Inorganic Zinc Silicate Primer | Understanding the Role of Zinc in Corrosion Protection

Inorganic Zinc Silicate Primer: Industrial Applications and Case Studies

Inorganic Zinc Silicate Primer is a long-term corrosion protector, generally made from polymer-based binders.These types of coatings contain a large amount of zinc metallic dust mixed with a binder.Since zinc performs in higher temperatures (Up to 400 deg.C.). It can be used as a single coat at a specific thickness on tanks such as some kind of chemicals tanks.

Here are the uses of Inorganic Zinc Silicate primer listed numerically

Marine industry: IZS primer is used to protect ships and offshore structures from the corrosive effects of saltwater.
Oil and gas industry: IZS primer is used to reduce the rate of corrosion in equipment and structures found in oil rigs and refineries.
Power generation industry: IZS primer is used to protect structures such as power plants, transmission towers, and wind turbines from the effects of corrosion.
Transportation industry: IZS primer is used to protect vehicles such as trains, trucks, and buses from the effects of corrosion caused by exposure to salt and other corrosive materials used to keep roads and highways free from ice and snow during the winter months.
Overall, IZS primer is a versatile and effective coating that is commonly used in various industries to protect structures and equipment from the damaging effects of corrosion.

Let’s take a case study in the case when the low dry film thickness is observed:

Inorganic Zinc Silicate Primer – Low DFT Observed

Let’s put this issue in the following manner, Inorganic Zinc Silicate primer low DFT was observed. The DFT achieved after paint application was 25 to 30 microns and the required DFT was 60 microns. Is this DFT acceptable and if not what precautions is one going to take?

Minor damaged areas or small areas having low DFT can be built up with Zinc Rich Epoxy. But DFT cannot be rebuilt for large areas. IOZ acts as a galvanic and barrier protection but is not an inhibition protector.

Reblast

Zinc-rich primers are not supposed to be over-coated with the same primer on the existing coating. The reason being it can lead to mud cracking. Hence, a mist coat of 15-20 microns shall be applied before applying the primer.

In this case, the only method acceptable is to re-blast the entire area affected area.

Can One Mix Organic -Zinc Rich Silicate by Thinning 30% to Build up Sufficient Thickness?

In one case this can be considered, provided the temperature is below 120 degrees C. Organic Zinc Rich Epoxy can be over-coated to build up the required thickness.

How Do Measure the WFT Thickness of Zinc Rich Coating?

As soon as the sprayer applies the coating it is recommended to check the wet film thickness (WFT). But the accuracy of WFT is questionable.

One cannot take proper WFT readings, hence the only option is to use a professional applicator to achieve the necessary results.

How Do Measure the DFT Thickness of Zinc Rich Coating?

The thickness of a zinc-rich coating can be measured using several methods, including:

Magnetic gauges: Magnetic gauges are commonly used to measure the thickness of zinc-rich coatings. These gauges use a magnet to measure the distance between the magnetic tip of the gauge and the substrate. The thickness is calculated based on the strength of the magnetic field measured.

Eddy current gauges: Eddy current gauges use an electrical current to measure the thickness of zinc-rich coatings. The gauge emits a magnetic field that induces an electrical current in the substrate. The thickness is calculated based on the change in electrical resistance measured.

Ultrasonic gauges: Ultrasonic gauges use sound waves to measure the thickness of zinc-rich coatings. The gauge emits a high-frequency sound wave that travels through the coating and reflects back from the substrate. The thickness is calculated based on the time taken for the sound wave to travel through the coating and reflect back.

Cross-section microscopy: Cross-section microscopy involves cutting a sample of the coating and substrate and examining it under a microscope. The thickness is calculated based on the thickness of the coating layer observed under the microscope.

It is important to note that the accuracy of the measurement depends on several factors, including the type of gauge used, the calibration of the gauge, and the preparation of the surface being measured. It is recommended to follow the manufacturer’s guidelines for the specific method and gauge being used to ensure accurate measurements.