--------

IS 12753: lPS9
(Reaffirmed 2001)

Indian Standard
ELECTROGALVANIZED COATINGS ON
ROUND STEEL WIRE - SPECIFICATION
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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.

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
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
I§ 12733 : 19891
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
to 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 Pickling in acid; other similar purpose, the minimum mass of

4 Rinse; coating shall be reduced by 5 percent.
4 Electrol’)tic cleaning; 7.1.2 Care shalltbedexercised to avoid damaging
f 1 Rinsing- the samples in detaching them from the finished
g) Mechan ‘1cal cleaner; strand or cable or coil.
h) Electra-galvanizing;
3 Cold water rinse; 7.2 Freedom from Defects
k) Hot water rinse; The electrogalvanized steel wire shall be uni-
4 Supplementary treatment, if desired: form, smooth and free from visible plating
i) Chromate passivation ( light coating), defects such as blisters, pits, roughness, nodules,
ii) Phosphate coating ( light coating); cracks, burning or unplated area and shall not
be stained, rusted or discoloured. The zinc
n> Rinsing and drying; and
coating shall be continuous and firmly adherent
P> Take-up unit. to the surface of steel.
NOTE - The electroplated zinc surface is attacked 7.2.1 At allpoints more than 3 cm from a cut
by supplementary treatments, thereby diminibhirig the
coating thickness. It is recommended that extra end, the coating shall -withstand the number of
thickness be built for making up this loss. dips in copper sulphate solution set out in
Table 1 and Table 2. when subjected to the
7 COATING REQUIREMENTS 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.
7.1.1 If the wire is tested after being used for
stranding, armouring, barbing, binding or any
Unless otherwise, stated, the finish shall be bright
or semi-bright or dull subject to the agreement
between the purchaser and the manufacturer.
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

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 of Dips Coating of Dips
Above Up to and g/m8 -*-3 g/m* F-*-Y g/m” ‘;--*T g/m* r--h--I
Including 1 1 t 1 t
min min min min min min min min
(f 1 (2) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13 1 (14)
0’200 0.315 No test No test 15 No test No test 45 No test No test 45 No test No test
requir- requir- requir- requir- requir- requir- requir- requiri
ed ed ed
0.315 0.400 20 Fl: z”, 15 :: 70 do do Cz
0.400 0.500 do do 15 do do - ;8 do :“o
0.500 0,560 :o” do 20 do 1% - 1 100 do do
0560 0.63 :: 20 110 - 110
0.63 0.71 :: do :: 3’0” :: 120 - : 120 d”: :
0.71 0 80 30 140 - 140 do 1
0.80 0.90 40 dd: :: 30 ddoo 150 : 150 do
0.90 1.00 40 do do 170 r 0 150 :
1.00 1.25 40 do do 40
40 do 180 160 : -
1.25 I.40 50 40 do 200 : I
1’40 I .60 60 :: :: 50 do 210 1 - 180
190 : 1
1.60 1.80 60 - 60 230 1 200 1 -
1’80 2.00 i0 - : z :: 240 : - 210 1 -
- 1 240 210
2.00
2’24
2.24
2.50 z - 70 :o, 260 g z 230 : 1
2’50 2’80 r - 70 do 260 2 - 230 2 1
2.80 3’15 1:: 1 - 270
3.15 3.55 110 - s’o” :: 270 f 250
240 2’ -
3’55 4.00 120 : 1% 11 280 i 260 2 Y-
4.00 5’00 130 1 290 2 : 275 2 1
5.00 7.10 140 110 1 290 2 1
7.10 10.0 140 : - 300 3 - 290
300 23 L
110 1

::2
 IS 12753 : 1989

Table 2 Requirements for Medium ( Z-Type ) Table 3 Requirements for Adhesion Test
Electroplated Coatings of Zinc C C&use 8.1.2)
( Clauses 7.1 and 7.2.1 )
Nomin;jH&neter Minimum Complete Rutio Between
Nominal Diam’eter of Mass of Number of Dips Turns of Wrap Mandrel Dia-
Coating ---? meter and of
Galvanized Wire, mm
s/n-P 1 &in * min Wire
1Jp to and including 10 4
f”l”, (2) (3) (4) 3.55
0.200 and Up top315 30 -
- Over 3.55 upto and 10 6
Above 0.315 ,, 0.400 35 including 7.10
,. 0.400 ,, 0.500 45 Over 7’10 f_ C
. one 90” bend ) 6
,, 0’500 ,, 0.560 60 - 9
,? 0.560 ,, 0.63 60 - 1
*, 0.63 0.71 60 - bending, the plated coating does not flake off
,V 0’71 :; O*SO 75 - :
- 1 nor crack to such an extent that there is possibi-
,’ 0.80 ,, 0.90
9, 0.90 1, 1’00 7755 1 lity of removing any zinc by rubbing with bare
__
., 1’00 .. 1.25 90 1 - fingers, the use of nail being not allowed.
__
,I
1.25
-~
1: 1.40 90
1, 1’40 :: 1.60 95 : 8.3 The electrogalvanized coating shall not flake
1, ,. 1.80 1 - off, when subjected to dry or wet drawing. Ths
.~_
. ;I;; .. 2.00 1:; -
2.00 :: 2.24 105 total reduction should be minimum 20 percent.
.,*. :
,3 2’24 ;, 2.50 110 L;
1) 2’50 ,, 2.80 120 : 1 9 SAMPLING
,* 2’80 ,, 3’15 120 1
a.
?- 3.15 .. 3.55 135 1 : 9.1 The size of the batch and the number of
,, 3.55 ;; 4.00 135 1 samples to be selected shall be as per the sampl-
3, 4.00 ,, 5.00 150 : - ing plan specified in the standard governing the
wire or article fabricated from wire. In the
electroplaters responsibility for defects in the absence of such standard, the degree of sampling
zinc coating, resulting from such conditions shall be as agreed to between the electrogalvani-
shall be waived. zer and the purchaser.
8 ADHESION OF ZINC COATING 9.1.1 Coil for testing shall be selected by the
purchaser.
8.1 Test Specimen
9.1.2 Portions of wires which are obviously
8.1.1 The test specimen consists of a piece of damaged shall not be used as samples.
wire, long enough to allow the test to be carried
out properly. 9.2 Batch
8.1.2 The test specimen shall be wound round a For the purpose of this standard a batch shall
cylindrical mandrel so as to form close spirals as consists of wires of same dimensions processed
specified in Table 3. together from pretreatment to final electrogalva-
nizing.
8.2 Proceduie
8.2.1 Winding shall be carried out at a rate not 10 RETEST
more than 15 turns per minute.
10.1 If the batch sample fails to meet any of the
8.2.2 When so wound or bent around the man- requirements of this standard, double the num-
drel, the zinc plating shall remain adherent to ber of samples, further shall be tested for each
the steel wire and shall be considered as meeting failure and if any of the sample fails, the batch
this requirement if owing to such winding or shall be treated as rejected.

ANNEX A
( Foreword )
GENERAL GUIDANCE FOR APPLICABILITY OF TYPE OF COATING FOR
DIFFERENT APPLICATIONS

Application Type of Coating Application Type of Coating

r----h-__, r----h----
Heavy Light Mediuz Heavy Light Mediuz
Fencing wire X x - Telephone wire x - -
Stay strand wire X - .- Cycle spoke wire X -
Signal strand wire x - - Barbing wire ( line ) X x -
Chain link wire x - - Barbing wire ( point ) - X -
Rope wire x - X PC. wire x - -
Spring wire - X Lighting conductor x - -
Cable armouring wire x - - wire
ACSR wire x - - Rubber hose rein- X x -
Mild steel wire X x - forcement wire

x Applicable, -Not applicable.

3
I I
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I I
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‘( !
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Revision of Indian Standards

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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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