Problem Solving Forum
January 27 - January 31, 2020
If I apply 140 microns of inorganic zinc to a steel substrate with a 75 micron profile, is there any concern about cracking of the primer during storage, shipment, and erection of the structure, or with field-application of a topcoat?
William (Willie) Mandeno of WSP NZ on
February 7, 2020:
It depends on the formulation of the IOZ but mud c ...read more It depends on the formulation of the IOZ but mud cracking will be less of a problem with high-ratio waterborne type. Similarly, it depends on the type of field-applied topcoat, e.g., low VS could result in blistering due to solvent entrapment unless IOZ has weathered for several months to reduce porosity..
HECTOR MEDINA of PEQUIVEN on
February 2, 2020:
Good point from Larry Muzia. But I think that it's ...read more Good point from Larry Muzia. But I think that it's always important gto contact the coating manufacturer to assess the risk of mudcracking.
Larry Muzia of Exceletech Coating & Applications, LLC on
January 31, 2020:
To start, a 3-mil profile is excessive for an ioz ...read more To start, a 3-mil profile is excessive for an ioz application, but having this depth and insuring you have covered the peaks with sufficient film thickness has been successful on numerous occasions. Here in Florida, the Space Center has often gone with untopcoated ioz on carbon steel exposed to the salt environment at 3-5 mils as a specification requirement. I agree that, at the higher dft, there is both a chance of mudcracking or splitting of the zinc film, which has low tensile strength to begin with. Typically, the first location of mudcracking will be in the filet area for structural steel. When I have seen zinc applied at the higher end of the thickness range near or at 5 mils, I would suggest watching the film thickness of the overcoats and keep to the minimum recommended dft to minimize film stress to the zinc film. Topcoating a heavier ioz film is also more conducive to outgassing because the film of the zinc has more porosity because of the depth, unless it has weathered and the porosity has been reduced by the formation of zinc carbonate salts. Also, remember, for shop applications, the cure time must be extended before overcoating.
David Lemke of Team Industries on
January 30, 2020:
While most IOZ is recommended for application at&n ...read more While most IOZ is recommended for application at 2-3 or 2-4 mils DFT, there some coating manufacturers that have statements on the Product Data Sheet, such as "Do not exceed 6 mils DFT." Some manufacturers state a minimum profile of 2 mils and some 1-3 mils. In reality, this case would be at the outer limits for some manufacturers, but still tolerable. Put the material on in a hot 90° sun with 85% humidity, and it has a better chance of #1 happening. Slow down the drying speed with a lower temperature and RH, and it has better chance of not being a problem. The deeper profile might help for nicks and chipping during handling, provided a reasonable dry time was used. If a topcoat consists of heavy mil coats in a multi- coat system, the heavier IOZ could have a chance to stress the coating system. The heavier IOZ with a top coat of high-temp silicone designed for 1000° service could have chance to be a problem. A single top coat on a system not designed for high elevated temperatures, with a reasonable dry time for the IOZ, I think, it would be satisfactory.
Jon Cavallo of Jon R. Cavallo PE LLC on
January 30, 2020:
Just a few items to clear up. 1. "Mud Cracking" i ...read more Just a few items to clear up. 1. "Mud Cracking" is actually a defect phenomenon called "checking." The defects manifested in checking do not go completely through the affected coating film. 2. History shows that all brands of IOZ are prone to "mud crack" when applied in excess of 5 mils DFT. 3. The "mud cracking" phenomenon results from liquid silicate binder migrating toward the substrate during cure. When the IOZ film is built in excess of 5 mils, insufficient silicate binder is left at or near the film surface after curing; hence, shrink checking occurs (called "mud cracking"). Hope this helps.
Josh Skinner of The Sherwin-Williams Company on
January 30, 2020:
140 microns (5.5 mils) DFT for IOZ is excessive. ...read more 140 microns (5.5 mils) DFT for IOZ is excessive. At that thickness, you're at risk for mudcracking. Always consult the product data sheet for recommended film thickness.
Ron Berry of NZ Corrosion Services Ltd on
January 29, 2020:
There should not necessarily be a concern, particu ...read more There should not necessarily be a concern, particularly if no additional solvent is added If it does not mud crack within the first 24 hours at normal drying conditions, it is unlikely to do so later. A 75-micron profile is high for IOZ. Why is it this high?
Kalpesh Patel of Endura Manufacturing Co. Ltd. on
January 28, 2020:
For IOZ coatings, mud cracking is very common prob ...read more For IOZ coatings, mud cracking is very common problem, and the main causes of the problem are film thickness and insufficient curing of the film. If you apply the right thickness and let it cure completely before you recoat or topcoat, you can minimize the problem. The thickness you are going to apply looks reasonable, but it needs to be consistent and make sure there is sufficient humidity to cure it completely.