When a customer tells us that cold galvanizing "didn't work," we almost always find the cause in the application, not in the product. The good news is that these mistakes are easy to avoid.
1. Not preparing the surface
The zinc must touch the steel to protect it. If you apply it over loose rust, old paint, or grease, there will be no contact and the coating will peel off. Solution: brush or sand down to sound metal and degrease with xylene. More details in our surface preparation guide.
2. Not mixing the product properly
Zinc is very heavy and settles at the bottom of the container. If you don't mix it, you'll apply solvent with very little zinc. Solution: mix thoroughly before starting and stir again every 20–30 minutes. With the spray, shake for at least 1 minute until you hear the ball rattling and shake again while working.
3. Thinning with the wrong solvent
GALVANOL should only be thinned with xylene, and only if necessary (for example, when using a spray gun, up to 15% by weight). Other solvents can damage the product.
4. Applying a single thick coat
A very thick coat takes a long time to dry and can sag and crack. Solution: apply several thin coats (about 40–60 µm each), allowing 30–60 minutes between them.
5. Applying a coat that is too thin
The other extreme: a single thin coat "just to see how it goes." The durability depends on the thickness. Solution: apply at least 2 coats, or 3 in marine or industrial environments. Use the calculator to make sure you don't use too little product.
6. Applying a coat that is too thick
More is not always better: above about 200 µm dry, microcracks may appear. With 3–4 normal coats, you'll have more than enough.
7. Painting over with the wrong paint or at the wrong time
If you want a finish, use solvent-based paints and wait at least 4–6 hours. We explain it in how to paint over GALVANOL.
Bonus: forgetting difficult areas
Welds, screws, and edges need a brush-applied primer coat before the general coat. If you want to start with everything you need, the GALVANOL 2 kg application kit includes paint, xylene, a roller, a brush, and sandpaper at a 10% discount.
Ready to protect your steel?
GALVANOL contains 96% zinc in the dry film, has been tested in an ENAC-accredited laboratory according to ISO 12944, and complies with ISO 1461 and ASTM A780. We manufacture it in Spain and ship it within 24–72 hours, free of charge to the mainland and Balearic Islands on orders over €50.
👉 GALVANOL 2 kg · GALVANOL Spray 500 ml · GALVANOL 2 kg application kit · calculator: How much GALVANOL do I need?
