Session: Economics of Corrosion: Associated Direct and Indirect Costs
Expected Service Life and Cost Considerations for Metallic Zinc and Duplex Zinc Coatings (C2026-00067)
Thursday, March 19, 2026
10:30 AM - 11:00 AM Central
Location: 370 AB
Earn .5 PDH
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Designed to assist the coatings engineer or specifier with the selection of metallic zinc coatings for specific service environments across a broad array of applications, this paper will provide accurate and reliable information about the expected service life of hot dip galvanized, thermal spray zinc metallized and duplex zinc coatings. The durability of metallic zinc coatings for protecting steel from corrosion is directly related to the thickness of the coating. The uniform rate of corrosion allows long term performance of zinc coatings to be predicted for specific service environments. Duplex coatings will last even longer. The total life of a metallic zinc coating with a paint topcoat is greater than the sum of the lives of the zinc plus the paint. The benefit in service life is at least 1.5x longer than the sum of the life of the individual coating components. Yet there are still published coating durability guidelines that contain erroneous and misleading information about the expected longevity of metallic zinc and duplex zinc coatings. Established corrosion rates for zinc metal in specific service environments and documented performance of duplex coatings provide real and meaningful information about the expected service life of metallic zinc and duplex zinc coatings.
