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IS 12753 (1989): Electrogalvanized Coatings on Round Steel
Wire [MTD 7: Light Metals and their Alloys]
“!ान $ एक न' भारत का +नम-ण”
Satyanarayan Gangaram Pitroda
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है”
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“Knowledge is such a treasure which cannot be stolen”
--------
IS 12753: lPS9
(Reaffirmed 2001)
Indian Standard
ELECTROGALVANIZED COATINGS ON
ROUND STEEL WIRE - SPECIFICATION
ma *3;cmfh
UDC
YnaS ST?if;
faavaw~~*df~f*~
669’14-426’2
: 669’587
@ BIS 1990
BUREAU
MANAK
February 1990
OF
BHAVAN,
INDIAN
STANDARDS
9 BAHADUR
SHAH
NEW DELHI 110002
ZAFAR
MARG
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 applications.
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
protection far both types is similar. In order to rationalize the requirements of different
galvanized wires, coatings have been grouped into three types, that is, heavy, light and
For general guidance, Annex A indicating applicability of various types of coatings on
wires has been included.’
corrosion
types of
medium.
different
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
are in accordance with definitions in IS 3554 :
1966 and IS 1956 ( Part V ) : 1976.
1.1 This standard covers the requirements
of
electrogalvanized
coating on steel wires of circular section in diameters from 0’2 mm up to
and including 10 mm and lays down specifications for:
4 SUPPLY OF MATERIAL
4.1 General requirements relating to the supply
of material shall conform to IS 1387 : 1967.
a) mass of zinc coating,
5 GENERAL REQUIREMENTS
~b) uniformity
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 formation of sludge is minimized while the quality of
coatings is better maintained.
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 electrogalvanized after fabrication.
5.2 Sometimes insoluble anodes as well as soluble zinc anodes of lesser purity, along with continuous filtration of electrolytes are also used.
6 MATERIALS
1.4 The relevant Indian Standard governing a
particular type of wire should refer to this standard for specifying the requirements of electrogalvanized zinc coating.
2 REFERENCES
2.1 The following Indian Standards are necessary
adjuncts to this standard.
Title
.ZS No.
IS 1387 : 1967
General
requirements for the
supply of metallurgical materials
( Jirst revision )
Glossary of terms relating to
IS 1956
( 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
electroplating
relating
to
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
AND MANUFACTURE
6.1 The coatings shall be uniform,
reasonably
smooth
and essentially
produced by electro-deposition.
adherent,
pure zinc
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 coating. 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 electrogalvanized 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 resistance 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’, fluoroboplants
rate, etc. Continuous electrogalvanizing
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:
L.___...._...~.__
_
18 12753:1989
4 Pickling in acid;
4 Rinse;
4 Electrol’)tic cleaning;
f 1 Rinsingg) Mechan ‘1cal cleaner;
other similar purpose, the minimum
coating shall be reduced by 5 percent.
mass of
7.1.2 Care shalltbedexercised to avoid damaging
the samples in detaching them from the finished
strand or cable or coil.
h) Electra-galvanizing;
3 Cold water rinse;
k) Hot water rinse;
4 Supplementary treatment, if desired:
i) Chromate passivation ( light coating),
ii) Phosphate coating ( light coating);
Rinsing and drying; and
P> Take-up unit.
n>
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.
7.2 Freedom from Defects
The electrogalvanized
steel wire shall be uniform, 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.
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
Table 1
7.2.3 Even the best electroplating
practice cannot remove the defects, for example, scratches,
cracks, pits, inclusions, die-marks, etc, on the
surface of the basis steel wire. Accordingly,
the
Mass of Electroplated Coating of Zinc and Number of Dips
( Clauses 7.1 and 7.2.1 )
Light Coated Wire
Heavy Coated Wire
Nominal
r-___-_-__
L-__-)
r----Diameter
Soft
Soft
Hard
Hard
of Electroc-_‘_-_-_~
-h_----,
r-_-h--~
r____h___._~
Galvanized
c--Number
Mass of
Number
Mass of
Number Mass of
Mass of
Number
Wire
of Dips
Coating
of Dips
Coating
of Dips Coating
Coating
of Dips
r--h?
g/m*
F-*-Y
g/m”
‘;--*T
g/m*
Above Up to and g/m8
-*-3
r--h--I
1
1
1
Including
t
t
min
min
min
min
min
min
min
min
(11)
(12)
(5)
(6)
(9)
(10)
(13 1 (14)
(7)
(8)
(f 1
(2)
(4)
No test
No test
15 No test No test 45 No test No test
45
No test No test
0’200
0.315
requirrequirrequirrequirrequirrequir- requiri
required
ed
ed
70
::
z”,
15
Cz
do
Fl:
do
0.400
20
0.315
do
;8
do
do
do
15
:“o
do
0.500
0.400
1%
do
do
20
100
do
do
1
:o”
0,560
0.500
110
::
20
110
0.63
0560
::
120
:
::
3’0”
::
120
d”:
:
do
0.71
0.63
140
140
do
1
0 80
30
0.71
::
150
dd:
150
do
:
30
ddoo
40
0.90
0.80
r
170
0
do
150
:
40
do
1.00
0.90
do
160
:
180
do
40
40
do
1.00
1.25
40
:
I
200
do
40
50
I.40
1.25
180
190
:
1
1
::
do
210
::
50
I .60
60
1’40
1
200
1
230
60
60
1.60
1.80
:
:
240
::
z
210
1
i0
2.00
1’80
1
210
240
2.00
2.24
g
70
:o,
230
:
1
260
z
2.50
2’24
2
230
2
1
260
do
70
r
2’80
2’50
1
270
1::
2.80
3’15
250
240
2’
::
f
s’o”
270
110
3.55
3.15
i
260
2
Y280
11
1%
:
4.00
120
3’55
2
290
:
1
275
2
1
5’00
4.00
130
2
1
1
110
290
140
7.10
5.00
3
290
300
23
L
300
:
140
10.0
7.10
1
110
z
::2
IS 12753 : 1989
Table 2 Requirements for Medium ( Z-Type )
Electroplated Coatings of Zinc
( Clauses 7.1 and 7.2.1 )
Mass of
Coating
s/n-P
(2)
f”l”,
30
0.200 and Up top315
0.400
35
0.315
,,
0.500
45
0.400
,,
0.560
60
0’500
,,
0.63
60
0.560
,,
0.71
60
0.63
O*SO 75
0’71
:;
0.90
0.80
,,
7755
1’00
0.90
1,
1.25
90
1’00
..
1.25
1:
1.40
90
Nominal Diam’eter of
Galvanized Wire,
Above
,.
,,
,?
*,
,V
,’
9,
__
.,
__
,I
1,
1,
.~_
.
.,*.
,3
1)
,*
a.
?-
,,
3,
-~
1’40
;I;;
2.00
2’24
2’50
2’80
3.15
3.55
4.00
Nomin;jH&neter
---?
1 &in
* min
(3)
-
(4)
-
9
1
-
mm
1Jp to and including
3.55
Over 3.55 upto and
including 7.10
Over 7’10
Minimum Complete
Turns of Wrap
10
Rutio Between
Mandrel Diameter and of
Wire
4
10
6
f_ C
. one 90” bend )
6
1
:
1
:
:
1
1
bending, the plated coating does not flake off
nor crack to such an extent that there is possibility of removing any zinc by rubbing with bare
fingers, the use of nail being not allowed.
:
1
1
-
8.3 The electrogalvanized coating shall not flake
off, when subjected to dry or wet drawing. Ths
total reduction should be minimum 20 percent.
L;
1
9 SAMPLING
-
:
9.1 The
samples
ing plan
wire or
absence
shall be
zer and
:
1
electroplaters
responsibility
for defects in the
zinc coating, resulting from such conditions
shall be waived.
8 ADHESION
Requirements for Adhesion Test
C C&use 8.1.2)
Number of Dips
95
1.60
1.80
2.00 1:;
2.24 105
2.50 110
2.80 120
3’15 120
3.55 135
4.00 135
5.00 150
::
,.
..
::
;,
,,
,,
..
;;
,,
Table 3
size of the batch and the number of
to be selected shall be as per the samplspecified in the standard governing the
article fabricated from wire. In the
of such standard, the degree of sampling
as agreed to between the electrogalvanithe purchaser.
9.1.1 Coil for testing shall be selected by the
purchaser.
9.1.2 Portions of wires which are obviously
damaged shall not be used as samples.
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.
9.2 Batch
For the purpose of this standard a batch shall
consists of wires of same dimensions processed
together from pretreatment to final electrogalvanizing.
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 mandrel, the zinc plating shall remain adherent to
the steel wire and shall be considered as meeting
this requirement if owing to such winding or
10 RETEST
10.1 If the batch sample fails to meet any of the
requirements of this standard, double the number 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
Application
FOR APPLICABILITY
OF TYPE OF COATING
DIFFERENT APPLICATIONS
Type of Coating
r----h-__,
Heavy
Light
Mediuz
Fencing wire
Stay strand wire
Signal strand wire
Chain link wire
Rope wire
Spring wire
Cable armouring wire
ACSR wire
Mild steel wire
X
X
x
x
x
-
x
-
x
x
X
x
.X
X
-
x Applicable, -Not
applicable.
Application
Telephone wire
Cycle spoke wire
Barbing wire ( line )
Barbing wire ( point )
PC. wire
Lighting conductor
wire
Rubber hose reinforcement wire
3
FOR
Type of Coating
r----h----
Heavy
x
Light
X
Mediuz
-
x
x
x
X
-
-
X
x
-
X
-
I
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Dot : No. MTD 20 ( 3161)
Amendments Issued Since Poblicatioo
Amend No.
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