Technical note
Why 96% Zinc in the Dry Film Matters in a Cold Galvanizing Compound
The key scientific issue is electrical percolation. Zinc particles must form a conductive network to the steel for sustained cathodic protection.
Evidence-based corrosion guidance
Read with the current GalvoKote TDS and project specification.
Zinc-rich coatings protect steel most effectively when metallic zinc particles are electrically connected to each other and the substrate. That network is often described through the idea of an electrical percolation threshold.
Research shows a strong zinc-content effect
A 2023 ACS Omega study comparing zinc-rich epoxy coatings at 85, 75 and 65 wt% zinc dust found the 85 wt% system delivered superior cathodic protection, while the 65 wt% system did not provide effective cathodic protection in that formulation. The exact threshold changes with particle shape, binder and additives, but the direction is clear.
Controlled GalvoKote specification
The controlled GalvoKote specification lists 96% zinc by weight in the dry film. This high loading supports a formulation designed around galvanic action rather than treating zinc only as a colouring or barrier pigment.
High zinc is not enough by itself
Even a high-zinc product can fail if it is applied over old paint, oil, salts or heavy rust, because the electrical contact pathway is interrupted. Correct DFT and agitation are equally important.
Related pages
Primary product
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