Galvanite™: Repair Galvanizing Right with Lead-Free Galvanite™

Galvanite™ solder is a new Lead-Free formulation designed specifically for high quality repairs to galvanized Steel surfaces. Galvanite™ is simple, effective and easy to use, in both manufacturing and field applications. Just like the original galvanizing, Galvanite™ metallurgically bonds to the Steel, for a seamless protective barrier. Galvanite™ exceeds performance standards as specified by ASTM standard A780-92 for repair of galvanized coatings.

Benefits and Uses

Galvanite™ has been designed to accomplish three important objectives:

  • Provide excellent cathodic and barrier protection, far superior to Zinc paints and alternative Lead solders in abrasion resistance, adhesion and hardness
  • Allow easy application at low temperatures with any heat source
  • Produce a Lead-Free composition to address environmental and health concerns

Galvanized Surface Repair with Lead-free Galvanite™

Galvanite™ Instructions in PDF Format
  1. Pre-clean the parent metal. Use emery cloth, a wire brush, sandblasting, etc. Cleaning galvanized steel surfaces is often done with a stainless steel wire brush. To ensure a smooth surface result, surface preparation should extend into the surrounding undamaged galvanized coating. Breaking the oxide layer by agitation is an important key to successful Galvanite™ application.

  2. If the area to be repaired includes welds, all weld flux residue and weld spatter shall be removed by wire brush, chipping, grinding or power scaling.

  3. Use a soft flame, heat gun or soldering iron to heat the parent metal repair area to at least 600°F/315°C. Do not heat the surface over 750°F/400°C or allow the surrounding galvanized coating to burn. If you use a direct flame, please keep it moving. A direct flame held on the repair area is likely to overheat the solder. Wire brush the surface during heating. Pre-flux using Kapp CopperBond™ flux if there is an adhesion problem. NOTE: Most applications don't require flux.


  4. Hold the torch tip 4 to 6 inches away from the parent metal. If it is necessary to apply the flame directly to the rod to get it started, pull the torch tip back even farther from the work surface and keep it moving.

  5. Drag the rod over the area to be soldered, until it begins to flow. ONCE THE ROD FLOWS, STOP APPLYING THE HEAT! Deposit the desired thickness of Galvanite™. The stainless steel brush works well to spread the solder and ensure it is adhering. If additional layers are needed, continue to drag the rod over the area. Bring back the heat only to keep the Surface, NOT the Rod hot enough to push the solder around to where you want it.

  6. Sometimes it is necessary to heat the tip of the rod with the flame to help the solder flow more easily onto the repair area. DO NOT HEAT THE ROD TO THE MELTING POINT!

  7. Blend the repair into the undamaged galvanized coating. The most common oversight in repairing galvanized is failing to feather the Galvanite™ layer into the undamaged galvanized coating. If they don't join in sufficient thickness to form a seamless barrier (skin), corrosion will occur right where they meet.

  8. Observe the solder deposit. The solder should bond smoothly. DO NOT OVERHEAT!

    The solder rod will melt if overheated, but will not bond properly. Spread the solder deposit evenly over the repair area. A stainless steel brush works well for this step.

  9. If you stopped soldering and want to apply more solder or flow out the deposit more, let the area cool below the solid temperature of 390°F/200°C, and reheat. The existing Galvanite™ will help the bonding process, whether adding more solder or just flowing out the previous deposit. If substantial time has elapsed since the original Galvanite™ was applied, pre-clean the repair area again to remove any oxide coating that will impair bonding. Again, a Stainless Steel brush works well for this step.

  10. Smooth the repair area and remove any excess Galvanite™ with a wire brush.

  11. Repeat these steps to build up additional layers of Galvanite™ protection.

Hot Dip Galvanizers: Small defects in the surface of freshly galvanized Steel can be easily repaired with Galvanite™. Typically, residual heat is sufficient to melt and apply Galvanite™. The high Zinc content provides excellent cathodic protection and the repair blends and bonds with the original galvanizing.

Fabricators and Welders: In the shop and field, galvanized surfaces are often damaged by cuts and welds. Due to its moldable nature, Galvanite™ can be applied to a substantial thickness in almost any orientation. The solder penetrates deep into cracks and imperfections to provide a seamless protective barrier.

Physical Properties & Technical Data
Melting Range 390°F - 570°F / 200°C - 300°C
Tensile Strength 39,000 psi
Compression Strength 60,000 to 75,000 psi
Shear Strength 34,000 psi
Impact Strength (Charpy) 4 ft.lbs. to break 1/4" bar
Hardness (Brinell-500 kg. load) 100
Ductility Good
Density .25lbs./cu. in.
Elongation 3% in 2 inches
Linear Expansion Coefficient 15.4 x 106 / °F
Electrical Conductivity 24.9 (%IACS)
Thermal Conductivity .24 cal / cm3 / °C
Corrosion Penetration 300 x 106 in 1 1 / R
Flux Kapp Golden Flux
ASTM Specifications Exceeds A780-92