or wet storage stain, the complete, the part shall be cooled to a temperature sufficiently
surface can be prepared for powder coating by performing the below the curing temperature of the powder coating before the
steps in 5.1. application of the powder coating.
5.3 Fully Weathered Galvanized Metal—Fully weathered 7. Inspection
galvanized metal has been galvanized for six months or longer 7.1 Testing, including sampling, lot size, etc., shall be
with the exposed surface consisting mainly of water-insoluble according to the regime specified in Specification A123/
zinc carbonates. Zinc carbonate forms a rough surface layer A123M or A153/A153M. The galvanized component of the
that does not need further roughening to be ready to accept a duplex coating shall meet all requirements of Specification
powder coating. A123/A123M or A153/A153M. Coating thickness values for
5.3.1 Surface Cleaning—Fully weathered galvanized metal either the galvanized coating or the powder coated component
has developed a stable and finely etched surface that is very shall be measured independently.
suited for powder coating adhesion. If there are organic
contaminants, such as oil, grease, or soot on the surface of the 8. Keywords
part, surface cleaning in accordance with 5.1.2 shall be 8.1 galvanized steel; galvanizing; hot-dipped galvanizing;
performed before any other processing is done. phosphating; powder coating; surface preparation; zinc coating

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