Designation: D6386 − 16a

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 U.S. Department of Defense.

1. Scope* A780 Practice for Repair of Damaged and Uncoated Areas

1.1 This practice describes methods of preparing surfaces of of Hot-Dip Galvanized Coatings
new and weathered hot-dip galvanized steel for painting with B201 Practice for Testing Chromate Coatings on Zinc and
liquid paint and coating products. Preparing surfaces of new Cadmium Surfaces
and partially weathered galvanized steel for powder coating is D4285 Test Method for Indicating Oil or Water in Com-
addressed in Practice D7803. Hot-dip galvanized steel is pressed Air
produced by the immersion of fabricated or unfabricated D6492 Practice for Detection of Hexavalent Chromium On
products in a bath of molten zinc, as specified in Specifications Zinc and Zinc/Aluminum Alloy Coated Steel
A123/A123M or A153/A153M. This practice covers surface D7091 Practice for Nondestructive Measurement of Dry
preparation on iron and steel products and hardware that have Film Thickness of Nonmagnetic Coatings Applied to
not been painted previously. Galvanized surfaces may have Ferrous Metals and Nonmagnetic, Nonconductive Coat-
been treated with protective coatings to prevent the occurrence ings Applied to Non-Ferrous Metals
of wet storage stain. This practice does not apply to sheet D7396 Guide for Preparation of New, Continuous Zinc-
galvanized steel products nor to the coil coating or continuous Coated (Galvanized) Steel Surfaces for Painting
roller coating processes. Sheet and coil surface preparation can D7803 Practice for Preparation of Zinc (Hot-Dip Galva-
be done in accordance with Practice D7396. nized) Coated Iron and Steel Product and Hardware
Surfaces for Powder Coating
1.2 The values stated in SI units are to be regarded as the E376 Practice for Measuring Coating Thickness by
standard. The values given in parentheses are for information Magnetic-Field or Eddy-Current (Electromagnetic) Test-
only. ing Methods
1.3 This standard does not purport to address all of the 2.2 Society for Protective Coatings Specifications:3
safety concerns, if any, associated with its use. It is the Surface Preparation Specification No. 1 Solvent Cleaning
responsibility of the user of this standard to establish appro- Surface Preparation Specification No. 2 Hand Tool Cleaning
priate safety and health practices and to determine the Surface Preparation Specification No. 3 Power Tool Clean-
application of regulatory limitations prior to use. ing
Surface Preparation Specification No. 7 Brush-Off Blast
2. Referenced Documents Cleaning
2.1 ASTM Standards:2 Surface Preparation Specification No. 11 Power Tool Clean-
A123/A123M Specification for Zinc (Hot-Dip Galvanized) ing to Bare Metal
Coatings on Iron and Steel Products Surface Preparation Specification No. 16 Brush-Off Blast
A153/A153M Specification for Zinc Coating (Hot-Dip) on Cleaning of Non-Ferrous Metals
Iron and Steel Hardware Paint Specification No. 27 Basic Zinc Chromate-Vinyl Bu-
tyral Wash Primer
1
SSPC Guide 15 Field Methods for Extraction and Analysis
This practice is under the jurisdiction of ASTM Committee D01 on Paint and
Related Coatings, Materials, and Applications and is the direct responsibility of
of Soluble Salts on Steel and Other Nonporous Substrates
Subcommittee D01.46 on Industrial Protective Coatings.
Current edition approved June 15, 2016. Published June 2016. Originally
3. Summary of Practice
approved in 1999. Last previous edition approved in 2016 as D6386 – 16. DOI: 3.1 This practice describes the preparation methods that
10.1520/D6386-16A.
2
For referenced ASTM standards, visit the ASTM website, www.astm.org, or
provide clean and suitable galvanized surfaces for painting,
contact ASTM Customer Service at service@astm.org. 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.

*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 − 16a
specifically so that an applied coating system can develop the that the base coating is not removed by the smoothing methods.
adhesion necessary for a satisfactory service life. After smoothing, the surface shall be inspected for confor-
3.2 The zinc coating is constantly in a state of change. From mance to the required zinc thickness in accordance with
the time the steel part is removed from the galvanizing kettle, Specifications A123/A123M or A153/A153M utilizing a mag-
the exposed zinc coating interacts with the environment to netic thickness instrument in accordance with Practice E376
form, first zinc oxides, next zinc hydroxides, and then zinc and/or Practice D7091. Any item falling below the required
carbonates.4 The process of complete conversion of the outer zinc thickness, before or after removal of any high spots, shall
layer of zinc carbonates can take up to two years of exposure be repaired in accordance with Practice A780.
to the environment, depending on the local climatological 5.3 Surface Cleaning—Hot-dip galvanized surfaces must be
conditions. During the first stage, known as newly galvanized clean and free of oil and grease before they are painted. Soluble
steel, the exposed surface consists mainly of zinc metal with a salts shall be removed to the degree specified in the painting/
small amount of zinc oxide. During the second stage, known as coating specification. Removal of Soluble salts can be ex-
partially weathered galvanized steel, the exposed surface tracted using SSPC Guide 15. Adhesion problems have been
consists mainly of zinc oxides and zinc hydroxides with some experienced with newly galvanized articles that have been
zinc carbonates. At the final stage, known as weathered water quenched or treated with chromate conversion coatings.
galvanized steel, when the part has been openly exposed to the These two post-galvanizing treatments are not recommended
elements for more than twelve months, the exposed surface for galvanized articles that are to be painted. Practice B201 or
consists mainly of water-insoluble zinc carbonates, some zinc D6492 can determine if contamination is on the galvanized
oxides, and rarely, zinc hydroxides. The surface preparation for surface prior to painting.
each of these stages must be treated separately. 5.3.1 Aqueous Alkaline Cleaning—An alkaline solution, pH
3.3 Variations in surface preparation produce end conditions in the range of 11 to 12 definitely not greater than 13, can be
that differ, hence they do not necessarily yield identical results used to remove traces of oil, grease, or dirt. The alkaline
when paints are subsequently applied. Service conditions will solution nominally is 2 to 5 % sodium compounds, with small
dictate the type of surface preparation to be selected, although additions of emulsifying, chelating, or sequestering agents, or
the quality produced by any individual process may vary with a combination thereof. This solution can be applied through
different compositions of the zinc surface. immersion in a tank filled with the solution, sprayed, or
brushed with a soft bristle brush, usually nylon and not steel or
4. Significance and Use copper. When dipping or spraying, the solution works best in
the temperature range from 60 to 85°C (140 to 185°F). After
4.1 This practice describes the procedures that can be used
cleaning, rinse thoroughly in hot water or water under pressure.
to prepare new and weathered zinc-coated surfaces on after-
Allow to dry completely before proceeding. Whenever galva-
fabrication steel products for painting, and that can improve the
nized steel is rinsed, it is desirable to use heated drying to
bond of paint to the zinc surface.
accelerate the complete removal of water from the surface.
5. Processes for Newly Galvanized Steel NOTE 1— An alkaline cleaner is unsuitable for removal of heavy
build-up of zinc oxide or wet storage stain (see American Galvanizers
5.1 Newly Galvanized Steel—The category of newly galva- Publications, Wet Storage Stain,5 for description of these conditions). See
nized steel refers to zinc-coated steel that has no surface 5.3.3 or 5.4 for removal of zinc oxide layer.
treatment after galvanizing, such as water quenching or chro- 5.3.2 Solvent Cleaning—Typical cleaning solvents, such as
mate conversion coating, and has been galvanized within the mineral spirits or high-flash naphtha, can be used to remove oil
previous 48 h. There also should be no visible signs of zinc and grease. The procedure to be used is as specified in SSPC
oxide or zinc hydroxide, which first appear as a fine white Surface Preparation Specification No. 1. Proper rags or brushes
powder. should be used to wipe the galvanized parts. (Warning—These
5.2 Surface Smoothing—Hot-dip galvanized surfaces gener- rags or brushes should be cleaned or recycled often since oil
ally are relatively smooth after galvanizing. There may be can accumulate on their surfaces and be transferred back to the
some thick/rough edges at the drip line due to excess liquid galvanized part.) Small parts may be dipped or cleaned in
zinc run-off during the galvanizing process, or high spots in the ultrasonic baths of solvents. After cleaning, rinse thoroughly in
coating due to included iron-zinc intermetallics (dross) or zinc hot water or water under pressure. Allow to dry completely
oxide particles. These high spots and rough edges must be before proceeding.) Whenever galvanized steel is rinsed, it is
smoothed to avoid paint film gaps in the areas of the high spots. desirable to use heated drying to accelerate the complete
5.2.1 Zinc high spots, those that would cause paint film gaps removal of water from the surface.
such as the metal drip line, should be removed by smoothing 5.3.3 Hand or Power Tool Cleaning—Hand or power tool
with hand or power tools as described in SSPC Surface cleaning using equipment as specified in SSPC Surface Prepa-
Preparation Specification No. 2 or No. 3. The zinc should be ration Specification No. 2 or No. 3 is one method to clean light
removed until it is level with the surrounding area, taking care deposits of zinc reaction by products, such as light wet-storage
stain.
4
This interaction is described in “Duplex Systems,” van Eijnsbergen, J.F.H.,
5
Elsevier Science, New York, NY 1994, and in Zinc Handbook, Porter, F., Marcel Available from American Galvanizers Association (AGA), 6881 S. Holly
Dekker, Inc., New York, NY 1991. Circle, Suite 108 Centennial, CO 80112, http://www.galvanizeit.org.

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 D6386 − 16a
5.4 Surface Preparation—Hot-dip galvanized surfaces have with clean water and allowed to completely dry before appli-
a layer of zinc oxide and zinc hydroxide that must be removed cation of the paint system. Whenever galvanized steel is rinsed,
before paint will adhere to the zinc coating. Zinc coatings it is desirable to use heated drying to accelerate the complete
generally are relatively smooth and may be slightly roughened removal of water from the galvanized surface. This procedure
prior to painting. The following five methods may be used to should be completed at the same location as the paint applica-
prepare the galvanized surface for painting. tion.
5.4.1 Sweep Blasting—Abrasive sweep or brush blasting in 5.4.4 Wash Primer Treatment—This process involves the
accordance with procedures described in SSPC Surface Prepa- use of a metal conditioner to neutralize surface oxides and
ration No. 16, which uses a rapid nozzle movement will hydroxides along with etching the surface. One example of a
roughen the galvanized surface profile. The abrasive material wash primer is SSPC Paint Specification No. 27. The process
must be chosen with care to provide a stripping action without is based on three primary components: a hydroxyl-containing
removing excess zinc layers, removal of up to 25 microns (1 resin: a pigment capable of reacting with resin and acid: and,
mil) is acceptable. One of the materials that has been used an acid capable of making the resin insoluble by reacting with
successfully is aluminum/magnesium silicate. Particle size the resin, the pigment, and the zinc surface. The result is a film
should be in the range of 200 to 500 µm (8 to 20 mils). Other of approximately 8 to 13 µm (0.3 to 0.5 mils). Failures can
materials that can be used are soft mineral sands with a MOH occur if the film exceeds 13 µm (0.5 mils). The film usually is
hardness of five or less, organic media, such as corn cobs or applied by spray but may be applied by soft bristle brush, dip,
walnut shells, corundum, and limestone. Depending on the or roller coater. Using these latter coating methods, it may be
value of hardness for the abrasive medium, blasting pressure difficult to control the film thickness. For drying time prior to
may need to be determined for the appropriate nozzle to top coating, follow the manufacturer’s instructions. This wash
work-piece distance, geometry of the component, and blasting primer treatment may be better suited to certain types of paint
medium. For some all-alloy coatings, even the relatively systems. See SSPC Paint Specification No. 27 for the best
low-pressure blast of 0.15 to 0.25 MPa (20 to 40 psi) can be too match of this treatment to a paint system. This procedure
great, causing cohesion problems. Oil contamination of the should be completed at the same location as the paint applica-
compressed air will degrade paint adhesion to sweep-blasted tion.
hot-dip galvanized surfaces, Test Method for determining this
5.4.5 Acrylic Passivation/Pretreatment—The passivation/
contamination is D4285. Care is needed in averting this type of
pretreatment process consists of applying an acidic acrylic
contamination. Care must be taken to leave zinc layers intact.
solution to the newly galvanized surface and then allowing it to
The purpose of sweep blasting is to deform, not remove the
dry, forming a thin film coating. When applied, the solution
galvanized metal. Any area falling below the required zinc
first reacts with the zinc surface forming a passivating conver-
thickness, before or after sweep blasting, should be repaired in
sion coating while simultaneously forming an acrylic coating
accordance with Practice A780. The procedure for this process
suitable for painting on top of the passivation layer. The
can be found in SSPC Surface Preparation Specification
underlying conversion coating provides strong adhesion to the
No. 16. Sweep blasting of zinc should be not less than 110
galvanized surface while the thin film acrylic layer provides
m2/h (1200 ft2/h) using these abrasive materials. The substrate
barrier protection, which inhibits corrosion and provides a
should be maintained at a temperature greater than 3°C (5°F)
highly compatible surface for the application of organic paint
above the dew point temperature. This procedure should be
films. There are versions of these solutions that contain chrome
completed at the same location as the paint application.
and versions without chrome. The application methods for
5.4.2 Surface Grinding—Power tools such as grinders or these water based treatments are dipping, flow coating,
sanders will roughen the surface of galvanized steel and spraying, or other appropriate means. Following application
produce a surface profile suitable for paint adhesion as per the coating is dried in an oven or in air. In some instances, the
SSPC Surface Preparation Specification No. 11. The grinder or coating is applied to hot-galvanized articles, in which case
sander shall not be applied with sufficient force to remove all separate drying is not necessary. Rinsing is not required. The
of the zinc coating rather a removal of up to 25 microns (1.0 coating is approximately 1-µm (0.04-mils) thick. Painting is
mil) is acceptable. This procedure should be completed at the possible any time during a period of four months after
same location as the paint application. application, as long as the surface is free of visible zinc oxides
NOTE 2—This grinding or sanding process may produce a sharper or zinc hydroxides; however, if harmful contaminants, such as
surface profile if the galvanized steel is over 50°C (122°F) as the zinc dust, dirt, oils, grease or deposits are present, they must be
metal is softer at elevated temperatures. removed with a mild alkaline degreasing solution (pH 11.5
5.4.3 Zinc-Phosphate Treatment—This conversion-coating max) followed by a thorough rinse with hot water (60°C
process consists of reacting the newly galvanized zinc surface maximum temperature) or a pressure wash, then thoroughly
in an acidic zinc phosphate solution containing oxidizing dried. This treatment is applied in the galvanizing plant or later
agents and other salts for accelerating the coating action. The in the paint shop. When applied in the paint shop, the surface
zinc surface is converted to a crystalline phosphate coating of must first be appropriately cleaned as just described to remove
the proper texture to inhibit corrosion and increase the adher- contaminants picked up after galvanizing.
ence and durability of the paint film. This process may be 5.4.6 Notification of Surface Treatment—The paint shop
applied by immersion, spray or soft bristle brush application. must be notified as to how the galvanized articles have been
After a time period of 3 to 6 min, the surface should be washed processed and which surface treatment method, if any, is used

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 D6386 − 16a
to prepare the surface. The method and extent of surface Section 5.3.3 describes one method of removing wet storage
preparation shall be mutually agreeable to the purchaser and stain. Another method is careful brushing with a mild ammonia
the supplier. solution using a soft bristle brush; this will remove mild cases
5.5 Coating Application Time—Blow down prepared sur- of wet storage stain. Thorough water rinsing must immediately
faces with clean, dry compressed air following surface prepa- follow the brushing. More severe cases of wet storage stain that
ration. In some atmospheric conditions, such as high humidity have thick white corrosion products on the zinc surface, or
or high temperature or both, the formation of zinc oxide on the even black corrosion products, can be cleaned using vigorous
freshly prepared surfaces will begin very quickly. Zinc oxide soft bristle brushing with a mild acidic solution with a pH of
formation is not visible to the unaided eye; therefore, in any 3.5 to 4.5, such as acetic acid or citric acid, but not hydrochlo-
atmosphere, painting should be started as soon as possible and ric or sulfuric acid solutions. Thorough water rinsing must
preferably within one hour after surface preparation but no immediately follow the brushing. After the part has completely
later than eight hours after surface preparation. dried, the surface shall be prepared in accordance with 5.4, and,
then the surfaces should be blown down with clean, com-
6. Processes for Partially Weathered Galvanized Steel pressed air. If no protective treatment, such as those described
in 5.4.3 – 5.4.5 is applied, in some atmospheric conditions,
6.1 Before preparing the surface of partially weathered such as high humidity, or high temperature, or both, the
galvanized steel, the surface must be checked for the presence formation of zinc oxide on the surface will begin very quickly
of chromate conversion coating. The presence of a chromate so the paint coating should be applied within 30 min. If a
conversion coating can severely impair the adhesion of some protective treatment is applied, it is not necessary to paint
paint coating system. Chromate conversion coatings can be immediately. Zinc oxide formation is not visible to the naked
applied at the galvanizing facility to protect the newly galva- eye; therefore, in any atmosphere, painting should be started as
nized surface from excessive growth of zinc oxide and zinc soon as possible after surface preparation.
hydroxide, commonly called wet storage stain. The presence of
chromate conversion coatings can be detected by the procedure 6.3 If there is no indication of either chromate conversion
outlined in Appendix X1. The removal of the chromate coating or wet storage stain, the surface can be prepared as
conversion coating also is outlined in Appendix X1. The detailed in Section 5.
acrylic passivation/pretreatment coating described in 5.4.5 is 7. Processes for Weathered Galvanized Steel
not a chrome conversion coating, but it may test positive using
the procedure in Appendix X1. The acrylic passivation/ 7.1 Fully weathered galvanized steel, as described in 3.2,
pretreatment coating does not need to be removed if it tests has developed a stable and finely etched surface that is very
positive. If the galvanized surface has thick edges or high suited for paint coating adhesion. If there are organic
spots, these should be removed, see 5.2.1. When the high spots contaminants, such as oil, grease, or soot on the surface of the
have been treated and the chromate has been removed com- part, surface cleaning in accordance with 5.3 should be
pletely by sanding or sweep blasting in accordance with 5.4.1, performed before any other cleaning is done.
surfaces should be blown down with clean, compressed air. In 7.2 The natural corrosion of the zinc metal produces a
some atmospheric conditions, such as high humidity or high roughened surface film consisting primarily of basic zinc
temperature, or both, the formation of zinc oxide on the blasted carbonate. The surface preparation that is needed is a power
surface will begin very quickly so the paint coating should be wash with warm water to remove loose particles from the
applied within 30 min after sweep blasting. Zinc oxide forma- surface. The power wash should use water jets with a pressure
tion is not visible to the naked eye; therefore, in any of less than 10 MPa (1450 psi) so as not to damage the
atmosphere, painting should be as soon as possible after protective film. This film is naturally roughened in its growth
surface preparation. process, so no extra surface profiling is needed. Allow the
6.2 Before preparing the surface of partially weathered surface to completely dry before application of the paint
galvanized steel, the surface must be checked for the presence system.
of wet storage stain. Wet storage stain is the whitish zinc 7.3 Fully-weathered galvanized steel can be painted suc-
corrosion product formed when galvanized parts are exposed to cessfully with the application of appropriate paint systems
moist air without sufficient air circulation between the parts including primers and top coat paints. The use of
and is described in the American Galvanizers Association pretreatments, such as those described in 5.4, can enhance
Publication, Wet Storage Stain.5 Wet storage stain consists paint adhesion and extend long term performance.
primarily of beta zinc hydroxide and small percentages of zinc
oxide and zinc carbonate. Since wet storage stain is hygro- 8. Keywords
scopic and has a larger volume than zinc metal, paint adhesion 8.1 galvanized steel; galvanizing; hot-dipped galvanizing;
can be affected seriously when painting over wet storage stain. painting; paint preparation; surfacing preparation; zinc coating

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 D6386 − 16a
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 X1.3.2 Abrading the surfaces by sanding, or
steel is a hexavalent chromium solution. This treatment pre- X1.3.3 Sweep blast clean in accordance with 5.4.1.
vents adhesion of many paint coatings to zinc coated steel
surfaces. X1.4 The presence of hexavalent chromium on galvanized
surfaces can be determined by spot testing used Practice B201
X1.2 If zinc-coated steel to be painted is galvanized to
or D6492.
order, the order should prohibit the use of hexavalent chro-
mium humid-storage strain treatments. X1.5 Conduct the spot test on several representative spots
X1.3 Hexavalent chromium treatment can be removed from on each individual piece of galvanized steel.
galvanized surfaces by one of the following three methods: X1.6 Test, in accordance with Practice B201 or D6492,
X1.3.1 Weathering the surfaces for six months, or 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 (D6386–16)
that may impact the use of this standard. (Approved June 15, 2016.)

(1) Revisions were made throughout the standard.

Committee D01 has identified the location of selected changes to this standard since the last issue (D6386–10)
that may impact the use of this standard. (Approved May 1, 2016.)

(1) Sections 5.2 and 5.2.1 were revised.

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