IS : 2633 - 1986 (Reaffirmed 2006 ) Indian Standard METHOD FOR TESTING UNIFORMITY OF COATING ON ZINC COATED ARTICLES ( Second Revision ) ‘Thitd Reprint MARCH 1997 UDC 669.58:669.1-4:620.163 © Copyright 1987 BUREAU OF INDIAN STANDARDS MANAK BHAVAN, 9 RAHADUR SHAH ZAFAR MARG. NEW DELHI 110002IN: 2641 - tON0 Ceeatta wet 2979) Indian Standard METHOD FOR TESTING UNIFORMITY OF COATING ON ZINC COATED ARTICLES ( Second Revision ) Hot-Dip Sprayed and Diffusion Coatings Sectional Committee, SMDC 28 Chairman Representing Siri V, P. SUBRAMANIAN Indian Hot Dip Galvanizers' Association, New Detht Members Sint V. K, AGRaawat, Hindustan Aluminiuin Corporation Lid, Renubewe UNG. Santa ( Alternate y Sia PK, BaNeRee ‘National Thermal Power Corporation Lisl, New Delt Sunt JN, Buarracuanyyn National Test House, Caleutta Suni_M. Y. Boneee Ministry of Defence { DGL) ‘Sint A. DHAFTACHARYA ( Alleriate ), Dr A. Ciuorraoiry Usha Martin Industries Ltd, Ranchi Fy Of Railways Chemist de Merautunoise ‘Astisrant Chemise &¢ Meta. uuroisr ( Alternate ) ‘Chune Excinern (TransMisSion ) Gujarat Flectricity Boned, Vadodara TExecunive ENGINEER { sllternate) SaardeC ERey Steel Authority of India Lid ( Rokaro Steet Phat Wokato Steel City, Snat_G. Gaxesuane Kamani Engineering Corporation (1, Womb ‘Swat BG. Sonowt Alternate ) ‘Suey BRULAL Kwastasva ‘sect Authority of India Ltd (Rourkela Steel Rourkela nt), Suni 3.1N. Buawony ( Alternaze ) Sua MEM, L. Kitttar “The Tinplate Co of India Ltd, Golmu ‘Sunt PC, BaNraiee ( Alternate Jarashedput Sw fisran Cavite Mastasan ‘The India Ststand Wite Products Ld, Jamshedpur ‘Suri Darstan Sinan ( Alternate ) ee (Continued on page 2) © Copyright 1987 BUREAU OF INDIAN STANDARDS, This publication ig protected under the Hillam Copyright Act (XIV of 1957 ) and. feproduetion in whole or i pare by any means exden with Menten permansion ot | the publisher shall be deemed to be aa infringement of copyright under the said Act.633 - 1986 i (Continued from page \y Members Representing | Du M.D, Manesnwarey “The Indian Tube Co Lid, Jamshedpur Suni R Navamasan ( Alternate) \ Suui’S) Mavupan Tirectorsie Generel of Technical Development, New Dethi Sue PG. Mukoenave Indian Posts & Telegraphs Department, Calcutta Du. Muknensce ‘The Tats Iron & Steel Co Ltd, Janishedpor Sint BUN SSiscH ( tleemate } Sim 8, NEBLAKANTAN Zenith Steet Pipes Ltd, Bombay Dic A, RL KESEAR ( lUrermte J Suet D. Bai Guest, Keen, Williams Ltd, Caleutta ‘Shutt L PUgazHeNriy India Lead, Zinc Information Centte, New Dethi Suni S. N.'Sixoie EMC Steelal Led, Caicutta Suits Prsaer Coiosu ( Alternate) Stat NK, Singiiat, “The Indian fron and Steel Co Lid, Ruenpur A SiNGUeTA ( Alternate ‘Sones Special Steel Limited, Bombay nM. Decron (alternate Raanaveronasy Birgetor General, BIS ( Ex-officto Member ) Diseewe (‘Struc & Mel) . Secretary Suri S. K, Gurra Deputy Director ( Metals ), BIS Hot-Dip Galvanizing Subcommittee, SMDC 28:1 Convener Suna VR. Suanawantans Indian Hot Dip Galvanizers* Association, New Delhi Members Sunt L, Pucaziewrny ( Altemate to Shar Spent Hope's Weal Windows (india) Lidy Cauita Sir Some ¢ dtemare) e Dinicron (Teaweaston ral Elect ‘Steen Bintcron | Peans- femon ) ( llternate } Shai. R. Subramanian i Suny Sr A EMC Stel Le, Calta i Shs SSS cate gia He Bact") 0) Designs Dieetorats, Chardin ° ty Authority, New Delhi Sner . Burra. ‘The Indian Tube Co Ltd, Jamshedpur Si A. K-Gona The Fort Willam Co Ltd, Calcutta Sire S: Kustan ( Alternate ) Jom Dinteron ( Cie) Ministry of Railways orst Dincerox (11}-1 ( Alteruaze ) { Continued on page 10)£2643 - 19R6 Indian Standard i METHOD FOR TESTING UNIFORMITY OF COATING ON ZINC COATED ARTICLES ( Second Revision ) L 0 FOREWORD « .4 This Indian Standard (Second Revision) was tdopted by the Indian Standards Institution on 26 September 1986, after the deaft Anslized. by the Hot-Dip Sprayed and Diffusion Coatings Sectional Ca . ‘been approved by the Structural and Metals Division Council. | 0.2 This test known as ‘Preece Test” is designed as an inspection or : acceptance test for determining the thinnest spot in a zinc couting ( hot. } : dipped, electroplated, sherardized or sprayed) on iron or steel articles Shieh | are coated after the shape is produced. “This standard was first published in 1964 and subsequently revised in 1972. In this revision, more detaiy have been incorporated about preparation of samples md testatg procedure for determining the uniformity of zinc comings, In ndditios Sualitative tests for all types of zine coatings have also been incorporated 0.3 Preece test is designed for newly coated items. In ease off ayed or weathered zinc coated items, the method given in Appendix A may tke used Preece test should not be used for determining mass of vine coatings as | these are produced by different processes and have widely different rates of solubility in copper sulphate solution. Electroplated and. sprayed. vine coatings (see IS: 1573-1986* and 18:5905-1970} respwetively) which @o ° consist essentially of pare zinc, dissolve rapidly than hot-dinped contin Which are composed of zine iron alloy layer next to stecl, and newrly pure zine layer in the outer part of the coating, 0.4 The rate of reaction increases with increase in tempernture. It has iat tints es of cue ftan th tet |, ee “Electroplated coatings of zine on iron and ste! ( second revision . Sprayed aluminium and zine coatings on iron and sted, 3i 1S : 2633 - 1986 0.5 This test is suitable for the following articles. 0.5.1 Sheet, wire, tube, bolts, nuts and other threaded articles of similar sive 0.5.2 Articles fabricated from strip, bar or tube up to a length of one metre and not exceeding 75 mm in width or 50 mm in diameter. 0.5.3 Castings, angle brackets and structural shapes with an overall size of not more then 200° x 150 x 100 mm of approximate mass not more then 4 kg coated after fabrication, 0.5.4 Atticles having dimensions greater than those specified in 0.5.2 and 0.5.3 shall be subjected to visual inspection only as laid down under 0.5.8. 0.5.5 Samples of such articles, after galvanizing, shall be stored for at least one week under cover, but with ail surfaces as far as possible, exposed to free movement of air. The zinc coating as seen by visual inspection at the end of this period after storage shall be clean, smooth, continuous and free from acid spots. 0.6 In the preparation of this standard, assistance has been derived from the following publications: BS:729-1971 Hot dip galvanized coatings on iron and steel tubes. British Standards Institution. ASTM.A-239-1973 Locating the thinnest-spot in a zinc (galvanized) coating on iron and steel articles by the Preece test (copper sulphate dip). American Society for Testing and Materials, ‘JIS H: 0401-1983 Method of test for hot dip galvanized coatings. Japanese Industrial Standards Committee. 0.7 For the purpose of deciding whether a particular requirement of this standard is complied with, the final value, observed or calculated, express- ing the result of a test or analysis, shall be rounded off in accordance with IS:2-1960*. The aumber of significant places retained in the rounded of value should be the same as that of the specified value in this standard. 1, SCOPE LA This standard covers the procedure for determining uniformity of zinc coating (hot-dipped, electroplated, sherardized or sprayed) on iron or steel articles. "Rules for rounding off numerical values (revised ) 4IS: 2048-1986 2. SAMPLING AND PREPARATION OF TEST PIECES. 2.1, Sampling —The number of samples to be tested shall be nn sprcitied in material specification, In the absence of such a ntundud, the degree of santpling shall be as agreed to between the galvinizer nnd the purclnser 2.2-Preparation of Test Pieces 2.241 Sheet — A test piece of 100 x 100 mm salt be cut off from a sheet selected as per material specification. 2.22 Wire—The sample length of the wire shall be vat from one or both ‘ends of the coil under test. Portions of wire whiclt aro obviously damaged shall not be used as sample. In caso of strands or armoured wire, or wire which has undergone any other similar process, oare should be taken to avoid damage in preparing the sample, A Aniniplo of suituble Jength but not less than 150 mm, shall be cut from ous of both ends of the selected coil 2.2.3 Articles Other Than Sheets and Wires-— ‘Vest xjlinens shall be selected from the material galvanized but if the material ly af {uconvenient length, shorter pieces of the same section and of tlie amo 4tgdl composi tion, not less than 90 em long, may be introduced us text apoelinons. 2.2.3.1 All test specimens shall be treated in the same wintiner, in the same bath and at the same time as the material whose coating churacteris- tics they are intended to represent. Note — The sample selected for test shall bo such that It ese frvin abuasions or ‘cuts in the zine costings except those which occur iting snanfnetie t« preysration ‘of sample fr testing. ‘Where the area of uncoated surface may maritl) deplete the ‘srength of copper sulphate solution, precautions muy he take Mich fe pigs for tubule’ mated oF Mequer,paraiBa Or -otber sultile sont fo 2.3 Cleaning of Sample 2.3.4 The test piece shall be cleaned with a volatile orgapio solvent such. as ether, trichloroethylene, carbon tetrachloride, etc, und thon rinsed. with alcohol ‘and finally washed thoroughly with clean ‘water and. wiped dry with clean cotton cloth. Lacquer or varnish coatiugs shill bo removed with a suitable clean volatile organic solvent which will not attuck the zinc coating or leave a greasy or waxy deposit. Test pieces shall be brought to a temperature of 15 to 20°C prior to the beginning of the tent. 2.3.2 Abnormal cases may arise when, by reason of ususual surface conditions, the copper sulphate solution may not act normally on the zinc coating, for exemple, the solution may have no apparcut attack on all or part of the surface, ot false deposits of copper may appear on the zinc Coating. If there is any such abnormality of performance of test pieces, 5 !1S : 2633 - 1986 they shall be discarded and new ones selected. The new test pieces shall be cleaned in alcohol, rinsed and wiped dry, and then immersed for 3 minutes in a solution consisting of one part by volume of ammonium hydroxide (sp gr 0-90) and nine parts of distilled water. The test pieces muy be secubbed with cotton cloth during this immersion. After cleaning, the test pieces shall be washed and wiped dry. 3. COPPER SULPHATE SOLUTION 3. Preparation ) Dissolve about 36 g of technical grade copper sulphate crystals conforming to IS :261-1982* in 100 ml of distilled water (see Note). ‘Heat the water to aid solution, but if heated, the solution should be cooled before neutralizing. b) Neutralize the free sulphuric acid’ in solution by shaking with ‘excess of copper carbonate (laboratory grade) or copper hydroxide laboratory grade), (about 1 g/l of solution) and allow to stand for at least 24 hours before filtering or decanting the solution from the sediment. ¢) The specific gravity of the test solution during the test shall be 1-186 at 18 + 2°C. Adjustment may be made by adding distilled water or solution of higher specific gravity, Noxs -- Chemically pure copper sulphate erystals are preferable to. commercial ‘grade, although not necessary for this test, 32 Volume of Solution 3.2.1 Wire — Test pieces of wire shall be tested in a glass container of at Jeast 50 mm inside diameter for 2-00 mm wires and smaller and with at least 75 mm inside diameter for wires of more than 2-00 mm in diameter. ‘The container shall be filled with fresh test solution to a depth of at least 190 mm. This quantity of solution shall be used for simultaneous testing of one to seven test pieces." The solution shall be discarded after comple tion of the test and fresh solution used for any additional tests. 3.2.2 For Articles Other Than Wires The volume of the solution shall be sufficient to immerse the test pieces completely and shall not be less than 6 mifem? of surface area of test piece. 4 Femporatare of Solution —The temperature of solution shall not jary beyond the limits of 18 + 2°C, either at the commencement of the test or through the duration of the test. ©"‘*Specitication for copper sulphate ( second revision ) 61S: 2633-1986 4, PROCEDURE “ka The clean test pices, shall be subjected to 6 NUNN tninute and Aad The ote successive dips as preseribed if, the tm standard, ia atte sulphate soltion (see 3) Kept at a ten perth ar TR 1 28C, Half core ie hall be carried out after completion ‘of all the one-minute Tips Jf possible, immerse the test pieces Completely, taking cave that they dis. #1 Pech each other. During the test, neither (e Test pieces. nor the do mol rofalt be agitated. After each dip, within the text pieces, rinse solution fey in glean ronning water (see. Note |) Remove any” black igposit including holes and pockets by & suitable briish (see Note 2). Wipe deposit ntact pieces with @ clean soft clot and rete immediately to solution. 4.1.1 Successive dips of one-minute ceach shall be continued, with wash- sng'ana wiping o the test pieces after etch ap, unite Ce pieces have withstood the sot fred number of dips or until tho end point hs been, reached. Nove 1 =f no running_ water, svallble, the cave, With 0H, hanged ot etdabagnt preferably aver ch i, 60 cosas at Feusonably free [rom oe ee Te temperature ofthe rinse water shoul ie Ww DWE Tose 2 Brish conforuing to TS:11041984¥ my be wis Gor Ie purnons 4.2 Interpretation of Test “aga The material passes this test if at the el of the speciticd number of gps, when the test pices is finally rinsed ant ‘wiped day.Sit does not of is, qangrent red. deposit of copper upon {he Dir Ss In ease of show any (cg deposit of copper within 25 mm of the cil af the sample eee aot be interpreted as a failure of the sample, “daa A fine line appearance of copper on {0M ef sero tveads, or on shay edges of articles, or within 25 mm oF ott portion of & specimen, Se eobe judaed as failure. Likewise, the Tait ‘of a coating at OF slyjucent 10 aay cut or abrasion present on the original test piece shall not be considered as a failure. 423 Detection of Flase End Polnt— 1C it i (usin the pth Pcapper deposit with an ink erager oF 10 Peet with the edge of a bright eoPeet ras the back of a Knife blade, and zine AUT fonderneath Sstont tool tn an appearance of deposited copper stall Pe cconsirued a8 false end point, 5, NUMBER OF DIPS ay Wire — The sample, ov samples shall bo subjected ta sre number 5.1 Wace ips of exactly onenminate or exactly hnifmvinute duration 28 “Specification shes, lettering (second revision) 72633 - 1986 proscribed in 18:4826-1979* or any other relevant Indian Standard specification, ‘The haif-minute dips shall be carried out after the completion of all the one-minute dips, 5:2 Other Articles — Unless otherwise specified, the sample shall be subjected to four successive dips in the solution, each lasting one minute. 6, SUPPLEMENTARY TESTS 6.0 If at any time during the test, there is any doubt as to the presence of exposed base metal, as determined by visual inspection, one or more of the tests given in 6.1 of 6.2 may be used, 6.1 Supplementary Tests for All Types of Zine Coatings 6.1.1 Microscopic Test — Section the test piece through the copper deposit, mount and polish it metallographically. Etch the polished surface using an etching solution composed: of 20g of chromic acid, 1°5g of sodium sulphate and 100 ml of distilled water. After etching, wash the test piece with alcohol. Examine the etched test piece under a microscope, using a magnification of 100 diameters, or greater if necessary. Look for the exposed base metal. : 6.1.2. Qualitative Test for Zine — Apply a drop (or several drops) of dilute hydrochloric acid (1:1) to the area in question (depending on its size). The presence of zinc is indicated by immediate vigorous ellerves. cence (evolution of hydrogen). If no appreciable zine is present, the effervescence will be mild, By carefully removing the acid, a confirmatory test for zine may be made as follows. 6.1.2.1 Neutralize the acid with ammonium hydroxide, acidify with acetic acid and pass hydrogen sulphide into the solution, a white precipitate (zine sulphide ) confirms the presence of zinc. 6.2 Supplementary Test for Electroplated, Sherardized and Sprayed Zinc Coatings 62.1 Water Immersion Test— Pattially immerse the test_ pieces in distilled water at room temperature. Failure of the coatings is indicated by the appearance of iron rust spots in a few hours to several days, ‘This test may be made on material as received, or to substantiate the Preece (est at any stage. for galvanized coatings on round steel wires ( first revision ). 81986, APPENDIX A (Clause 0.3) APPLICATION OF PREECE TEST TO WEATHERED * GALVANIZED WARE Ac, Preece test is not applicable to aged or weathered materia! hecause of the corrosion film present on zine coating. IFitis desired to use the Precee {est on such material, the corrosion fim should be removed before testing, by immersing the test pieces ia an ammonium hydroxide solution [1 past by volume of ammonium hydroxide (sp gr 090} to9 parts by volume of sitled water , rinsing them in clean Water and wiping them dey.WW nme VC aationat pee page 2 Meter Representing A Vitay baron ers, Keon, Wiliams Hd, Howrah niet “The inion Slee! & Wire Products Ltd, Jamshedpur bins Avram isc ¢dternate sn th Nnatsia. cel Authority of India Ltd (Rourkela Steet Plant), Rourke uni tN Sins ( Alternace) sua he Mlgqatian Directorate General of Technical Development, New Delhi Devivovsuni Orricen GAME) Allene) sh Aleit General Enginsering Works, Bharatpur, Rajasthan niente Posts & Tekegraphs Department, Calcutta ny, NT Ctra) Mya Tata Iron & Steel Co Ltd, Jamshedpur aya Zenith Steel Pipes Lia, Bombay sat Alternate ) ani Kamnani Engineering Corporation Lie, Bombay sina Me in ‘The Indian tron a Steet Co Ltd, Buinpur Sin be les Special Stee! Ltd, Bombay in bocron ( Atternate ) sun ‘ANA Biase General of Supplies & Disposals, New ih Skt és WGuria¢ Alternate ) 0| | BUREAU OF INDIAN STANDARDS Hoadquarters: Manak Bhavan, 9 Bahadur Shah Zafar Mag, NEW DELHI 110002 ‘Telephones: 323 0131, 323 3375, 323 9402 Fax: St 11 9234082, 81 11 3239509, $1 11 soseae2 ‘Telegrams : Manaksanstha (Commen w a Of) Contra! Laboratory phone. Plot No. 20/, Site IV, Sahibabad Indusbial Area, Sahibabad 201010 8:77 0032 Regional Offices: Cental: Manak Bhavan, 9 Bahadur Shah Zafar Marg, NEW DELHI 110002 3237817 ‘*Eastem 1/14 CIT Scheme Vii M, VP. Road, Maniftola, CALCUTTA 700054 337 88 62 Norther : SCO 335-936, Sector 34-A, CHANDIGARH 180022 6038 43 ‘Souther :C.L.T. 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