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IS 12753 (1989): Electrogalvanized Coatings on Round SteelWire [MTD 7: Light Metals and their Alloys]

--------

IS 12753 : lPS9

Indian Standard

ELECTROGALVANIZED COATINGS ON ROUND STEEL WIRE - SPECIFICATION

YnaS ST?if; ma *3;cmfh faavaw~~*df~f*~

UDC 669’14-426’2 : 669’587

@ BIS 1990

BUREAU OF INDIAN STANDARDS MANAK BHAVAN, 9 BAHADUR SHAH ZAFAR MARG

NEW DELHI 110002

February 1990 Price Groq 2

__--. I... --. .---

‘Metallic and Non-Metallic Finishes Sectional Committee, MTD 20

FOREWORD

This Indian Standard was adopted by the Bureau of Indian Standards on 20 July 1989, after the draft finalized by the Metallic and Non-Metallic Finishes Sectional Committee had been approved by the Metallurgical Engineering Division Council.

Electrogalvanizing of steel wires is a growing industry; however it is yet to intensify its applica- tions. Electrolytic process has not found wider acceptance in comparison to the zinc coating by hot-dipping process [ covered by IS 4826 : 1979 ‘Hot dipped galvanized coatings on round steel wire (First revision )’ I, because of the initial high capital cost of installation and of skilled personnel.

Advantages of electrogalvanizing over the hot dip process are: a) Closer control of coating thickness and, therefore, saving of zinc; b) Electrogalvanized zinc is pure, more concentric and uniform and is more versatile in usef c) No ash or zinc dross is formed; d) Heavier coatings ( up to 1’2 kg/m2 ) is possible only with electrogalvanizing; e) Plant can be shut down quickly and restarted quickly; and f) Electrogalvanized steel wires are better for further drawing and stranding.

However, hot dip galvanizing requires less space and gives lustrous zinc coatings, while corrosion protection far both types is similar. In order to rationalize the requirements of different types of galvanized wires, coatings have been grouped into three types, that is, heavy, light and medium. For general guidance, Annex A indicating applicability of various types of coatings on different wires has been included.’

For the purpose of deciding whether a particular requirement of this standard is complied with, the final value, observed or calculated, expressing the results of a test or analysis, shall be rounded off in accordance with IS 2 : 1960 ‘Rules for rounding off numerical values ( revised )‘. The number of significant places retained in the rounded off value should be the same as that of the specified value in this standard.

I§ 12733 : 19891

Indian Standard

'ELECTROGALVANIZEDCOATINGSON ROUND STEEL WIRE-SPECIFICATION "

1 SCOPE

1.1 This standard covers the requirements of electrogalvanized coating on steel wires of cir- cular section in diameters from 0’2 mm up to and including 10 mm and lays down specifica- tions for:

a) mass of zinc coating,

~b) uniformity of zinc coating, and

c) adhesion of zinc coating.

1.2 It also lays down methods of testing for these properties and provides for such testing to be carried out before and/or after the wire has been used for armouring, stranding, etc.

1.3 This standard makes no reference to the quality of wire itself. It does not apply to the articles made from wire which have been electro- galvanized after fabrication.

1.4 The relevant Indian Standard governing a particular type of wire should refer to this stan- dard for specifying the requirements of electro- galvanized zinc coating.

2 REFERENCES

2.1 The following Indian Standards are necessary adjuncts to this standard.

.ZS No. Title

IS 1387 : 1967 General requirements for the supply of metallurgical materials ( Jirst revision )

IS 1956 Glossary of terms relating to ( Part V ) : 1976 iron and steel: Part V Bright

steel bar wire ( first revision )

IS 2605 : 1985 Zinc anodes for electroplating ( first revision )

IS 2633 : 1986 Method of testing uniformity of coating of zinc coated articles ( second revision)

IS 3554 : 1966 Glossary of terms relating to electroplating

IS 6745 : 1972 Methods for determination of mass of zinc coating on zinc coated iron and steel articles

3 TERMINOLOGY

.3.1 Definitions of the terms used in this standard

are in accordance with definitions in IS 3554 : 1966 and IS 1956 ( Part V ) : 1976.

4 SUPPLY OF MATERIAL

4.1 General requirements relating to the supply of material shall conform to IS 1387 : 1967.

5 GENERAL REQUIREMENTS

5.1 Quality of Zinc

For best results, zinc anodes of special high grade ( 99’99 percent pure zinc ) as given in IS 2605 : 1985 are recommended in continuous electrogalvanizing plants. With this, the forma- tion of sludge is minimized while the quality of coatings is better maintained.

5.2 Sometimes insoluble anodes as well as solu- ble zinc anodes of lesser purity, along with con- tinuous filtration of electrolytes are also used.

6 MATERIALS AND MANUFACTURE

6.1 The coatings shall be uniform, adherent, reasonably smooth and essentially pure zinc produced by electro-deposition.

6.2 Defects in the surface of steel wire, such as scratches, cracks, pits, inclusions, die marks, etc, may adversely affect the appearance and performance of the electro-deposited zinc coat- L: ing. The steel wire shall be subjected to such polishing or buffing operations as are necessary to yield deposits with the desired final lustre and appearance. The specifications covering the basic steel wire to be electrogalvanized shall be agreed to between the purchaser and the supplier, according to the applications of the electro- galvanized steel wires.

6.3 Cleaning of Basis Metal

Proper preparatory procedures and thorough cleaning and rinsing of the basis steel wire ( dry or wet drawuandlor annealed ) shall be done to ensure satisfactory adhesion and corrosion resis- tance performance of the coating.

6.4 Electrogalvanizing

Electrogalvanizing or electroplating of zinc on steel wires may be from any suitable bath like sulphate, sulphate-chloride, chloride’, fluorobo- rate, etc. Continuous electrogalvanizing plants of horizontal line or vertical line are normally designed and the process of electrogalvanizing shall be generally as follows:

a)’ Pay-off reels; b) Heat treatment (dipping in molten lead,

etc ) if required;

‘” 1

L.___...._...~.__ _

18 12753:1989

4 4 4 f 1 g) h) 3 k) 4

n> P>

Pickling in acid; Rinse; Electrol’)tic cleaning; Rinsing- Mechan cal cleaner; ‘1 Electra-galvanizing; Cold water rinse; Hot water rinse; Supplementary treatment, if desired: i) Chromate passivation ( light coating),

ii) Phosphate coating ( light coating); Rinsing and drying; and Take-up unit.

NOTE - The electroplated zinc surface is attacked by supplementary treatments, thereby diminibhirig the coating thickness. It is recommended that extra thickness be built for making up this loss.

7 COATING REQUIREMENTS

7.2.1 At allpoints more than 3 cm from a cut end, the coating shall -withstand the number of dips in copper sulphate solution set out in Table 1 and Table 2. when subjected to the Preece test prescribed in IS 2633 : 1986.

7.1 Mass of Zinc Coating 7.2.2 Finish

When determined in accordance with IS 6745 : 1972, the mass of zinc coating shall not be less than the mass specified in Table 1. For Z-type coating, the requirements given in Table 2 shall apply.

Unless otherwise, stated, the finish shall be bright or semi-bright or dull subject to the agreement between the purchaser and the manufacturer.

7.1.1 If the wire is tested after being used for stranding, armouring, barbing, binding or any

7.2.3 Even the best electroplating practice can- not remove the defects, for example, scratches, cracks, pits, inclusions, die-marks, etc, on the surface of the basis steel wire. Accordingly, the

other similar purpose, the minimum mass of coating shall be reduced by 5 percent.

7.1.2 Care shalltbedexercised to avoid damaging the samples in detaching them from the finished strand or cable or coil.

7.2 Freedom from Defects

The electrogalvanized steel wire shall be uni- form, smooth and free from visible plating defects such as blisters, pits, roughness, nodules, cracks, burning or unplated area and shall not be stained, rusted or discoloured. The zinc coating shall be continuous and firmly adherent to the surface of steel.

Table 1 Mass of Electroplated Coating of Zinc and Number of Dips

( Clauses 7.1 and 7.2.1 )

Nominal Light Coated Wire Heavy Coated Wire Diameter r-___-_-__ r----- L-__-) of Electro- Soft Hard Soft Hard Galvanized c--- -h_----, r-_-h--~ c-_‘_-_-_~ r____h___._~

Wire Mass of Number Mass of Number Mass of Number Mass of Number r--h? Coating of Dips Coating of Dips Coating

g/m* F-*-Y of Dips Coating of Dips

Above Up to and g/m8 Including

-*-3 r--h--I 1 1 t

g/m” ‘;--*T g/m* 1 t

( f 1 0’200

(2) 0.315

0.315 0.400 0.400 0.500 0.500 0,560 0560 0.63 0.63 0.71 0.71 0 80 0.80 0.90 0.90 1.00 1.00 1.25 1.25 I.40 1’40 I .60 1.60 1.80 1’80 2.00 2.00 2.24 2’24 2.50 2’50 2’80 2.80 3’15 3.15 3.55 3’55 4.00 4.00 5’00 5.00 7.10 7.10 10.0

20

:o”

:: 30 40 40 40 50 60 60 i0

z

1:: 110 120 130 140 140

min min min min min min min min (4) (5) (6) (7) (8) (9) (10) (11) (12) (13 1 (14)

No test No test 15 No test No test 45 No test No test 45 No test No test requir- requir-

Fl: z”, do do

:: do

do ::

dd: :: do do do do

:: :: - - : - 1

- r - 1 -

: -

1

: -

requir- requir-

15 15 20 20

3’0”

30

40 40 40 50 60 z

70 70

s’o” 1%

110 110

:: do do

::

ddoo

do do do do

::

:o, do

:: 1 1

1 1

70

1% 110 120 140 150 170 180 200 210 230 240 240 260 260 270 270 280 290 290 300

requir- requir- ed ed do do do - - 1 - - : -

r : 0

: I 1 -

1 : -

g z 2 -

i f

2 : 2 1 3 -

requir- requiri

Cz ed

;8 do :“o 100 do do 110 120 d”: : 140 do 1 150 do 150

: :

160 -

180 190 : 1 200 1 - 210 1 - 210 230 : 1 230 2 1

240 250 2’ - 260 2 Y- 275 2 1

290 2 300 3 L

::2

IS 12753 : 1989

Table 2 Requirements for Medium ( Z-Type ) Electroplated Coatings of Zinc

( Clauses 7.1 and 7.2.1 )

Table 3 Requirements for Adhesion Test C C&use 8.1.2)

Nominal Diam’eter of Mass of Number of Dips Nomin;jH&neter Minimum Complete Rutio Between

Turns of Wrap Mandrel Dia-

Galvanized Wire,

f”l”, 0.200 and Up

Above 0.315 ,, ,. 0.400 ,, ,, 0’500 ,, ,? 0.560 ,, *, 0.63 ,V 0’71 :; ,’ 0.80 ,, 9, 0.90 1, __ 1’00 . .

Coating s/n-P (2)

top315 30 0.400 35 0.500 45 0.560 60 0.63 60 0.71 60 O*SO 75 0.90 1’00 7755 1.25 90

mm 1Jp to and including

3.55 10

meter and of Wire

4

., __ 1.25 1: 1.40 90 ,I -~

1, 1’40 :: 1.60 95 1, . . ;I;;

,. 1.80 . . 2.00 1:; ~_

. . 2.00 :: 2.24 105 ,* ,3 2’24 ;, 2.50 110 1) 2’50 ,, 2.80 120 ,* 2’80 ,, 3’15 120 a. 3.15 . . 3.55 135 ?- ,, 3.55 ;; 4.00 135 3, 4.00 ,, 5.00 150

---? 1 &in

(3) - -

- - - - -

1

: 1

:

: 1 1

:

* min

(4)

9 1

: 1 1

-

- -

L; 1

: 1

-

electroplaters responsibility for defects in the zinc coating, resulting from such conditions shall be waived.

8 ADHESION OF ZINC COATING

8.1 Test Specimen

8.1.1 The test specimen consists of a piece of wire, long enough to allow the test to be carried out properly.

8.1.2 The test specimen shall be wound round a cylindrical mandrel so as to form close spirals as specified in Table 3.

8.2 Proceduie

8.2.1 Winding shall be carried out at a rate not more than 15 turns per minute.

8.2.2 When so wound or bent around the man- drel, the zinc plating shall remain adherent to the steel wire and shall be considered as meeting this requirement if owing to such winding or

Over 3.55 upto and 10 6 including 7.10

Over 7’10 f C one 90” bend ) 6 _ .

bending, the plated coating does not flake off nor crack to such an extent that there is possibi- lity of removing any zinc by rubbing with bare fingers, the use of nail being not allowed.

8.3 The electrogalvanized coating shall not flake off, when subjected to dry or wet drawing. Ths total reduction should be minimum 20 percent.

9 SAMPLING

9.1 The size of the batch and the number of samples to be selected shall be as per the sampl- ing plan specified in the standard governing the wire or article fabricated from wire. In the absence of such standard, the degree of sampling shall be as agreed to between the electrogalvani- zer and the purchaser.

9.1.1 Coil for testing shall be selected by the purchaser.

9.1.2 Portions of wires which are damaged shall not be used as samples.

obviously

9.2 Batch

For the purpose of this standard a batch shall consists of wires of same dimensions processed together from pretreatment to final electrogalva- nizing.

10 RETEST

10.1 If the batch sample fails to meet any of the requirements of this standard, double the num- ber of samples, further shall be tested for each failure and if any of the sample fails, the batch shall be treated as rejected.

ANNEX A

( Foreword )

GENERAL GUIDANCE FOR APPLICABILITY OF TYPE OF COATING FOR DIFFERENT APPLICATIONS

Application

Fencing wire Stay strand wire Signal strand wire Chain link wire Rope wire Spring wire Cable armouring wire ACSR wire Mild steel wire

Type of Coating r----h-__, Heavy Light Mediuz

X x - X - .- x - - x - - x - X - X x - - x - - X x -

Application

Telephone wire Cycle spoke wire Barbing wire ( line ) Barbing wire ( point ) PC. wire Lighting conductor wire

Rubber hose rein- forcement wire

Type of Coating r----h---- Heavy Light Mediuz

x - - X -

X x - - X - x - - x - -

X x -

x Applicable, -Not applicable.

3

I I Standard Mark

I The use of the Standard Mark is governed by the provisions of the Bureau of Indian

Standards Act, 1986 and the Rules and Regulations made thereunder. The Standard Mark on products covered by an Indian Standard conveys the assurance that they have been produced to comply with the requirements of that standard under a well defined system of inspection, testing and quality control which is devised and supervised by BIS and operated by the pro- ducer. Standard marked products are also continuously checked by BIS for conformity to that standard as a further safeguard. Details of conditions under which a licence for the use of the Standard Mark may be granted to manufacturers or producers may be obtained from the Bureau of Indian Standards.

I I

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BIS is a statutory institution established under the Bureau of Indian Standards promote harmonious development of the activities of standardization, marking certification of goods and attending to connected matters in the country.

Copyright

; ‘( !

Act, 1986 to and quality

BIS has the copyright of all its publications. No part of these publications may be reproduced in any form without the prior permission in writing of BIS. This does not preclude the free use, in the course of implementing the standard, of necessary details, such as symbols and sizes, type or grade designations. Enquiries relating to copyright be addressed to the Director ( Publications ), BIS.

Revision of Indian Standards

Indian Standards are reviewed periodically and revised, when necessary and amendments, if any, are issued from time to time. Users of Indian Standards should ascertain that they are in possession of the latest amendments or edition. Comments on this Indian Standard may be sent to BIS giving the following reference:

Dot : No. MTD 20 ( 3161)

Amendments Issued Since Poblicatioo

Amend No. Date of Issue Text Affected

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