BRITISH STANDARD Specification for Testing zinc coatings on steel wire and for quality requirements ‘pe eonse.ee0.1-196 NO COPYING WITHOUT BSI PERMISSION EXCEPT AS PERMITTED BY COPYRIGHT LAW BS 443:1982 Incorporating ‘amendment No. 1; BS 443:1982 Se Cooperating organizations ‘The Iron and Steel Standards Committee, under whose direction this British Standard was prepared, consists of representatives from the following: British Constructional Steelwork Association British Internal Combustion Engine Manufacturers’ Association % British Ironfounders’ Association British Railways Board British Steel Corporation British Steel Industry” British Steel Industry (Wire Section)” Concrete Society Limited Council of Ironfoundry Associations Department of Industry (National Physical Laboratory) S Electricity Supply Industry in England and Wales - Engineering Equipment Users’ Association ‘Federation of Civil Engineering Contractors Institute of Quality Assurance” Institution of Production Engineers 2 Institution of Structural Engineers 5 International Tin Research Institute 5 Lloyd's Register of Shipping National Association of Drop Forgers and Stampers Oil Companies Materials Association Process Plant Association Royal Institute of British Architects Society of Motor Manufacturers and Traders Limited Steel Casting Research and Trade Association Water-tube Boilermakers’ Association ‘Tho organizations marked with an asterisk in the above list, together with the following, were directly represented on the Technical Committee entrusted with the preparation of this British Standard: ‘This British Standard having i tema preuidtarte” British Wire Netting Associaton rection of he Tem a : direction ofthe Iron and. Fencing Contractors’ Association Spublniedunierthe "Society of Chain Link Fencing Manufacturers buthoriy ofthe Board ‘BST and somon Into affect on 20 February 198 ‘OBST 121998 ‘iret published Mareh 1082 ‘iat Fovison Never 1098 econ rvieien January 1861 ‘Thirkrevisio January 1968. Amd.No. | Date of issue / Comments Fourth revision February 1982 Amendments issued since publication 6158 December 1989 Indicated by a sideline in the margin “The fllowing BSI references Felate tothe work on this andar {Committe reference 1531/26 Dai for eomment 60771262 DC ISBN 0 980 12612 9gical, Ve Technol BS 443:1982 ooo —Yyv_hy_—e _ ,_ Contents Cooperating organizations Foreword Section 1. General Scope Reference ‘Metallurgical quality of coating ‘Test pieces ‘Test pieces from fabricated wire products Surface condition Uniformity and adherence Section 2. Test methods 8 Determination of mass of coating 9 Test for uniformity of coating (Procce dip method) 10 _Adhesion of coating Section 3. Standard coating 11 _Thickness and quality Appendix A Conversion factors Figure 1 — Apparatus for determining coating mass by gas-volumetric method ‘Table 1 — Length of test piece ‘Table 2— Correction factors for temperature and barometric pressure used in calculating mass of coating ‘Table 3 — Ratio of mandrel diameter to wire diameter ‘Table 4 — Minimum mass of coating and number of dips ‘Standards publication referred to Page Inside front cover Tnside back cover ost 12.1098BS 443:1982 oo ___ 2 Foreword ‘This British Standard has been prepared under the direction ofthe Iron and Steel Standards Committee. This edition has been technically up-dated in detail although the major technical concepts have not been altered significantly. BS 443:1969 is now withdrawn, With the emphasis on adoption of international standards in national standards, there is the future possibility that some British Standards may not refer to the standard values for coating thickness given in section three of this standard, or may not require the dip test. Ease of cross-reference will, therefore, be improved by separation of test methods and general quality requirements. ‘The standard coatings specified in section three are intended for a wide variety of e wire applications in which medium/long term protection of the steel against 5 corrosion is desired, It is emphasized that the protection afforded by the zinc is : sacrificial and the duration of the protection is therefore dependont on the conditions in which the zine coated wire will be expected to function. ‘The dip test has been retained as a standard requirement but it isnot intended as an indirect measurement of the mass of coat. It is intended only to reveal any serious eccentricity of a coating that could lead to failure over a portion of the circumference, even though the total mass of coat may be in accordance with the standard. Following international practice which is becoming established, the term “zine coated” rather than “galvanized” has been adopted in this standard. The terms are synonymous. Factors for converting coating mass from imperial to metric units and for converting coating mass to coating thickness are included in appendix A. ‘A British Standard does not purport to include all the necessary provisions of a contract. Users of British Standards are responsible for their correct application, The Brit $n correct as of Compliance with a British Standard do from legal obligations. not of itself confer immunity Summary of pages This document comprises a front cover, an inside front cover, pages i and ii, pages 1 to 8, an inside back cover and a back cover. ‘This standard has been updated (see copyright date) and may have had amendments incorporated. ‘This will be indicated in the amendment table on the inside front cover. it © 3st 12-1998BS 443:1982 Section 1. General 1 Scope ‘This British Standard specifies the methods of testing zine coated steel wires and products fabricated from them to determine the nominal ‘mass of the zine coating, its uniformity and its adhesion. In addition, requirements aro specified (Gee section three) for mass, uniformity and adhesion of coating on steel wires of circular section in diameters from 0.23 mm to 10.0 mm. These requirements are not applicable to articles made from wire which have been coated after fabrication. NOTE Coatings in accordance with section three are not. necessarily avaiable in every combi tensile strength grade und reference appropriate Beth Standard forthe typeof wire, 2 Reference ‘The title of the standards publication referred to in. this standard is given on the inside back cover. 8 Metallurgical quality of coating ‘The metallurgical quality of the coating is dependent on the quality of the zine used. Wire shell be coated in a bath using zine of purity not less than, grade Zn 3 of BS 3436. 4 Test pieces 4,1 The number and basis of selection of test pieces shall be that specified in the standard for the product. In the absence of such a standard the degree of sampling shall be agreed between the ‘manufacturer and the purchaser. 4.2 In removing the test pieces care shall be taken to avoid surface damage. Portions of wire which are obviously damaged shall not be used. 4.3 For all the tests a piece of total length of at least 500 mm will usually be needed (see 8.2.2, 8.3.4, 9.4 and clause 10). 5 Test pieces from fabricated wire products If the test pieces have been taken from a product. fabricated from zine coated wires, then unless otherwise stated in the product standard, the specified minimum coating mass shall be reduced by 5 % and the specified dips shall be reduced by one half-minute dip. # 6 Surface condition ‘The coating on wire shall be continuous and reasonably smooth. It is recognized that thick ‘coatings produced by the final hot dip process may exhibit some surface irregularities, but the coating shall be free from imporfoctions, such as gross dross contamination, not consistent with good coating practice. 7 Uniformity and adherence ‘The coating on wire shall be reasonably uniform, as judged by the copper sulphate solution dip test, and shall be adherent to the steel under the conditions of the adhesion wrap test (see clause 10). OBST 12-1908 taBS 443:1982 Section 2. Test methods 8 Determination of mass of coating 8.1 General. The mass of coating shall be determined by either a gravimetric or volumetric method. The latter has an acceptable degree of accuracy and has the advantage of rapidity. It is therefore the preferred method for routine testing of all the sizes of wire which can be conveniently accommodated in the measuring apparatus. In any case of dispute, the gravimetrie method shall be accepted as the referee method. NOTB_ The methods of test contained in thie standard do not ‘octasarily dota all precautions the 8.2 Gravimetric method 8.2.1 Reagents. The following reagents are used. Antimony chloride solution. Dissolve 20 g antimony trioxide or 32 g antimony trichloride in 1 000 ml hydrochloric acid, of relative density of between 1.16 and 1.18, Stripping solution. Add 6 ml of the antimony chloride solution to every 100 ml hydrochloric acid, of relative density of between 1.16 and 1.18. 8.2.2 Test piece. For wires of diameter 3 mm and largor, the length of the test piece should not be less than 100 mm. As a guide to the length for smaller sizos of wiro, this should be such that the mass in grams is numerically not less than approximately four times the diameter in millimetres. After cleaning the test piece in a suitable organic solvent, e.g. methylated spirit, wipe the wire dry with a clean, soft cloth and weigh it to the nearest 0.01 g. 8.2.8 Stripping the zine. Strip the coating from the steel wire by complete immersion of the test piece in, any convenient volume of the stripping solution. NOT ‘Tho same solution may be repeatedly wed, without further additions of antimony ehlorde solution, until the time of stripping becomes inconvenienty long. ‘The temperature of the stripping solution should not be allowed to exceed 38 °C and the number of test pieces immersed at any one time shall not exceed 3 per 100 ml of solution. ‘As soon as the violent chemical action has ceased, remove the wire from the acid, wash it thoroughly in. running water and wipe dry. The diameter of the wire shall then be determined to the nearest 0,02 mm by taking the average of two ‘moasuroments at right angles to each other. Weigh each piece of stripped wire to the nearest 0.01 g. 8.2.4 Determination. The mass of zinc coating in glm? of steel surface is given by the formula Mas — Ws). s 1962 where We, is the mass (in g) of the zine coated steel W, is the mass (in ) of the bare steel wire dis the diameter (in mm) of the bare steel wire. NOTE The expressions derived from the relationship Betwoon ‘he curved surface aren anqthe volume of exlindr andthe ensity a steal (850 ka 8.8 Gas volumetric method 8.3.1 Principle. The volumetric method of determining the mass of coating depends on the fact that a metal dissolved in acid always releases a quantity of hydrogen proportional to the amount of metal dissolved, ie. the chemical equivalent of the metal in question. 1g of zinc releases 343 ml of hydrogen at a temperature of 0°C and a pressure of 1 014 mbar”. NOTE With very large wire problems of et piece preparation nd damage tothe ase bure.e may be troduced. This method fermion tert nly ited ows of 8.8.2 Reagent. The same stripping solution as specified in 8.2.1 is used, subject to the folowing ‘qualifications. Acid concentration may affect the result in the volumetric method, strong acid giving slightly high results and weak acid giving low results, Assuming a 36 % mass content of HClin tho concentrated acid (relative density 1.18),70 parts by volume should be mixed with 30 parts by volume of ‘water to give a mass concentration of approximately 25 % HCI (relative density approximately 1.18) NOTE_ The stripping solution shouldbe replaced when the acid concentration i Fedued level where, for example vigorous tvlution of ge lane engr than about aa witha tine ase 1200 gt 8.3.3 Apparatus. The apparatus consists of a 100 ml glass buretie fitted with a stopcock at the top and bottom and connected at the bottom with a rubber tube to a reservoir. The apparatus is shown in Figure 1(a) set up for the commencement ofa test. ‘The 100 ml burette should be graduated to at loast 0.5 ml subdivisions. NOTE. Wher small sis of wir, ny las than 15 mm ‘ameter, are regularly ete, ay be found Ueto 160 miburete af abou the same length and graduated to at Teast 0.2 ml eubdivisons © Bsr 12.1908al, Version co ary, Nanyang Te Ms. Nanyang Tech University 8.3.4 Test pieces. From a straightened and undamaged longth of wire, test pieces of the required length are accurately cut (error no more than 1%). The most suitable length of test piece depends upon the size of burette, diameter of wire and expected mass of coating. The lengths indicated in Table 1 will usually be found convenient. ‘Table 1 — Length of test piece Zine coated wire diameter | Longth of test plece Over] Uptoand | foral00ml | foras0ml Including | burette | burette 0.45 oss — 200 0.85 1.06 200 150 1.06 18 100 5 18 36 5 — 36 5.0 50 = 8.3.5 Procedure. Pour the acid reagent into the reservoir C until it completely fills the burette leaving a small portion in the reservoir when in the elevated position. ‘To carry out a test, adjust the height of the reservoir Cs that the acid reagent just fills the burette up to the stopcock A with the bottom stopeock B closed, Drop the test piece, cut to the specified length, into the burette and immediately close the stopeock A. NOTE Where lng test pecs are necessary, rapid entry into the burete may be difficult and i maybe fore convenient 9, Arop two short piece simultaneously through the stopenc. ‘The zine coating rapidly dissolves and liberates hydrogen and the test is continued until evolution of hydrogen, but for a few fine bubbles, has ceased, ‘Then lift the reservoir from its supporting ring and place alongside the burette until the levels of the acid reagent in the burette and the reservoir are the same, as shown in Figure 1(b), then read off the voluine of hydrogen on the burette scale. ‘When the test is concluded open stopeock A and draw all acid reagent from the burette by lowering the reservoir to a position below stopcock B. Then ‘open stopcock B to eject the test piece and close again. The procedure given above may then be repeated for a succeeding test. ‘The stripped wire shall then be washed, wiped dry and the diameter measured, 8.3.6 Determination. The mass of zine coating is calculated from the formula: Mass of coating/unit aroa of stel surface = ¥ x f where Vis the volume of hydrogen evolved in millilitres co) dis tho stripped wire diameter lis the length of test pioee Where length and diameter are in millimetres, f= 872, to give a mass of zinc coating in g/m? NOTE In practio the mass of zine (in gn?) is read directly from tables relating mace of sine te diametor of eripped wire and volume of hydrogen. ©nst2-1998BS 443:1982 (a) Arrangement of spparatus when commencing tet L - Feeds Sol (b) Arrangement of apparatus when measuring volume of hydrogen on completion of text Figure 1 — Apparatus for determining coating mass by gas-volumetric method 8.8.7 Correction for temperature and barometric pressure. The factor (f) has been calculated for a temperature of 18 °C and a barometric pressure of 1 014 mbar. If the atmospheric pressure is outside the range 987 mbar to 1 040 mbar or if the temperature is outside the range 16 °C to 20°C, apply the appropriate correction factor from Table 2. If the combination of pressure and temperature results in a correction factor within + 0.02 of unity (see outlined zone in Table 2), then the factor need not be applied to the calculated ‘mass of zine or to that obtained from tables. NOTE 1 Where the test raul ie within 5 gm of the ‘minimum value, itis desirable to cheek the atmosphere and temperature, incase a negative correction is neces ‘Where climate or altitude cause permanent divergence from standard conditions, the formula shall be corrected to suit provailing conditions. If tables are used these shall be corrected, NOTE 2 At high alttudos it will be foundsonvenieat to have a Dburetteof greater capacity than 60 malo 100 ml ©BSI 12-1908fang Tech Universit 9 Test for uniformity of coating (Preece dip method) 9.1 General. The uniformity of the coating shall be tested by the method described below, 9.2 Reagent. The following reagent is used Copper sulphate solution. Dissolve approximately 36 g of crystalline coppor sulphate (CuS0,,5H,0) in each 100 ml of distilled or deionized water. The water may be heated to aid solution of the crystals; but if heated, the solution shall be allowed to cool before neutralizing. For neutralization, shake the solution with an excess of basic cupric carbonate (1 gi to 2 g/l of solution) and allow it to stand, preferably for at least 24h, before filtering or decanting the solution from the sediment, NOTE Analytical reagent quality copper sulphate is not essential, Tho pH ofthe solution is initially 2.0 to 2.7 and after ton” with basi cupric carbonate the pH 3.79 88, and it appears tobe consistont over a period of me. Ifcupric ‘oxide is used for “neutralisation” with a recommended standing 48h, the pH will bo in the range 26 t0 3.3 and may vary with time. For those reasons only the basic cupric carbonate is pec alizing agent, ity of the test solution shall be 1.186 at 18 °C. Adjustment may be made by adding distilled (or de-ionized) water or solution of higher relative density, as appropriate. ‘The solution shall be discarded and replaced with, fresh solution after six samples have been tested, 9.3 Apparatus, The following apparatus is required. Glass or plastics container of internal diameter not less than 50 mm for wires of 2.8 mm diameter and smaller or 75 mm for larger wires. It should be filled with copper sulphate solution to a depth of at least 100 mm, 9.4 Test pieces. The test piece should be not less than 150 mm in length and shalll be undamaged as far as possible. The test piece may be hand straightened and shall be cleaned with an organic solvent, e.g. methylated spirit, and then wiped dry with a clean soft cloth. 9.5 Temperature. At the commencement, and during the progress of the test, the temperature of the test pieces and of the solution shall not vary outside the limits of 18 + 2 °C, 9.6 Procedure. It is preferable that not more than three test pieces be immersed in the solution at one time, The test pieces shall not touch one anather. During the immersion the test pieces shall not be disturbed, and the solution shall not be agitated. ‘The test piece or test piaces shall be subjected to successive dips of exactly 1 min. After each dip remove the sample and immediately rinseitinclean running water and wipe dry with a clean soft cloth. If running water is not available, the rinse water shall be changed frequently so that there is no obvious contamination with copper sulphate solution. Half-minute dips, where specified, shall be given after the completion of all the one-minute dips 9.7 Examination. After the specified number of dips, the final rinsing and wiping dy, the test piece shall not show any adherent bright deposit of ‘metallic copper on the steel. Any deposit of metallic copper within 25 mm of the cut end shall be disregarded. Table 2 — Correction factors for temperature and barometric pressure used in calculating mass of coating [Temperature “Atmospheric pressure, mbar “C | eas | Wa | aT | Tis | wo] wT | as | ae0] OT | OT ho Joos [0780 [ores jorrea fosit oes oes [aae2 020 [O97 2 oss Jo.725 |o7s2 Jo.r70 Ja.sos |o.sss fo.sco |o.ass losis Jo.e10 na oss |o.720 |oza7 Jo.774 Ja.so0 |o.s2r fo.ase |o.se0 Jo.sos Jo.ss4 he oso |o.71s |ors2 Jo.r68 Jo795 |o.sze Jo.sis |o.ers fo.s01 |o.o27 18 loose [0-710 |o7s7 Jo.763 Jo-7a9 Jo.sis Josie |o.ses loses |o.o21 20 ovo 0.705 Jo7s2 Jo.768 |o788 |o.sto Ja.sse |o.s62 loses [0.15 2a ooze [o-700 Jorer Jo.zs2 |o778 |o.s05 Ja.ss0 |o.sss Jo.ss2 |o.008 2 oer Joes Jorzz Jo.zas |o-778 |o.s00 Ja. |o.es1 Jo.sr7 |o.009 26 loses Jo.aor Jo.ri7 Jo.zaz |o.rs9 Jo.796 Josie loses Jost: |oss6 las oer o.s7 Jo.ms Jo.7ss |o.r6s Jo.ra9 |o.si4 Jo.ss9 Joes |o.sor 190 Joos7 Jose o.708 |o.rs2 |o.757 |o.78s |o.sos o.ssa oaso Ja.ses 520 —|s«0_|560 [680 [600 [e20 [oso —|e60 [680 [700 Height of barometer, amy ons 12-1908Ne BS 443:1982 ——— ee — 10 Adhesion of coating For wires of 7.6 mm and smaller the adhesion of the zinc shall be tested by wrapping the wire at least six close turns round a cylindrical mandrel. Larger wires shall be bent through an angle of at least 90° round the mandrel. The ratio of mandrel diameter to wire diameter (d) shall be in accordance with Table 3, Table 3 — Ratio of mandrel diameter to wire diameter Wire diameter Mandrel diamater Up to and including 3.8 | 4d Over 3.8 bd ‘The zine shall remain firmly adherent to the steel and shall not crack or flake to such an extent that any flakes of zine can be removed by rubbing with bare fingers. © BS 12-1998ry. Nany at F BS 443:1982 Section 3. Standard coating 11 Thickness and quality ‘The coating shall be adherent in accordance with When tested in accordance with clauses Sand 9, the B® adhesion wrap test (see clause 10) zine coating mass and the number of dips in the oppor eulphato solution when testing for ‘uniformity of coating shall comply with the requirements given in Table 4 Table 4 — Minimum mass of coating and number of dips Nonitnal ameter of coated “Wire of tensile sirens ‘wire {540 Nim? and shove Over] Unioand Number of dipr Miniom ‘Number of ipa including Minute | Halfmimate] asset [—Himute | Halt inate coating coating a oo as ein? 0.23 0.33 45 no test 45 no test 0.38 0.40 60 no test 60 iio test 0.40 048 1 — 1 % — 1 0.46 0.53 90 1 E: 90 L = 0.53 0.68 105 1 = 105 1 Ee 0.63 0.75 120 a = 120 1 = 0.76 0.85 185 1 1 135 1 1 0.85, 0.95 150 1 1 140 1 1 0.95 1.08 170 2 - 160 1 a 1.06 118, 185 2 = 360 2 | 118 1.32 200 2 — 170 2 | 1.32 1.55 215 B = 180 2 = 1.55 18 200 2 1 200 2 — 18 224 240 8 — 215 2 = 224 272 260 3 = 230 2 1 272 35 275 3 a 240 3 = 3.15, 3.55 275 3 s 1250 3 | ~|3.55 4.25 290 8 1 |260 3 ee 425 50 290 8 1 275 3 1 5.0 80 290 3 L 290 3 1 8.0 100 805 4 Ke 305 4 ES ‘©BsT 1998 7BS 443:1982 SS Appendix A Conversion factors From To Maltiply by 5 oaitt® sim? 305.152 2 [[isssotcoat [Average radial thickness of coat 3 frown? 42,926 um (micrometres) 8 [teim® (0.1407 pm (icrometres) 8 © BSI 12-1998BS 4 _ i Standards publication referred to BS 8436, Ingot zinc. © BSI 12-1998,