Designation: A 780/A 780M – 09

Standard Practice for

Repair of Damaged and Uncoated Areas of Hot-Dip
Galvanized Coatings1
This standard is issued under the fixed designation A 780/A 780M; 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* 2. Referenced Documents

1.1 This practice describes methods that may be used to 2.1 ASTM Standards:2
repair damaged hot-dip galvanized coatings on hardware, A 902 Terminology Relating to Metallic Coated Steel Prod-
structural shapes, and other products fabricated prior to hot-dip ucts
galvanizing, and uncoated areas remaining after initial hot-dip D 520 Specification for Zinc Dust Pigment
galvanizing. The damage may be the result of welding or 2.2 Society for Protective Coatings (SSPC) Documents:3
cutting (flame), in which case the coating will be damaged SSPC-PA2 Measurement of Dry Paint Thickness with Mag-
predominantly by burning. This practice can also be used to netic Gages
repair hot-dip galvanized coatings damaged by excessively SSPC-SP2 Hand Tool Cleaning
rough handling during shipping or erection. Requirements SSPC-SP5/NACE No.1 White Metal Blast Cleaning
concerning the renovation of uncoated areas remaining after SSPC-SP10/NACE No.2 Near-White Blast Cleaning
initial hot-dip galvanizing are contained within the applicable SSPC-SP11 Power Tool Cleaning to Bare Metal
material specification.
1.2 This practice describes the use of low melting point zinc 3. Terminology
alloy repair rods or powders made specifically for this purpose, 3.1 Definitions—For definitions of terms used in this
the use of paints containing zinc dust, and the use of sprayed practice, refer to Terminology A 902.
zinc (metallizing).
1.3 The extent of repair shall be limited to an area mutually 4. Materials
agreeable to the contracting parties. Similarly, contracting 4.1 Properties—The material used for repairs shall have the
parties shall agree to the repair method to be used. following characteristics:
1.4 This specification is applicable to orders in either 4.1.1 One application of the material shall provide a coating
inch-pound units (as A 780) or in SI units (as A 780M). thickness of at least 2.0 mils (50.8 µm).
Inch-pound units and SI units are not necessarily exact 4.1.2 The applied coating shall provide barrier protection
equivalents. Within the text of this specification and where and shall preferably be anodic to steel.
appropriate, SI units are shown in brackets. Each system shall 4.1.3 Application of the coating material shall be possible
be used independently of the other without combining values in under shop or field conditions.
any way. 4.2 Types—There are three types of material that possess
1.5 This standard does not purport to address the safety the required properties and may be used to repair damaged
problems, if any, associated with its use. It is the responsibility galvanized coatings, as follows:
of the user of this standard to establish appropriate safety and
health practices and determine the applicability of regulatory
limitations prior to use.

2
For referenced ASTM standards, visit the ASTM website, www.astm.org, or
1
This practice is under the jurisdiction of ASTM Committee A05 on Metallic- contact ASTM Customer Service at service@astm.org. For Annual Book of ASTM
Coated Iron and Steel Products and is the direct responsibility of Subcommittee Standards volume information, refer to the standard’s Document Summary page on
A05.13 on Structural Shapes and Hardware Specifications. the ASTM website.
3
Current edition approved May 1, 2009. Published May 2009. Originally Available from Society for Protective Coatings (SSPC), 40 24th St., 6th Floor,
approved in 1980. Last previous edition approved in 2006 as A 780 – 01(2006). Pittsburgh, PA 15222-4656, http://www.sspc.org.

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

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 A 780/A 780M – 09
4.2.1 Zinc-Based Solders—Zinc alloy solders are to be used used shall be selected by the galvanizer, unless the purchaser
for repairs. The most common types of solders are zinc- specifies a particular concentration or paint system. Corrosion
cadmium, zinc-tin-lead, and zinc-tin-copper alloys. Zinc- resistance and service performance are very dependent on the
cadmium and zinc-tin-lead alloys have liquidus temperatures in properties of the paint system, the extent of surface prepara-
the ranges from 518 to 527°F (270 to 275°C) and 446 to 500°F tion, and skills of individual applicators. Annex A2 describes
(230 to 260°C), respectively. (The liquidus temperature is that the use of paints containing zinc dust. Specification D 520
temperature above which an alloy is completely molten.) The describes the zinc dust component of these paints.
zinc-tin-copper alloys have a liquidus temperature in the range 4.2.3 Sprayed Zinc—This method involves the application
from 660 to 670°F (349 to 354°C), but they are applied while of a zinc coating by spraying the surface to be repaired with
in a semisolid state in the preferred application temperature droplets of molten metal using wire or ribbon, or powder
range from 480 to 570°F (250 to 300°C). The solders can be processes. Annex A3 describes the use of sprayed zinc.
used in rod form or as powders. Annex A1 describes the use of
4.3 For further information, reference may be made to the
zinc-based solders.
papers, procedures, and specifications in Refs. (1) through (4)
4.2.2 Paints Containing Zinc Dust—These are usually
(see list of references at the end of this practice).
based on organic binders, pre-mixed and formulated specifi-
cally for use on steel surfaces. Paints containing zinc dust, with
5. Keywords
concentrations of zinc dust in the range of 65 to 69 % or above
92 % in the dried film, are considered equally effective for the 5.1 coatings—zinc; galvanized coating repair; galvanized
repair of damaged galvanized coatings. The repair paint to be coatings; touch-up; zinc coating repair; zinc coatings

ANNEXES

(Mandatory Information)

A1. REPAIR USING ZINC-BASED ALLOYS

A1.1 Clean the surface to be reconditioned using a wire burned. Wire brush the surface to be reconditioned during
brush, a light grinding action, or mild blasting. To ensure that preheating. Pre-flux, if necessary.
a smooth reconditioned coating can be effected, surface prepa-
ration shall extend into the surrounding, undamaged galva- A1.4 Rub the cleaned, preheated area with the repair stick
nized coating. to deposit an evenly distributed layer of the zinc alloy. When
powdered zinc alloys are used, sprinkle the powder on the
A1.2 If the area to be reconditioned includes welds, first cleaned, preheated surface and spread out with a spatula or
remove all weld flux residue and weld spatter (of a size that similar tool. The thickness of the applied coating shall be as
cannot be removed by wire brushing or blast cleaning) by agreed upon between the contracting parties.
mechanical means, such as chipping, grinding, or power A1.5 When the repair has been effected, remove flux
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scaling, etc. residue by rinsing with water or wiping with a damp cloth.
A1.3 Preheat the cleaned area to be reconditioned to at least A1.6 Take thickness measurements with either a magnetic,
600°F (315°C). Do not overheat the surface beyond 750°F electromagnetic, or eddy-current gage to ensure that the
(400°C), nor allow the surrounding galvanized coating to be applied coating is as specified.

A2. REPAIR USING PAINTS CONTAINING ZINC DUST

A2.1 Preparation of the damaged surface will be influenced A2.1.2 Where anticipated, field service conditions include
by the type of paint selected and the anticipated service immersion, blast clean the surface in accordance with SSPC-
conditions. Experience shows that in general, organic zinc-rich SP10/NACE No. 2 near white metal. For less critical field
systems are tolerant of marginal surface preparation. Most exposure conditions, clean the surface to bare metal, in
organic paints containing zinc dust are not critical of climatic accordance with SSPC-SP11, as a minimum. Where circum-
or atmospheric conditions for curing. The following general stances do not allow blast or power tool cleaning, it is
guidelines shall apply: permissible to hand tool areas clean in accordance with
A2.1.1 Surfaces to be reconditioned with paints containing SSPC-SP2. To ensure that a smooth reconditioned coating can
zinc dust shall be clean, dry, and free of oil, grease, preexisting
paint, and corrosion by-products.

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 A 780/A 780M – 09
be effected, surface preparation shall extend into the undam- manufacturer’s printed instructions in a single application
aged galvanized coating. The method and extent of surface employing multiple passes to achieve a dry film thickness to be
preparation shall be mutually agreeable to the contracting agreed upon between the contracting parties. Allow adequate
parties. curing time before subjecting repaired items to service condi-
A2.1.3 If the area to be reconditioned includes welds, first tions in accordance with the manufacturer’s printed instruc-
remove all weld flux residue and weld spatter (of a size that tions.
cannot be removed by wire brushing or blast cleaning) by A2.1.5 Take thickness measurements with either a mag-
mechanical means, such as chipping, grinding, or power
netic, electromagnetic, or eddy-current gage to ensure that the
scaling, etc.
applied coating is as specified in accordance with SSPC-PA2.
A2.1.4 Spray or brush-apply the paints containing zinc dust
to the prepared area. Apply the paint as in accordance with the

A3. REPAIR USING SPRAYED ZINC (METALLIZING)

A3.1 Surfaces to be reconditioned by zinc metallizing shall means of metal-spraying pistols fed with either zinc wire or
be clean, dry and free of oil, grease, and corrosion products. zinc powder. Apply the sprayed coating as soon as possible
after surface preparation and before visible deterioration of the
A3.2 If the area to be reconditioned includes welds, first surface has occurred.
remove all flux residue and weld spatter of a size or type that
cannot be removed by blast cleaning by mechanical means, A3.6 The surface of the sprayed coating shall be of uniform
that is, chipping, etc. texture, free of lumps, coarse areas, and loosely adherent
particles.
A3.3 Blast clean the surface to be reconditioned in accor-
dance with SSPC-SP5/NACE No. 1, white metal. A3.7 The nominal thickness of the sprayed zinc coating
shall be previously agreed upon between the contracting
A3.4 To ensure that a smooth reconditioned coating can be parties.
effected, surface preparation shall be extended into the sur-
rounding undamaged galvanized coating. A3.8 Take thickness measurements with either a magnetic,
electromagnetic, or eddy-current gage to ensure that the
A3.5 Apply the coating to the clean and dry surface by applied coating is as specified.

REFERENCES

(1) Van Eijnsbergen, J. F. H., et al, “Reconditioning Damaged Galvanized (3) MIL-P-21035 (Ships), Military Specification,“ Paint, High Zinc Dust
Surfaces,’’ 6th International Conference on Hot Dip Galvanizing, Content, Galvanizing Repair,’’ Amendment 1, U.S. Government
Interlaken, June 1961, pp. 128–141. Printing Office, Washington, DC, 1970.
(2) SSPC-Paint-20,“ Zinc Rich Coatings, Type I Inorganic, Type II (4) “Recommended Practices for Fused Thermal Sprayed Deposits,’’
Organic,’’ Steel Structures Painting Council, 4400 Fifth Ave., Pitts- American Welding Society, Inc., 550 N.W. LeJeune Rd., Miami, FL
burgh, PA 15213, 1979. 33135, 1975.

SUMMARY OF CHANGES

Committee A05 has identified the location of selected changes to this standard since the last issue
(A 780 – 01(2006)) that may impact the use of this standard. (May 1, 2009)
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(1) Revised 1.4 and changed designation to make standard

applicable in both units.

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 A 780/A 780M – 09
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