PROFESSIONAL STANDARD OF

JT
THE PEOPLE'S REPUBLIC OF CHINA
中华人民共和国交通行业标准
JT/T 281-1995

Corrugated Sheet Steel Beams for Expressway

Guardrail
高速公路波形梁钢护栏

Issued on January 05, 1996 Implemented on June 01, 1996

Issued by the Ministry of Communications of the People's Republic of China
 Contents

1 Subject Content and Application Scope ............................................................................... 1

2 Normative References.......................................................................................................... 1
3 Product Classification .......................................................................................................... 2
4 Physical Dimension and Permissible Deviation .................................................................. 4
5 Technical Requirements ..................................................................................................... 16
6 Test Method and Inspection Rules ..................................................................................... 21
7 Mark, Package, Transport, and Quality Certificate............................................................ 22
Appendix A Test Method for Zinc Adhesion Amount in Hot Dip Galvanizing (Antimonic
Chloride Method) (Additional) ................................................................................................ 24
Appendix B Test Method for Uniformity of Hot Dip Galvanizing Coat (Cupric Sulfate
Method) (Additional) ............................................................................................................... 26
Appendix C Test Method for Zinc Coating Adhesiveness in Hot Dip Galvanizing (Hammer
Method) (Additional) ............................................................................................................... 28
Additional Explanation ............................................................................................................ 29
 PROFESSIONAL STANDARD OF
THE PEOPLE'S REPUBLIC OF CHINA
中华人民共和国交通行业标准
JT/T 281-1995

Corrugated Sheet Steel Beams for Expressway Guardrail

高速公路波形梁钢护栏

1 Subject Content and Application Scope

This standard specifies the classification, physical dimension, permissible deviation,

technical requirements, inspection method, mark, package, transport and quality certificate of
corrugated sheet steel beams for expressway guardrail.
This standard is applicable to corrugated sheet steel beam guardrail for expressway and
Class I automobile special highway. Corrugated sheet steel beam guardrail for other classified
highway may be used by reference.

2 Normative References

GB 222 "Method of Sampling Steel for Determination of Chemical Composition and

Permissible Variations for Product Analysis"
GB 223 "Methods for Chemical Analysis of Iron, Steel and Alloy"
GB 228 "Metallic Materials-Tensile Testing"
GB 232 "Metallic Materials-Bend Test"
GB 470 "Zinc Ingots"
GB 699 "Carbon Constructional Quality Steel-Technical Conditions"
GB 700 "Carbon Structural Steels"
GB 708 "Dimension Shape Weight and Tolerance for Cold-rolled Steel Plates and
Sheets"
GB/T 1231 "Specifications of High Strength Bolts with Large Hexagon Head, Large
Hexagon Nuts, Plain Washers for Steel Structures"
GB 2975 "Rules for Sampling in Mechanical and Technological Testing of Steel
Products"
GB 3077 "Technical Specification of Alloy Structure Steels"
GB 6725 "Technical Requirements of Cold Forming Sectional Steel"
JTJ 074 "Specification for Design and Construction of Expressway Safety
Appurtenances"

1
3 Product Classification

The corrugated sheet steel beam guardrail (hereinafter referred to as guardrail) may be
classified into Grade A and Grade S according to impact protection grade and may be
classified into roadside guardrail and median guardrail according to setting position. The
guardrail is composed of such members as corrugated beam plate, post, terminal, fastener and
obstruction block.
3.1 Corrugated beam plate
The corrugated beam plate may be classified into circular arc and broken line types,
thereinto, circular arc corrugated beam plate may be classified into constant section and
variable section, and the dimension specification shall be in accordance with those specified
in Table 1.
3.2 Post
The post may be classified into steel pipe post and interior crimping U-steel post, and the
dimension specification shall be in accordance with those specified in Table 2.
3.3 Terminal
The guardrail terminal may be classified into ground anchor and round head types. The
ground anchor terminal shall be carried out according to the requirements of JTJ 074, and the
dimension specification of round head terminal shall be in accordance with those specified in
Table 3.
Table 1
Impact Specification (mm)
Corrugated Section
protection Code (plate length×plate width×wave height×plate Remarks
shape condition
grade thickness)

DB01 4320×310×85×3 Standard plate

Regulating
DB03 3820×310×85×3
plate
Constant
Regulating
section DB04 3320×310×85×3
plate

Regulating
DB05 2820×310×85×3
plate
Circular arc
BB01 4320×310×85×3 Standard plate

Regulating
A BB03 3820×310×85×3
plate
Variable
Regulating
section BB04 3320×310×85×3
plate

Regulating
BB05 2820×310×85×3
plate

RB01 4330×350×75×4 Standard plate

Constant Regulating
Broken line RB03 3830×350×75×4
section plate

RB04 3330×350×75×4 Regulating

2
 plate

Regulating
RB05 2830×350×75×4
plate

Stiffening
Constant DB02 4320×310×85×3
plate
section
Regulating
DB06 2320×310×85×3
plate
Circular arc
Stiffening
BB02 4320×310×85×3
Variable plate
S
section Regulating
BB06 2320×310×85×3
plate

Stiffening
RB02 4330×350×75×4
Constant plate
Broken line
section Regulating
RB06 2330×350×75×4
plate

Table 2
Product name Code Impact protection grade Specification (mm)

Steel pipe φ114×4.5 or

G-Z
Post φ140×4.5
A, S
Interior crimping
C-Z 125×62.5×25×5
U-steel post

Table 3
Product name Code Specification (mm) Remarks

D-I R-160 Radius R of various terminals may

Terminal D-II R-250 be properly adjusted according to

D-III R-350 geometrical line of highway.

3.4 Fastener
The fasteners of guardrail include the splicing and connecting pieces of plate, post and
terminal, and the dimension specification shall be in accordance with those specified in Table
4.
Table 4
Product name Code Specification (mm) Remarks

M16×32.5
Splice bolt JI-1
M16
Nut JI-2 Splicing used for corrugated beam plate
φ35×4
Washer JI-3

M16×32.5 Used for the connection of obstruction block and U-steel post
Connecting bolt
Used for the connection of corrugated beam plate and obstruction block
JII-1 M16×36
or U-steel post
JII-2
Used for the connection of obstruction block or bracket and φ140 steel
JII-3 M16×170
pipe post
Nut JII-4
Used for the connection of obstruction block or bracket and φ114 steel
Washer M16×140
pipe post

3
 JII-5 M16
Used in conjunction with connecting bolt
JII-6 φ35×4

Transverse beam
JII-7 74×44×4 Screen connecting bolt hole of corrugated beam plate
gasket

3.5 Obstruction block

The obstruction block of guardrail is classified into Type A and Type B, and shall be in
accordance with those specified in JTJ 074 and Table 5 of this standard.
Table 5
Product name Code Specification (mm) Remarks

Used in conjunction with steel pipe

Type A F-1 178×200×3
Obstruction post
block Used in conjunction with U-steel
Type B F-2 200×200×3
post

3.6 Bracket
The dimension specification of bracket shall be in accordance with those specified in
Table 6.
Table 6
Product name Code Specification (mm) Remarks

Used in conjunction with φ140 steel pipe

T-1 300×70×4.5 r =70
post
Bracket
Used in conjunction with φ114 steel pipe
T-2 300×70×4.5 r =57
post

4 Physical Dimension and Permissible Deviation

4.1 Corrugated beam plate

4.1.1 The shape of corrugated beam plate is detailed in Figure 1~Figure 5 and the nominal
dimension and permissible deviation of its cross section shall be in accordance with those
specified in Table 7.
Table 7
Code
Class B H l h1 h2 h3 E r1 r2 r3 α β θ Remarks

310 +-50 85+-30 3±0.16 83±2 39 14 24 24 10 55° 55° 10° I-I profile
Class BB
305.4 85 3±0.16 83 37.7 14 21 27 7 55° 55° 10° II-II profile

310 +-50 85+-30 3±0.16 83±2 42 14 24 24 10 55° 55° 10° III-III profile
Class DB

310 +-50 85+-30 3±0.16 83±2 39 14 24 24 10 55° 55° 10° IV-IV profile

310 +-50 75+-20 4±0.19 52±2 40 31 20 25 25 20 55° 60° - V-V profile

Class RB

310 +-50 75+-20 4±0.19 52±2 40 31 20 25 25 20 55° 60° - VI-VI profile

4
 Splicing blot Connecting blot The rest

Surrounding
Transition section

Note: The requirements for surface

roughness in this standard refer to the state
before coating treatment of member

Profile Profile

Figure 1 Corrugated Beam Plate (Class BB-1)

5
 The rest
Splicing blot

Surrounding
Transition section

Profile Profile

Figure 2 Corrugated Beam Plate (Class BB-2)

6
 The rest
Splicing blot

Surrounding
Splicing blot

Profile Profile

Figure 3 Corrugated Beam Plate (Class DB-1)

7
 Connecting blot
Splicing blot The rest

Surrounding
Splicing blot

Profile Profile

Figure 4 Corrugated Beam Plate (Class DB-2)

8
 Surrounding The rest
Splicing blot
Connecting blot

Profile
Profile

Figure 5 Corrugated Beam Plate (Class RB)

9
4.1.2 The specified length, bolt hole distance and permissible deviation of corrugated beam
plate shall be in accordance with those specified in Table 8.
Table 8
Product
Product name L D X Y L D X Y
name

4320±5 4000±4 4330±5 4000±4

3820±4 3500±2.5 3830±4 3500±2.5

Corrugated
Corrugated 3320±4 3000±2.5 3330±4 3000±2.5
beam plate
beam plate 160±1 100±1 170±1 100±1
(circular arc)
2820 +-32 2500±2 (broken 2830 +-32 2500±2
line)
+3
2320 -2
2000±2 2330 +-32 2000±2

4.1.3 The bolt holes on corrugated beam plate are classified into connecting bolt hole and
splicing bolt hole. The dimension specification is detailed in Table 9 and Figure 6.
Table 9
Nominal dimension and permissible deviation (mm)
Product name Code
a b R

Connecting bolt hole L-1 50 +-10.5 18+-10 9

P-1 24 +-10.5 20 +-10 10

Splicing bolt hole P-2 30 +-10.5 20 +-10 10

P-3 40 +-10.5 22 +-10 11

(1) Connecting bolt hole (L-1) (2) Splicing bolt hole (P-1)

Figure 6 Bolt Hole Dimension

4.1.4 The corrugated beam plate shall be free from any obvious torsion or lengthened
welding; the end burr must be cleaned up, and the form and position tolerance shall meet the
following requirements:
a) The straightness of corrugated beam plate per meter shall not be larger than 1.5mm
and total straightness shall not be larger than 0.15% of specified length of corrugated beam
plate;
b) The end surface notch of corrugated beam plate shall be perpendicular, and the
perpendicularity tolerance shall not exceed 30'.
4.2 Post
4.2.1 The post should adopt steel pipe and interior crimping U-steel and the section form

10
and dimension are detailed in Figure 7; the nominal dimension and permissible deviation of
post section shall be in accordance with those specified in Table 10.
Table 10
Nominal dimension and permissible deviation (mm)
Product name Type
D B h b φ t

Post Steel pipe 114±1.14 4.5

— — — 18+-10
140±1.40

Interior
crimping — 125±2.25 62.5±2.0 25±2.71 18+-10 5
U-steel

Figure 7 Post Section Form (Dimension Unit: mm)

4.2.2 The specified length of post shall meet the relevant requirements of Chapter 5 in JTJ
074 or shall be determined according to design drawing. The bolt hole position and
permissible deviation shall meet those specified in Figure 8.

Circular arc column cap

The rest

Figure 8 Post (Dimension Unit: mm)

a) ▽ is kerb top or pavement elevation; b) Number in brackets is the dimension with obstruction block

4.2.3 The wall thickness of welded steel pipe post shall be 4.5mm and the permissible
deviation of thickness shall be ±0.5mm. The normal thickness of U-steel post base metal shall
be 5mm and the permissible deviation of thickness shall meet the requirements of Class A

11
precision in GB 708.
4.2.3 The post shall be free from any obvious torsion or lengthened welding, and the end
burr must be cleaned. The form and position tolerance shall meet the following requirements:
a) The straightness of post per meter shall not be larger than 1.5mm and total
straightness shall not be larger than 0.15% of specified length of post;
b) The end surface notch of post shall be perpendicular, and the perpendicularity
tolerance shall not exceed 1°.
4.3 Terminal
4.3.1 The shape of round head terminal is detailed in Figure 9 and Figure 10, and the
nominal dimension and permissible deviation shall be in accordance with those specified in
Table 11.

12
 hole The rest
hole
The rest

Surrounding Surrounding

hole

The rest
hole

Figure 9 Terminal (D-I) Figure 10 Terminal (D-II or D-III)

13
 Table 11
Product Nominal dimension and permissible deviation (mm)
Code
name a b c d e f g R h1 h2 t

D-I 60 200±2 450 45 87.5 45+-12 130 160 406 +-15 310 +-15 3

Terminal D-II 250

+1
50 200±2 150 45 87.5 45 -2
130 350 +5 310 +-15 3
D-III 406 -1

4.3.2 The normal thickness of terminal base metal shall be 3mm and the permissible
deviation of thickness shall meet the requirements of Class A precision in GB 708.
4.3.3 The shape of terminal shall meet the following requirements:
a) The terminal shall be free from any obvious torsion;
b) The terminal notch shall be perpendicular and the perpendicularity tolerance shall
not exceed 30′; the end burr must be cleaned;
c) The curve part of terminal shall be round and smooth.
4.4 Fastener
4.4.1 The shape of fastener is detailed in Figure 11 and Figure 12 and the nominal
dimension and permissible deviation shall be in accordance with those specified in Table 12.
Table 12
Product name Nominal dimension and permissible deviation (mm)
Remarks
a b l M R φ d r φ1 φ2

10 19 R value of splicing bolt shall be

Splicing bolt JI-1 3.0 32.5 M16-6g SR20 36 16 —
-12 -23 adjusted correspondingly
Nut JI-2 31.2 27 16 M16-6H — — — — — — according to the difference of

Washer JI-3 — — 4 — — — — 35 17 splicing bolt dimension

Used for the connection of

obstruction block and U-steel
JII-1 2.5 32.5 10
post
M16-6g SR24 36 16 — —
Used for the connection of
corrugated beam obstruction
JII-2 2.5 36 10
Connecting block or U-steel post
bolt Used for the connection of
JII-3 10 170 obstruction block or bracket
and φ140 steel pipe post
M16—6g SR24 24 27.7
Used for the connection of
JII-4 10 140 obstruction block or bracket
and φ114 steel pipe post

Nut JII-5 31.2 27 16 M16—6H — — — — — —

Washer JII-6 — — 4 — — — — — 35 17

Transverse
beam JII-7 76±1 44±1 4 — — — — — — —
Gasket

4.4.2 After the threaded fastener is coated, the cooperation shall not be affected owing to

14
coating.
4.4.3 When the guardrail adopts theft-proof fastening technology, the mechanical
performance and installation and disassembling operating performance of fastener shall meet
the requirements of this standard.
4.5 Obstruction block
4.5.1 The shape and mark symbol of obstruction block are detailed in Figure 13 and Figure
14. The nominal dimension and permissible deviation shall be in accordance with those
specified in Table 13.

The rest

Bolt

Nut Washer

Figure 11 Splicing Bolt

Table 13
Nominal dimension and permissible deviation (mm)
Code Specification Remarks
a h b c d l φ R1 R2

Used in conjunction with

57
φ114 steel pipe post
F-1 Type A 178±3 200±3 89±1 102±2 — 3 60° 36
Used in conjunction with
70
φ110 steel pipe post

Used in conjunction with

F-2 Type B 200±3 200±3 100±1 15 700±8 3 — — —
U-steel post

4.5.2 The shape of obstruction block shall meet the following requirements:
a) The obstruction block shall be free from any obvious torsion;
b) The end surface notch of obstruction block shall be straight and even and the burr
must be cleaned;
c) The welded joints of obstruction block shall be smooth and flat; the position of
welded joints shall be located on any plane without bolt hole.
4.6 Bracket

15
4.6.1 The shape of bracket is detailed in Figure 15 and the nominal dimension and
permissible deviation shall be in accordance with those specified in Table 14.
Table 14
Product Nominal dimension and permissible number (mm)
Code Remarks
name a b c d e r t

Used in conjunction with φ140 steel

T-1 200±2 300 70+-10 31 100 70 4.5
pipe post
Bracket
Used in conjunction with φ114 steel
T-2 200±2 300 70+-10 31 100 57 4.5
pipe post

The rest

Bolt Bolt

Bolt or
Nut

hole

Washer Transverse beam gasket

Figure 12 Connecting Bolt and Transverse Beam Gasket

4.6.2 The shape of bracket shall meet the following requirements:
a) The shape of bracket shall be free from any obvious torsion;
b) The end surface notch of bracket shall be straight and even and the burr must be
cleaned.

5 Technical Requirements

5.1 Material requirements

16
5.1.1 The base metal materials used for corrugated beam plate, post, terminal, obstruction
block, bracket, etc. shall be carbon structural steels, and the mechanical performance and
chemical composition index shall not be less than the requirements of Q235 steel specified in
GB 700.
5.1.2 Base metal materials used for connecting bolt, nut, washer, transverse beam gasket, etc.
shall be carbon structural steels, and the main assessment index of mechanical performance
shall be tensile strength σb, and σb shall not be less than 375N/mm2.
5.1.3 The high-strength splicing bolt connector shall be manufactured by quality carbon
structural steels or alloy structure steels, and the chemical composition and mechanical
performance shall meet the requirements of GB 699 or GB 3077; the nominal diameter shall
be 16mm and Grade 8.8S tensile load shall not be less than 133kN.

17
 Column cap
D direction enlargement (local)

Corrugated beam
hole

Bolt

Bolt
or

obstruction block

post

Figure 13 Obstruction Block (Type A) (Dimension Unit: mm)

18
 The rest

Bolt

Bolt

Side view Front view (local) Elevation

Surrounding

Plane (local)
Expanded view

Note: The dash line of expanded view is fold line; the obstruction block adopts 3mm-thick thin steel plate with welded forming

Figure 14 Obstruction Block (Type B) (Dimension Unit: mm)

19
 Bracket The rest

Bolt
or

Ellipse hole
Ellipse hole

Elevation of pavement or kerb top

Surrounding

post

Figure 15 Bracket
5.2 Processing requirements
5.2.1 The corrugated beam plate shall generally adopt continuous rolling forming.
5.2.2 When the variable section corrugated beam plate adopts hydraulic cold roll forming,
each corrugated beam plate must be completed through single pressing without graded
pressing. When the constant section corrugated beam plate adopting continuous rolling
forming is further processed into variable section plate, the hydraulic cold roll forming shall
be adopted, and the stamping processing method shall not be adopted.
5.2.3 The interior crimping U-steel post shall adopt cold roll forming and bent processing
method shall not be adopted.
5.2.4 The bolt holes on corrugated beam plate must be of correct positioning; all splicing
bolts of each end shall be completed through single punching.
5.2.5 The terminal of steel guardrail shall adopt mould pressing forming.
5.2.6 For the steel guardrail installed to the road section with curve radius less than 70m, the
corrugated beam plate shall be processed into corresponding arc according to the size of curve
radius.
5.3 Appearance quality and anticorrosion treatment
5.3.1 The surface of cold bending black members of corrugated sheet steel beam guardrail
shall be free from any crack, bubble, folding, inclusion or end surface layering, but the slight
pit, bulging, impression or abrasion no larger than 10% of normal thickness may be allowed.
The surface defect may be cleaned with regrinding method; the shaping depth shall be larger

20
than 10% of normal thickness; the section and installation hole shall be free from curling,
flash edge or severe burr.
5.3.2 The anticorrosion treatment of metal shall be carried out for all members of guardrail
shall, and the hot dip galvanizing method should generally be adopted. When other corrosion
protection methods such as hot dip aluminizing and electrostatic spraying are adopted, the
reliable technical data and test verification information shall be available; the anticorrosion
performance shall not be less than the corresponding requirements for hot dip galvanizing
method specified in this standard.
a) When the hot dip galvanizing method is adopted for metal anticorrosion treatment,
the zinc used for hot dip galvanizing shall be No. 1 or No. 0 zinc specified in GB 470. The
zinc adhesion amount of galvanizing members shall be in accordance with those specified in
Table 15. The zinc adhesion amount shall be determined by antimonic chloride method (see
Appendix A), and the thickness of zinc coating may be determined directly with layer
thickness meter; if any dispute, the antimonic chloride method shall be adopted as the
arbitration test method.
b) The surface of galvanizing members shall have uniform and complete coating and
uniform color; the surface shall applicable and smooth and shall be free from sagging, drip
knurl or surplus agglomerate. The surface of galvanizing members shall be free from such
defects as missing and iron exposure. The thread shall be cleaned or the centrifugation may be
carried out for the threaded members after hot dip galvanizing.
Table 15

Average zinc Average zinc Minimum zinc

Minimum zinc
adhesion amount with adhesion amount with adhesion amount with
adhesion amount with
Member name three point method Member name three point method three point method
three point method
2 2
test (g/m ) (single test (g/m ) (single test (g/m2) (single
test (g/m2) (plane)
side) side) side)

Corrugated beam Fastener,

plate, post and 600 425 obstruction block 350 275
terminal and bracket

c) The zinc coating of galvanizing member shall be uniform; the sample shall not be
red (copper coating color, see Appendix B) after quintic copper sulfate solution erosion.
d) The zinc coating of galvanizing member shall be firmly combined with base metal
and the galvanizing coat shall be free from stripping or bulging (see Appendix C) through
hammer test.

6 Test Method and Inspection Rules

6.1 General requirements

6.1.1 Test method for guardrail shall be in accordance with those specified in Table 16.
Table 16
SN Inspection item Sampling quantity Sampling method Test method

One in each furnace

1 Chemical analysis According to GB 222 According to GB 223
number

21
 2 Tension test One in each batch According to GB 2975 According to GB 228

3 Bending test One in each batch According to GB 2975 According to GB 232

4 Zinc adhesion amount One in each batch According to Appendix A

Zinc coating
5 One in each batch According to Appendix B
uniformity

Zinc coating
6 One in each batch According to Appendix C
adhesiveness

Appearance and Adopt measuring tool and template to have

7 Item by item
dimension the test according to conventional method

Visual inspection and hand feeling

8 Superficial mass Item by item
examination

6.1.2 Guardrail supplier shall provide the quality certificate issued by the manufacturer of raw
material of this batch of members. If necessary for the demander he has the right to sample the
base material of this batch of guardrail members to have the mechanical performance or (and)
chemical analysis test(s); the test results shall meet the requirements of this standard and relevant
standards.
6.1.3 The test method and inspection rules of connector of high strength splicing bolt shall be
carried out according to the relevant requirements of GB/T 1231. The test method and inspection
rules of other fasteners shall be carried out according to the requirements of relevant standards.
6.1.4 Batching rules
Corrugated beam plate and post, etc. shall be inspected by batch and each batch shall be
composed of products with identical base material, identical size and identical surface treatment;
the weight of each batch shall not exceed 50t.
6.2 Check and acceptance
6.2.1 Guardrail quality shall be checked and accepted by supplier's quality inspection
department and only the products meet the requirements of this standard after the inspection may
be delivered.
6.2.2 The demander has the right to inspect the products at random and accept them according to
the requirements of this standard.
6.3 Reinspection and criterion rule
6.3.1 In any inspection, if only one item result cannot meet the requirements of this standard,
double samples shall be taken from the identical batch to have the reinspection. Even though only
one item result is unqualified in the re-inspection results (including any index required by this test),
this whole batch shall not be delivered.
6.3.2 The supplier is entitled to reprocess or classify the unqualified products in the reinspection
and then resubmit to have the test as new batch.

7 Mark, Package, Transport, and Quality Certificate

7.1 Such marks as manufacturer name (or logo) and production date shall be marked
respectively on both ends of each corrugated beam plate and the position shall be in the midmost
center of corrugated beam plate cross section 400 mm away from the end.
7.2 The package and mark of corrugated beam plate and post shall meet the requirements of GB

22
6725. The guardrail shall not be delivered in bulk and shall ensure to free from deformation and
damage in hoisting, transportation and stacking processes.
7.3 The package and mark of high strength splicing bolt connector shall be carried out by
reference to the relevant requirements of GB/T 1231. The package and mark of other fasteners
shall be carried out by reference to the requirements of relevant standards.
7.4 The guardrail products shall be firmly fixed in transportation process and prevent from
damaging coating or making the members deform because of bump and crash.
7.5 Certification of quality shall be attached to when the products are delivery from factory and
the material warranty book of manufacturer of this batch of steels raw material shall be provided.
The product quality certificate shall include the following contents:
a) Product (member) name;
b) Product (member) specification;
c) Material of Product (member) and original manufacturer name;
d) Quantity of this batch;
e) Production and inspection date;
f) Test results of each item specified by standards and the opinions of inspection department
on permitting to be delivery from factory (seal);
g) Manufacturer name;
h) Execution standard.

23
 Appendix A

Test Method for Zinc Adhesion Amount in Hot Dip Galvanizing

(Antimonic Chloride Method)

(Additional)

A1 Specimen preparation
A1.1 Supplier inspection
A1.1.1 Representative sample shall be selected according to material, material specifications and
product form and so on.
A1.1.2 After the sample is cut into proper size, it shall be galvanized with products in the
identical process conditions.
A1.1.3 Adhesion amount is calculated by three point method. Cut away 50mm on both ends of
the galvanized sample and then take three pieces from the middle part and both ends of the sample
to determine respectively the adhesion amount; the adhesion amount average value of the three
pieces of samples is the average adhesion amount of the sample.
A1.1.4 The testing area of each sample shall not be less than 100cm2 and the sample surface
shall be free from any damage or list edge.
A1.2 Spot check
During the spot check, three samples shall be cut from the middle part and both ends of the
inspected members and calculated by three point method.
A2 Test solution preparation
Dissolve 3.2g antimony trichloride (SbCl3) or 2g antimony trioxide (Sb2O3) in 500mL
concentrated hydrochloric acid with more than 1.18 relative density to prepare into the stock
solution; before the test, the distilled water shall be diluted into 1 L as the test solution.
A3 Test method
Clean the surface oil stain of the sample with such organic solvents as carbon tetrachloride,
benzol or three chlorinated ene, and then rinse with ethanol, wash with clear water, wipe day with
clean cloth and weigh after thorough drying (with the accuracy of 1%).
The amount of the test solution shall be prepared to according to no less than 10mL/cm2 on
sample surface. Place the weighted sample into the test solution (maintaining the temperature of
the test solution shall not be above 38℃) until the galvanizing coat is dissolved completely and
the hydrogen bubble reduces obviously. Take the sample out and wash it with clear water, remove
attachment on surface with scrubbing brush, wipe dry with cotton or clean cloth, and then immerse
it into ethanol, take it out and dry rapidly and weigh again with identical accuracy. Weigh the
sample and measure its superficial dimension (with the accuracy of 0.01mm).
A4 Adhesion amount calculation
Adhesion amount is calculated according to Formula (A1):
G1－G 2
A= ´ 106 …………………………………(A1)
S
Where:

24
 A——the adhesion amount, g/m2;
G1————the sample mass before the test, g;
G2————the sample mass after the test, g;
S——the superficial area of the sample, mm2
A5 Approximately thickness of galvanizing coat
Approximately thickness of galvanizing coat shall be calculated according to Formula (A2):

A
d= ………………………………………(A2)
r
Where:
δ——the thickness of galvanizing coat, µm;
A——the adhesion amount, g/m2;
ρ——the density of galvanizing coat, g/cm3, and the approximate value of ρ is 7g/cm3.
A6 Approximation relation between zinc adhesion amount and zinc coating thickness
Approximation relation between zinc adhesion amount and zinc coating thickness is detailed
in Table A1.
Table A1
Approximately thickness of zinc Approximately thickness of
Zinc adhesion amount (g/m2) Zinc adhesion amount (g/m2)
coating (µm) zinc coating (µm)

600 85 350 50

425 61 275 39

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 Appendix B

Test Method for Uniformity of Hot Dip Galvanizing Coat

(Cupric Sulfate Method)

(Additional)

B1 Specimen preparation
B1.1 Supplier inspection
B1.1.1 Representative sample shall be selected according to material, material specifications and
product form and so on.
B1.1.2 After the sample is cut into proper size, it shall be galvanized with products in the
identical process conditions.
B1.1.3 The specimen with more than 100cm2 area cut from the sample shall have the copper
sulfate test.
B1.1.4 Original of the small-scale member such as bolt and nut shall have the copper sulfate test.
B1.1.5 Remove the surface oil stain of the sample with such organic solvents as carbon
tetrachloride, benzol, wash with clear water, wipe dry with clean cloth and immerse into 2%
sulphuric acid solution (2mL sulfuric acid with 1.84 relative density is diluted with 98ml water)
for 15s, take it out and wash with clear water and wipe dry with clean cloth.
B1.1.6 The surface of the specimen shall be free from rugged face or any damage.
B1.2 Spot check
During the spot check, three samples shall be cut from the proper place in the middle and
both ends of the inspected corrugated beam plate and post members (if one of them is unqualified,
this member is unqualified). Take one sample in place from the rest members to have the test.
B2 Test solution preparation methods
B2.1 Dissolve the 36g CuS04·5H2O into 100mL distilled water, heat the solution until it is
dissolved, cool until room temperature, add cupric hydroxide or copper carbonate (1g in each 1L
copper sulfate solution), mix uniformly, place for more than 14h, and then filter or suck out the
settled solution above for use. The solution's relative density shall be 1.18 at the temperature of
18℃, or regulate it with concentrated copper sulfate solution or distilled water. The concentration
of cupric sulfate shall not be less than 90% of nominal solution in any case.
B2.2 Cupric hydroxide preparation method: place 10% of caustic soda solution into copper
sulfate solution with mass ratio of 1:5 and generate greenish cupric hydroxide precipitation and
then filter and wash the solution until it has no free alkali.
B3 Test preparation
B3.1 Copper sulfate solution shall be contained in inertia container which will not have chemical
reaction with cupric sulfate; the container shall have so appropriate volume that the sulphuric acid
solution is able to immerse the sample and the distance between the sample and vessel wall shall
be no less than 25mm.
B3.2 The amount of copper sulfate solution shall be prepared according to no less than
10mL/cm2 of the tested area of the sample.

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B4 Test method
B4.1 Place the prepared sample into 18℃±2℃ solution for 1min, in this period, don't stir the
solution or move the sample. After 1min, take the sample immediately, wash with clear water,
remove the black precipitate with flexible hairbrush, especially the precipitate at the recession of
the hole, dry with clean cloth and immediately have the next erosion.
B4.2 The sample shall be immersed into solution immediately except the last erosion.
B4.3 The test solution shall be dumped after 15 erosions.
B5 Determination of the erosion ends
B5.1 Erosion end arrives until the red metallic copper appears on the sample after the
above-mentioned tests. The erosion with metallic copper appearance is not counted as copper
sulfate test times.
B5.2 Scrape off the adhesive metallic copper with no-blade tools and if metallic zinc still
appears under the copper, it is not a corrosion end.
B5.3 If it is doubted whether the zinc coating exists under the bottom surface of the red metallic
copper precipitation, scrap the red precipitation and drip one or some drops of dilute hydrochloric
acid at this place; if the zinc coating exists, active hydrogen will generate. Moreover, zincoid
qualitative test may be used to determine: collect the dripping acid liquor with scrap filter paper or
filter paper or pipette, neutralize it with ammonium hydroxide to make it faintly acid, get through
hydrogen persulfide into this solution and determine by the evidence whether the white
precipitation (zinc sulfide) generates.
B5.4 The following situations are not included into the erosion ends:
a) When the red metallic copper appears within 25mm from the head of specimen;
b) When the red metallic copper appears at the sample's corner angle;
c) When red metallic copper appears at the damaged place after galvanizing and its
periphery.

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 Appendix C

Test Method for Zinc Coating Adhesiveness in Hot Dip Galvanizing

(Hammer Method)

(Additional)

C1 Hammer test device

The hammer for test shall be installed in solid wooden table; the test surface shall keep the
identical height with hammer pedestal and stay in the identical horizontal plane. The hammer test
device is shown in Figure C1.

Handle hole

Part

Figure C1 Hammer Test Setup Diagram (Dimension Unit: mm)

C2 Test rule
The specimen shall be placed flat; the hammerhead faces jack horse center and hammer shaft
has the free fall after it is vertical to pedestal plane and strike parallelly five points at the interval
of 4mm; check the surface conditions of zinc coating. The striking points shall be beyond 10mm
from the end and do not strike twice in the identical point.
C3 Test device material
C3.1 Hammerhead uses No. 45 steel. The mass is 210g (±10g) and the hardness of hammer

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blade (Shore) is above 40.
C3.2 The hammer shaft is produced by oak and the mass is about 70g.
C3.3 Pedestal steel plate is 15mm in thickness and 250mm×250mm in length and width; the
material is Q235.
——————————————

Additional Explanation
This standard is proposed by and under the jurisdiction of the Highway Administration
Department of Ministry of Communications.
This standard is drafted by Ministry of Communications Highway Scientific Research
Institute.
Chief drafting staffs of this standard: Yang Jiuling and He Yong.

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