BRITISH STANDARD BS EN

13858:2006

Corrosion protection
of metals —
Non-electrolytically
applied zinc flake
coatings on iron or steel
components

ICS 25.220.40

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BS EN 13858:2006

National foreword

This British Standard is the UK implementation of EN 13858:2006. It

supersedes BS EN 13858:2003 which is withdrawn.
The UK participation in its preparation was entrusted to Technical Committee
STI/33, Electrodeposited and related coatings.
A list of organizations represented on this committee can be obtained on
request to its secretary.
This publication does not purport to include all the necessary provisions of a
contract. Users are responsible for its correct application.
Compliance with a British Standard cannot confer immunity from
legal obligations.

This British Standard was Amendments/corrigenda issued since publication

published under the authority
of the Standards Policy and
Strategy Committee Date Comments
on 31 March 2008

© BSI 2008

ISBN 978 0 580 54308 1

EUROPEAN STANDARD EN 13858
NORME EUROPÉENNE
EUROPÄISCHE NORM November 2006

ICS 25.220.40 Supersedes EN 13858:2003

English Version

Corrosion protection of metals - Non-electrolytically applied zinc

flake coatings on iron or steel components

Protection des métaux contre la corrosion - Revêtements Korrosionsschutz von Metallen - Nicht elektrolytisch
non électrolytiques de lamelles de zinc sur des composants aufgebrachte schuppenförmige Zinküberzüge auf
en fer ou en acier Werkstücken aus Eisen oder Stahl

This European Standard was approved by CEN on 6 October 2006.

CEN members are bound to comply with the CEN/CENELEC Internal Regulations which stipulate the conditions for giving this European
Standard the status of a national standard without any alteration. Up-to-date lists and bibliographical references concerning such national
standards may be obtained on application to the Central Secretariat or to any CEN member.

This European Standard exists in three official versions (English, French, German). A version in any other language made by translation
under the responsibility of a CEN member into its own language and notified to the Central Secretariat has the same status as the official
versions.

CEN members are the national standards bodies of Austria, Belgium, Cyprus, Czech Republic, Denmark, Estonia, Finland, France,
Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway, Poland, Portugal, Romania,
Slovakia, Slovenia, Spain, Sweden, Switzerland and United Kingdom.

EUROPEAN COMMITTEE FOR STANDARDIZATION

COMITÉ EUROPÉEN DE NORMALISATION
EUROPÄISCHES KOMITEE FÜR NORMUNG

Management Centre: rue de Stassart, 36 B-1050 Brussels

© 2006 CEN All rights of exploitation in any form and by any means reserved Ref. No. EN 13858:2006: E
worldwide for CEN national Members.
EN 13858:2006 (E)

Contents Page

Foreword..............................................................................................................................................................3
Introduction .........................................................................................................................................................4
1 Scope ......................................................................................................................................................5
2 Normative references ............................................................................................................................5
3 Terms and definitions ...........................................................................................................................5
4 Information to be supplied by the purchaser to the processor ........................................................6
5 Designations ..........................................................................................................................................6
6 Requirements .........................................................................................................................................8
7 Sampling .................................................................................................................................................9
Annex A (informative) Additional information concerning coatings .........................................................10
Annex B (normative) Adhesion test methods...............................................................................................11
Annex C (normative) Sampling ......................................................................................................................12
Bibliography ......................................................................................................................................................13

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 EN 13858:2006 (E)

Foreword
This document (EN 13858:2006) has been prepared by Technical Committee CEN/TC 262 “Metallic and other
inorganic coatings”, the secretariat of which is held by BSI.

This European Standard shall be given the status of a national standard, either by publication of an identical
text or by endorsement, at the latest by May 2007, and conflicting national standards shall be withdrawn at the
latest by May 2007.

This document supersedes EN 13858:2003.

According to the CEN/CENELEC Internal Regulations, the national standards organizations of the following
countries are bound to implement this European Standard: Austria, Belgium, Cyprus, Czech Republic,
Denmark, Estonia, Finland, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania,
Luxembourg, Malta, Netherlands, Norway, Poland, Portugal, Romania, Slovakia, Slovenia, Spain, Sweden,
Switzerland and United Kingdom.

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EN 13858:2006 (E)

Introduction
The purpose of non-electrolytically applied zinc flake coatings, which may contain a small proportion of
aluminium flakes, is for corrosion protection of steel components. If needed, these coatings may also
incorporate an integral lubricant, for improving lubricity. Variations in colour or lubricity are obtained by
applying a suitable supplementary coating to zinc flake-based coatings.

The non-electrolytically applied zinc flake coatings for iron and steel components are obtained by cold
immersion or by pneumatic or electrostatic gun-spraying of the coating liquid, followed by curing. Coating
processes by cold immersion ensure complete coverage of components, even with complex shapes. These
coatings are not suitable for components that are used at temperatures higher than the curing temperature.

Mechanical cleaning methods of the metal surfaces are preferred for steels parts having a tensile strength of
1 000 MPa and greater (Rm ≥ 1 000 MPa) to avoid the risk of hydrogen embrittlement. If acid chemical
cleaning methods are used, stress relief heat treatment is required for high strength steels (Rm ≥ 1 000 MPa) if
they contain tensile stresses (see Clause 6.1.2).

Zinc protects steel by galvanic action, i.e. sacrificial action takes place to protect steel when it is in close
contact with the steel, and after weathering, zinc oxides are formed on the coating surface. These oxides are
voluminous and plug the pores in the coating to provide barrier protection. Apart from cathodic corrosion
protection, the zinc flakes also provide barrier properties due to the platelet structures.

Artificial atmosphere corrosion tests of these coatings can provide some measure of guidance for corrosion
protection. However, the duration and results of accelerated corrosion tests, such as the neutral salt spray test,
have no direct relation to the corrosion protection in other environments.

WARNING —This European Standard calls for the use of substances and/or procedures that may be
injurious to health if adequate safety measures are not taken. This European Standard does not
address any health hazards, safety matters or environmental conditions associated with its use. It is
the responsibility of the user of this European Standard to establish appropriate health and safety
practices and take suitable actions for any national and International regulations.

4
 EN 13858:2006 (E)

1 Scope
This European Standard specifies requirements for non-electrolytically applied coatings, composed mainly of
zinc flakes, for protection against corrosion of steel components, excluding threaded fasteners. These
coatings may also be provided with integral lubricant if needed.

NOTE 1 Requirements for threaded fasteners are given in EN ISO 10683.

The temperature and duration of curing the coating can influence the mechanical properties of components
because of their change of metallurgical conditions. These coatings should not be applied to components that
can be used at temperatures higher than the curing temperature, unless specifically ordered.

NOTE 2 If aluminium flakes, when added to zinc flake dispersion, form a continuous bond, a high risk of hydrogen
embrittlement for steels of tensile strength over 1 800 MPa may exist because of the sacrificial action of the coating during
corrosion reactions in storage and/or in service.

2 Normative references
The following referenced documents are indispensable for the application of this document. For dated
references, only the edition cited applies. For undated references, the latest edition of the referenced
document (including any amendments) applies.

EN 60454-2, Specifications for pressure-sensitive adhesive tapes for electrical purposes — Part 2: Methods of
test (IEC 60454-2:1994)

EN ISO 2064:2000, Metallic and other inorganic coatings — Definitions and conventions concerning the
measurement of thickness (ISO 2064:1996)

EN ISO 9227, Corrosion tests in artificial atmospheres — Salt spray tests (ISO 9227:2006)

EN ISO 16348:2003, Metallic and other inorganic coatings — Definitions and conventions concerning
appearance (ISO 16348:2003)

ISO 2859 (all parts), Sampling procedures and tables for inspection by attributes

ISO 4519, Electrodeposited metallic coatings and related finishes — Sampling procedures for inspection by
attributes

3 Terms and definitions

For the purposes of this European Standard, the terms and definitions given in EN ISO 2064:2000 and
EN ISO 16348:2003 apply.

5
EN 13858:2006 (E)

4 Information to be supplied by the purchaser to the processor

When ordering articles for non-electrolytically applied zinc flake coatings on iron or steel conforming to this
European Standard, the purchaser shall provide the following information in writing in the contract, purchase
order or in the engineering drawing:

a) number and date of this European Standard, i.e. EN 13858: 2006;

b) designation (see clause 5);

c) specification and metallurgical condition of the component (heat treatment, hardness and/or other
characteristics), which may be influenced by the coating process, and any process temperature limitation;

d) significant surface and the requirement of coating thickness on the significant surface, including the
coating of holes, recesses and presence of rack marks;

NOTE Requirements for coating thickness on the non-significant surface and the presence of uncoated areas can
also be specified (see 6.2.1);

e) requirement of dimensional tolerances including any excesses of coatings in complicated shapes of

components; these areas shall be agreed between supplier and purchaser;

f) tensile strength of the component and requirement of stress relief heat treatment;

g) requirements of the type of coating processes (see Annex A), type of coating (with aluminium flakes or
without aluminium flakes, see 6.1.3), coating thickness (see Table 1) and coating adhesion (see 6.2.3);

h) requirement of supplementary coating, e.g. sealants, lubricants, colours, etc. (see 6.2.4);

i) requirement of accelerated corrosion test (see clause 6.3);

j) requirement of any additional tests or performance tests for lubricated coatings whether using integral
coating lubricants, or lubricants applied after coatings;

k) sampling and inspection requirements (see clause 7).

5 Designations

5.1 General

The designation shall consist of the following:

a) term “non-electrolytically applied”;

b) number of this European Standard, EN 13858;

c) hyphen (-);

d) chemical symbol of the basis metal;

e) stroke (/);

f) symbols for the zinc flake coating and the method of application (see 5.4.1), as well as any coatings that
may be applied prior to or after deposition, separated by strokes for each stage in the coating sequence
in the order of application. The coating designation includes the thickness of the coating in
micrometers (µm).

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 EN 13858:2006 (E)

5.2 Basis metal

The basis metal shall be designated by its chemical symbol or its principal constituent if an alloy. For example,
Fe for iron and steel.

The specific alloy may be identified by its standard designation (for example, its UNS number as given in
ASTM DS-56G, or its national or regional equivalent) placed between the symbols “< >”, for example,
Fe<G434000>.

5.3 Pre-process stress relief heat treatment

Stress relief heat treatment prior to application of a coating may be required for some basis materials.
Brackets shall be placed around the letters, SR, the temperature in Celsius, and the time in hours. The
temperature shall be in parenthesis after the letters, SR; for example, [SR (210) 3].

5.4 Type and thickness of coatings

5.4.1 Type of coating

i immersion application;

p pneumatic application;

fl flake;

yc coating with chromate;

nc coating without chromate;

T1 paints, varnishes or similar coatings;

T2 organic or inorganic sealants;

T3 colour;

T4 oil or other lubricants.

5.4.2 Thickness of coating

Non-electrolytically applied zinc flake coating, by immersion or pneumatic processes, shall be designated by
the symbol "Zn" with the prefix "fl" and a further prefix "i" or “p” for immersion and pneumatic application
processes respectively, followed by a number giving the minimum local thickness of the coating in µm. For
example, iflZn4 or pflZn4 designate zinc flake coatings with 4 µm thickness by immersion or pneumatic
processes respectively. The minimum thickness of the zinc flake coating shall be in accordance with Table 1.

5.4.3 Examples of coating designations

A non-electrolytically deposited zinc flake coating, applied by immersion process, of 4 µm thick on steel (Fe),
with chromates:

Non-electrolytically applied zinc flake coating EN 13858 – Fe/iflZn4/yc

A non-electrolytically deposited zinc flake coating, without chromate, applied by pneumatic process, of 8 µm
thick on high strength steel that is stress relieved at 210 °C for 3 h before the application of the coating with
organic sealant (T2):

Non-electrolytically applied zinc flake coating EN 13858 – Fe/[SR(210)3]/pflZn8/nc/T2

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EN 13858:2006 (E)

6 Requirements

6.1 General

6.1.1 Basis material

This European Standard does not specify requirements for the condition, finish and surface roughness of the
basis metal prior to the application of non-electrolytically zinc flakes. Surfaces to be coated, however, shall be
free from oxides, pitting, tool marks, intergranular attack, or other defects and shall be clean and dry. If
necessary, cleaning can be by chemical or mechanical means.

NOTE When processing higher tensile parts (Rm ≥ 1 000 MPa) mechanical cleaning is preferred to ensure that no
hydrogen can be absorbed by the parts.

6.1.2 Stress relief heat treatment before coating

Steel parts with an ultimate tensile strength of 1 000 MPa and greater (Rm ≥ 1 000 MPa), that contain tensile
stresses caused by machining, grinding or cold forming operations, shall be given a stress relief heat
treatment prior to cleaning and deposition of the coating, in accordance with ISO 9587 or as specified by the
purchaser (see clause 4 f)).

6.1.3 Type of coating

The coating is produced by applying to the surface of a component a zinc flake dispersion, with or without
addition of aluminium flakes, in a suitable liquid medium. It may or may not contain chromate or have
supplementary coatings (see clause 4 g) and 4 h)).

If the coating contains aluminium flakes, it shall be specified (see 4g)).

6.1.4 Curing

The curing temperatures and duration period shall be as required for the composition of the coating material.

NOTE The temperature is generally above 180 ºC and the curing period is between 15 min to 60 min. The curing
temperature and/or its duration is not a substitute for stress relief heat treatment.

6.2 Coating requirements

6.2.1 Appearance

The coating shall be present on all significant surfaces, shall be silver grey and smooth, uniform, adherent,
and free from blisters, uncoated areas and other defects. The coating shall extend into holes and recesses to
a distance as specified in the drawing, contract or purchase order (see 4 d)).

Approved samples shall be used for comparison purposes to control the appearance of the final finish in
accordance with EN ISO 16348.

6.2.2 Coating thickness

The coating thickness specified shall be the minimum local thickness. The thickness shall conform to the
requirements of Table 1.

The minimum local thickness shall be measured using one of the methods given in EN ISO 1463,
EN ISO 2064, EN ISO 2178 or EN ISO 3882.

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 EN 13858:2006 (E)

6.2.3 Adhesion

Adhesion of the coating shall be tested by one of the appropriate methods described in EN ISO 2819, or given
in Annex B.

NOTE Paint adhesion tests may indicate some lamination of the zinc-flake coating but this lamination may not be
representative of typical service performance.

6.2.4 Supplementary coatings

To increase corrosion protection, or to change the appearance or friction properties of the coating, the non-
electrolytically applied zinc flake coatings can be covered by paints (conventional and electrophoretic),
lacquers and lubricants in accordance with the requirements of drawing, contract or purchase order (see 4 h)).

NOTE Some zinc flake coatings are supplied with a supplementary coating as part of the system.

6.3 Accelerated corrosion test

When tested in accordance with the neutral salt spray test specified in EN ISO 9227, the articles shall show
no evidence of corrosion of the basis metal when exposed for the duration given in Table 1.

Table 1 — Duration of salt spray testing for non-electrolytically deposited zinc flake
coating
a
Minimum test duration Minimum coating thickness
h µm
Coating with chromate Coating without chromate
flZnyc flZnnc
240 4 6
480 5 8
720 8 10
960 9 12
a
A coating mass per unit area may be converted to a thickness by use of the following factors:
− coatings with chromate, 4,5 g/m² = 1 µm thickness;
− coatings without chromate, 3,8 g/m² = 1 µm thickness.

NOTE 1 The duration and results of artificial atmosphere corrosion tests, such as neutral salt spray test, may have little
relationship to the service life of the coated article and therefore, the results obtained should not be regarded as a direct
guide to the corrosion resistance of the tested coatings in all environments where these coatings may be used.

NOTE 2 It is difficult to validate the results of artificial atmosphere corrosion tests unless appropriate process quality
control is carried out.

7 Sampling
A random sample shall be selected from the inspection lot in accordance with ISO 2859 and ISO 4519 (see
Annex C). The articles shall be inspected for conformance to the requirements of coating thickness and
coating adhesion tests in clauses 6.2.2 and 6.2.3 and Annex B.

9
EN 13858:2006 (E)

Annex A
(informative)

Additional information concerning coatings

A.1 Coating processes

Two types of coating processes (see 5.1 and 5.4) are used:

i) immersion in cold coating liquid, followed by draining or spinning to eliminate excess material used, for
example, for work on racks or bulk processing;

ii) pneumatic or electrostatic gun spraying – used, for example, for selective coating.

These processes and their parameters are used according to the geometry of parts in order to obtain optimum
characteristics of the coating system under relevant service conditions.

A.2 Corrosion protection

Corrosion protection of the basis metal occurs due to barrier properties of the platelet structures and galvanic
action of zinc flakes with or without the addition of aluminium flakes.

In most cases, zinc flake coatings in bimetallic contacts behave like other types of zinc coating. The materials
that can cause an adverse effect on the coating are, for example, graphite, chromium, stainless steel, copper,
tin, lead and other "noble" metals. To reduce or avoid any adverse effects, an insulating coating or layer may
be applied over the non-electrolytically applied zinc flake coatings.

The efficiency of a zinc flake based coating for corrosion protection depends on the thickness, permeability
and type of coating, adhesion to the substrate and to the subsequent coats, and on the type of corrosive
environment to which it is exposed.

NOTE If a subsequent coating is to be applied, there may be a risk of the formation of white corrosion on zinc flake
coated parts if they are stored for a prolonged period.

A.3 Thickness
Allowances for the thickness of the coating should be made by adjusting the dimensional tolerances during
manufacture of items with close tolerances.

A.4 Conductivity
Non-electrolytically applied zinc flake coatings are electrically conductive but to a lesser degree than
electroplated zinc coatings. The conductivity should be measured by a method relevant to the coated part and
its service requirements.

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 EN 13858:2006 (E)

Annex B
(normative)

Adhesion test methods

B.1 Adhesion of the coating to the basis metal shall be tested by one of the methods described in EN ISO
2819 or one of the following methods.

B.2 Scoring the surface of the coated article to expose the basis metal. Examine it at a minimum of 4x the
magnification (normal or corrected vision) for evidence of non-adhesion.

B.3 Firmly apply to the prepared surface a strip of pressure sensitive tape (see EN 60454-2) for example,
100 mm long by 25 mm wide, having a peel force for adhesion to steel of at least 3,5 N/10 mm.

After 5 min, remove it by peeling back at 180° as rapidly as possible. Carry out the test at (20 ± 5) ºC.

There shall be no sign that the coating has been removed from the substrate surface. Cohesive failure within
the zinc flake coating shall not be deemed a failure.

B.4 Clamp the components in a vice and then bend the projecting part back and forth until rupture occurs. If
the edge of the ruptured coating can be peeled back, or if the separation between the coating and the basis
metal can be seen at the point of rupture when examined, adhesion is unsatisfactory.

B.5 Rub a small area of the plated surface rapidly and firmly for about 15 sec at a pressure sufficient to
burnish the coating at each stroke but not to cut the deposit, using a suitable tool such as a steel rod of 6 mm
diameter with a smooth hemispherical end.

The coating shall not become blistered or otherwise detached from the basis metal.

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EN 13858:2006 (E)

Annex C
(normative)

Sampling

C.1 General
The articles in the sample shall be inspected for conformance to the requirements of this standard and shall
be classified as conforming to each requirement in accordance with the sampling plans of C.2.

C.2 Sampling plans

C.2.1 A sample that consists of 1 % from each batch of coated articles, but not less than two items for each
test, prepared and processed together, shall be selected for coating thickness and coating adhesion tests, as
specified in clauses 6.2.2 and 6.2.3, and Annex B. The items shall be selected randomly and from all positions
on the rack or fixture, and the number of articles for each test shall be approximately equal.

C.2.2 In exceptional circumstances, such as the coating of single large items, the sampling procedure may
be modified. Special test specimens coated along with the articles shall be used, due consideration being
given to their shape, size, material etc. The treatment of the test specimen shall be representative of that
applied to the articles being coated.

C.2.3 If any coated item fails a test (or tests), a further 1 % sample shall be selected in accordance with
C.2.1 and the whole of this sample shall be subjected to the relevant test (or tests). If any part of this sample
fails, the whole batch shall be rejected.

C.2.4 A sample comprising of not less than two items, from each type/class of coating, shall be selected and
subjected to salt spray testing (see 6.3).

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 EN 13858:2006 (E)

Bibliography

[1] EN ISO 10683, Fasteners — Non-electrolytically applied zinc flake coatings (ISO 10683:2000)

[2] EN ISO 1463, Metallic and oxide coatings — Measurement of coating thickness — Microscopical
method (ISO 1463:2003)

[3] EN ISO 2178, Non-magnetic coatings on magnetic substrates — Measurement of coating thickness —
Magnetic method (ISO 2178:1982)

[4] EN ISO 2819, Metallic coatings on metallic substrates — Electrodeposited and chemically deposited
coatings - Review of methods available for testing adhesion (ISO 2819:1980)

[5] EN ISO 3882, Metallic and other inorganic coatings — Review of methods of measurement of
thickness (ISO 3882:2003)

[6] ISO 9587, Metallic and other inorganic coatings — Pretreatments of iron or steel to reduce the risk of
hydrogen embrittlement

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BS EN
13858:2006
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