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Contents
Contents ............................................................................................................................................................................................. 1
Foreword ........................................................................................................................................................................................... 2
Introduction ....................................................................................................................................................................................... 2
1.0 Scope ..................................................................................................................................................................................... 3
1.1 General .....................................................................................................................................................................3
1.2 Not in scope ...........................................................................................................................................................3
2.0 Dealing with old/superseded/obsolete/phase out coatings....................................................................................... 4
3.0 Concessions ......................................................................................................................................................................... 4
4.0 Corrosion protection theory .......................................................................................................................................... 5
5.0 Mixing of various coatings on assemblies...................................................................................................................... 5
6.0 Supply condition.................................................................................................................................................................. 5
7.0 Considerations in choosing a coating ............................................................................................................................ 6
7.1 General .....................................................................................................................................................................6
7.2 Thread-forming screws into plastic components...........................................................................................6
7.3 Acceptance trials....................................................................................................................................................6
8.0 Stress relief........................................................................................................................................................................... 7
8.1 For fasteners ...........................................................................................................................................................7
8.1.1 Grade 8.8 .................................................................................................................................................................7
8.1.2 Grade 10.9 or higher ............................................................................................................................................7
8.2 For other than fasteners ......................................................................................................................................7
8.2.1 Stress relief prior to electroplating ...................................................................................................................7
8.2.2 Hydrogen embrittlement stress relief ..............................................................................................................7
9.0 Coating attributes............................................................................................................................................................... 8
9.1 Colour ......................................................................................................................................................................8
9.2 Conversion coatings (passivation) .....................................................................................................................8
9.3 Sealing (top coat) ...................................................................................................................................................8
9.4 Painting or other supplementary coatings .......................................................................................................8
9.5 Damage resistance .................................................................................................................................................8
10.0 APPROVED COATING TYPES ...................................................................................................................................... 9
11.0 Coating physical requirements ...................................................................................................................................... 14
11.1 Adhesion ............................................................................................................................................................... 14
11.2 Temperature resistance .................................................................................................................................... 14
11.3 Thickness .............................................................................................................................................................. 14
11.4 Corrosion performance requirements .......................................................................................................... 15
11.5 Friction coefficient .............................................................................................................................................. 15
12.0 Thread inspection ............................................................................................................................................................. 16
13.0 Corrosion test methods ................................................................................................................................................. 16
13.1 Neutral salt spray................................................................................................................................................ 16
13.2 Corrosion visual inspection.............................................................................................................................. 16
13.2.1 General .................................................................................................................................................................. 16
13.2.2 Components other than threaded fasteners................................................................................................ 16
14.0 Drawing call-out / identification .................................................................................................................................... 17
Foreword
This standard has been prepared under the authority of the JCB Standards and Legislation department
(Standards department).
This standard is intended solely for use in connection with the business requirements of J C Bamford Excavators
Ltd. (JCB) and is for use by appropriately qualified and competent people.
Contractual and legal considerations are not part of the scope of this standard. This standard does not
relinquish any responsibility, regulatory requirements, or duty of care.
Introduction
JCB GLOBAL REQUIREMENT IS TO PROHIBIT THE USE OF COATINGS WHICH CONTAIN
HEXAVALENT CHROME (Cr6) IN LINE WITH REACH LEGISLATION.
FOR JCB, THIS MEANS SPECIFICALLY TYPE 3 & 4 - ZINC AND YELLOW, WHICH IS TO BE PHASED OUT
ON BUILT PRODUCTS BY 01 JAN 2018.
CHANGES HAVE BEEN MADE TO THE DEFAULT RULES FOR FASTENERS IN ZINC AND YELLOW, AS
STIPULATED IN SECTION 2.0.
1.0 Scope
Always consult electronic master. Paper copies are uncontrolled.
1.1 General
The main body of this standard contains specifications for approved zinc-based coatings (‘zinc coatings’), applied
either by electrolytic or by mechanical processes (e.g. dip-spin) which may be used for corrosion protection and
/ or cosmetic purposes on JCB machines.
Designers must first check within JCB standards whether a coating(s) requirement specific to the component
already exists, before specifying a coating from this standard.
JCB Power Systems shall independantly manage their transition away from zinc and yellow.
JCB will revise relevant drawings and Bills of Materials to replace any reference to
Type 3&4 zinc and yellow with an alternative coating from this standard.
3.0 Concessions
In the case of a failure to conform to the requirements of this standard:
- where the procurement of specified coatings is unworkable due only to their non-availability, alternatives from
this standard may be specified by JCB (except for hydraulic components)
otherwise
- a documented concession should be generated following the requirements given in GRP-023. Suppliers should
contact their JCB purchasing contact to obtain a copy of the standard operating procedure covering concessions
(GRP-023).
principle that corrosion occurs in anodic (positively charged) areas and is facilitated by cathodic (negatively
charged) areas. The zinc base of the corrosion protection coating is naturally more anodic and therefore more
active than steel, which is more passive (noble), according to the galvanic table. This galvanic relationship makes
the steel into the more passive cathode whenever coupled to zinc which becomes the active anode. The zinc is
known as the sacrificial anode. The corrosion of zinc produces white, powdery zinc oxide (white rust) and only
once the majority of the zinc has corroded will the steel begin corroding, indicated by the presence of red rust
(iron oxide).
Hydraulic components:
Cleanliness and packaging shall conform to 9993/0003.
The finishing process shall provide protection against ‘flash rust’ on un-coated areas. Under normal storage
conditions (e.g. shop floor) these areas shall remain free of rust for a minimum of two weeks.
All parts shall be rust and damage free at the point of use.
7.1 General
Considerations to define the choice of coating include:
- colour - silver or grey or black (clause 9.1)
- longevity of corrosion protection (clause 13.1)
- effect of tooling damage to coating / reduction in corrosion protection (see clause 9.5)
- colour-matching to other components (clause 5.0)
- whether over-painting is a requirement (clause 9.4)
- risk caused by hydrogen embrittlement (electroplated coatings only – clause 8.2.2)
- cost (beyond the scope of this standard, but cost vs. quality must be considered)
- fastener grade and size (clause 8.0)
- thread-forming screws into plastic require special consideration (see clause 7.2)
The table in clause 13.1 specifies the minimum corrosion resistance requirements for each coating.
Note: coatings being phased out can now be found in section 15.0.
Coatings in this standard are allocated a type number for the purpose of simplification and are listed chronologically in this clause.
Column ‘Coating suffix for fasteners’ indicates the suffix to use in fastener part numbers (only) to denote a particular coating, where relevant (example of part numbers
incorporating the suffix letter can be found in Annex B.
Type Description Colour Image Attributes Limitations
Mechanically applied, usually via spray or Damaged by poor handling processes and impact/percussive
dip-spin. tools which will cause significant reduction of corrosion
resistance - it is recommended that trials be conducted
Can offer superior corrosion resistance prior to introduction.
White
Zinc aluminium for thinner coatings compared with May collect in recesses, thread roots, hex. sockets, etc.
Avoid use for threaded components smaller than M6, or
1 flake - (silver-
grey).
conventional coating methods.
No hydrogen-embrittlement; those with a thread pitch less than 1mm- Type 7 is
silver Dull. recommended for fasteners. suggested as an alternative. May cause sticking and/or
Self-repairing. marking of washers smaller than M10.
Usually electrically conductive.
Beneficial in removal/refit applications. KL100 with VH302 top coat contains silicate and may
Water or solvent based options. impede overpainting.
Note 1: Type 1 Zinc Flake - coatings approved for use (licence holder):
- Geomet 500A (NOF)
- Delta Protekt KL100 + VH302 friction control coating (Doerken)
- Delta Protekt KL105 - enhanced control of friction co-efficient where this is required e.g. for bolted joints (Doerken)
- Magni 565 or Magni 560 (Magni)
The licencing and application of the above is strictly quality controlled to provide reliable and controlled coatings.
Silver approved coatings are licenced. Licencing and application is strictly quality controlled to provide reliable and controlled coatings.
Note 2: According to BS EN ISO 10683 the description for the appearance of zinc flake is silver-grey. This and other JCB standards specify the appearance as ‘white aluminium’;
this description is retained here for clarity and continuity.
Type 8:
- Zinclad 1000B with Torque & Tension 15 top coat (MacDermid).
Type 8P:
- Zinclad 1000 with no top coat (MacDermid).
Mechanically applied usually significant reduction of corrosion resistance - it is recommended that trials be
via spray or dip-spin. conducted prior to introduction.
No hydrogen-embrittlement
issues. May cause infil to heads e.g. hex. sockets and collect in recesses and thread roots.
Self-repairing. Where possible avoid use on threads smaller than M6, or of less than 1mm pitch.
9 Usually electrically
conductive.
May casue sticking and/or marking of washers smaller than M10. For these
reasons, Type 8 is recommended instead.
Zinc Black, Beneficial in removal/refit
flake - slight applications. BU’s must assess and approve for their own use.
gloss Torque control lubricant
black intergrated within base coat
Not suitable for thread-forming screws into plastic components -
or top coat.
choose Type 8P or 9P.
As Type 9, but WITHOUT
the torque control lubricant. As Type 9.
9P Suitable for use on thread-
forming screws into plastics Only to be specified for thread-forming fasteners into plastic components.
(hence ‘P’ in 9P).
Approved for use (licence holder):
Type 9:
MKS Delta Protekt KL100 with Delta Seal GZ Black top coat (Doerken).
Type 9P:
MKS Delta Protekt KL100 with Delta Seal (Black) top coat (Doerken).
11.3 Thickness
Typical coating thickness is 10±5 microns (info).
Note*: Alternative / improved tooling may help reduce damage to coatings (see also clause 9.5 and 16.0).
Note**: Realigned with industry standard supply and demand; this applies to ‘coating white corrosion’
(required duration for base metal to red corrosion is not affected). 240hrs is preferred where available, but
168hrs will be accepted if (and only if) 240 cannot be achieved through manufacturing constraints.
Note 1: Type 8/8P and Type 9/9P are capable of achieving 1000hrs+; the table above specifies minimum
requirements.
Where a BU wishes to investigate the effects of screwthread tightening and untightening on the
durability of the corrosion preventive coating this should be performed after an initial assembly and
disassembly. It should be noted that the corrosion resistance of certain coatings will be adversly
affected if damaged by tooling or rough handling during this test. The following conditions are
suggested. Assembly prior to corrosion testing shall be by use of:
- tooling of the correct size (e.g. hexagonal chrome vanadium socket)
- calibrated manual torque wrench
- torque tightening to 75% of theoretical yield
- nut shall travel over a minimum of 2d thread engagement (where d is nominal diameter)
Parts shall be disassembled prior to corrosion testing.
Where hydraulic joints occur, or parts thereof, these shall be assembled and manually tightened
using the correct tooling to 100% of specification. The tightening method described for ‘sealing face
characteristics’ in Annex A shall be used where this is applicable to the joint design. Parts shall then
be disassembled prior to corrosion testing.
13.2.1 General
For the purposes of assessment, the presence of white corrosive product indicates corrosion of the
coating (‘white rust’) and the presence of red corrosive product indicates corrosion of the base
metal (‘red rust’).
Fastener-specific requirements can be found in Annex B.
constitute a failure.
There shall be no corrosion of the base metal.
Following the test duration required for the base metal there may be, at most, slight corrosion of
Always consult electronic master. Paper copies are uncontrolled.
14.2 Fasteners
Drawings shall include:
- the statement “CORROSION PROTECTION TO JCB STANDARD STD00017”
- the coating type number (e.g. Type 9)
- the finish colour (e.g. Black)
(see Note below)
NOTE:
Coating suffix letter (e.g. 1315/1234D)
Only common, standard fastener parts, as specified and listed in JCB Standards, carry a final suffix letter (tabulated in
Annex B); these letters are not to be used for non-standard parts.
15.1 Types
Type Description Colour Attributes Limitations Coating
suffix for
fasteners
Note 1: Types 3 and 4 were originally specified from differing British standards which are now obsolete. The coating specification for
Types 3 and 4 is now identical. Each of the type numbers 3 and 4 are retained within this document for clarity and continuity.
Note 2: Types 3 and 4 contain hexavalent chromium (Cr6) which is known to be environmentally harmful. This coating will become
increasingly difficult to source with impending legislative requirements to reduce its usage and with an expected gradual increase in cost.
However, Types 3 and 4 are currently the only approved choices where a yellow finish is a specific design requirement.
suffix for
fasteners
- the ability of the chosen tooling to repeatedly apply a pre-set calibrated torque value
- paint infill will affect torque tightness
- coating frictional coefficient will affect torque tightness
This standard (at issue 16) incorporated requirements for zinc coatings on hydraulic components
Always consult electronic master. Paper copies are uncontrolled.
Exceptions
Where a drawing calls up a superior performance coating, the drawing shall take precedence,
provided that the coating is not listed in section 2.0.
Threads
Always consult electronic master. Paper copies are uncontrolled.
After the application of a zinc coating, all hydraulic component threads shall conform to the relevant
JCB standard.
With the applied force (F1) removed and a force applied to F2 causing the pipe or hose fitting to
tend to rotate, the following relationship applies; F2 x Y >= 50% x F1 x X
i.e. the torque applied to the pipe before any movement occurs must not be less than 50% of the
applied tightening torque. Any movement of the pipe or hose fitting must not cause the swivel nut
torque to move.
Rules
Where a part would ordinarily fit into a part family / part number table in a JCB
standard (e.g. fasteners, clips) the user must first contact JCB S&L for advice.
Engineers may create special fasteners or other items, the specifications of which are
not detailed in JCB standards, by using a generic 'off the clock' part number with a
comprehensive specification (drawing).
Note: JCB utilise an intelligent part numbering sytem for standard bolts, set screws, nuts, washers and the like and a letter
as the final digit of the part number identifies the coating type. Parts are grouped into ‘part families’ for the designer to call
up.
Specials / non-standard fasteners not listed in JCB Standards should take an ‘off the clock’ number
and should not include the letter.
e.g. 1315/3208D:
Coating type Fastener final digit
no coating no digit
1 D
5 V
7 G
8 N
8P not assigned
9 B
9P not assigned
Coating thickness
Coating thickness measurement methods for fasteners is defined within BS EN ISO 10683 for
mechanically-applied zinc flake and in BS EN ISO 2081 for electroplated coatings.
Threads
Requirements have been relocated to fastener standards JCB STD00004 and STD00007.
Prepared by: Kim Spence
Date: 26/07/2017 Amended by: P Smallman Approved by: P Smallman
STD00017
GROUP STANDARD ISSUE: 18
TITLE: Corrosion preventive zinc-based coatings PAGE: 24 OF 28
THIS DOCUMENT IS THE PROPERTY OF J C BAMFORD EXCAVATORS LTD. IT MUST NOT BE COPIED, REPRODUCED OR TRANSMITTED WITHOUT PRIOR WRITTEN CONSENT
The JCB coatings phase out programme will mean that approved finishes within are of the same
coefficient of friction, such that the nominal tightening torque for a given fastener type will be
constant whatever coating is specified.
Lubricant test methods shall conform to the requirements of BS 7371-2. Ten consecutive fasteners
randomly selected shall be tightened until 75% of theoretical yield load is achieved. The variation in
installed torque shall not deviate by more than 10% from the mean value.
Threaded fasteners
Following the test duration required for the coating, there shall be, at most, slight corrosion of the
coating on less than 5% of the significant surfaces and moderate corrosion of the coating on other
surfaces (according to ISO 10289:2001). Black or grey staining or spotting should not constitute a
failure.
There shall be no corrosion of the base metal.
Following the test duration required for the base metal there shall be, at most, slight corrosion of
the base metal on less than 5% of the significant surfaces and moderate corrosion of the base metal
on other surfaces (according to ISO 10289: 2001).
The figure below identifies and classifies significant areas of fasteners for the purposes of assessing
corrosion protection offered by the coating.
Bolt / Screw significant surfaces (A):
- External head surfaces and drive surfaces
- End of bolt
Exclusions:
A - Internal drive surfaces
- Shank and thread
- Edge of flanged head (C)
Design
Incompatible coatings - Corrosion creep or migration
Specifying coatings with different corrosion resistance that are in contact (such as a bolt and washer)
will cause the earlier corrosion type to migrate and cause premature corrosion of the adjacent
coating.
Production Engineering
BU’s must ensure that:
- lineside operatives are adequately trained in the correct use of tooling
- there is adequate process control in place to prohibit the use of worn driver tips/sockets
- goods received with contamination within screw threads must be rejected
Note: Screw thread contamination:
It is NOT acceptable for screw threads to be contaminated by paint / foreign bodies as this will have a detrimental effect
on tightening up to a specified torque, hence joint tightness will be affected (e.g. torque clutch assembly tools can stall).
All threads are to be protected from shot blast, paint, or other material. (Paint clearing fasteners should not be required).
09 09/05/2014 Additional suffix letters defined to denote new coating types (introduced at issue 08) when used in -
fastener part numbers.
Note: Short period between this and previous issue means that revisions in issue 08 shall carry over for
issue 09.
New Type 8 black coating introduced (JCB Landpower request-application driven). -
New Type 9 black coating introduced (to replace Type 2 and black ‘Polyseal’).
Amend ‘Type 1 zinc flake’ to become ‘zinc flake – silver’ (to distinguish it from any other zinc flake
coating).
To indicate that a black proprietary coating ‘Polyseal’, referenced on certain JCB drawings, is increasingly
difficult to source (recently capability in the UK has ceased, now approx. only two platers worldwide) and
an alternative is recommended within.
08 14/03/14 VH302 friction control coating added to the specification for Delta Protekt KL100.
‘A’ added after Geomet 500 to guarantee the minimum salt spray requirement.
Enhanced salt spray requirements reflect coating process improvements.
'Relative cost' removed from coating attributes as these may not now reflect current status.
Coating ‘Typical Thickness’ deleted.
Neutral Salt Spray: requirement of assembling and disassembling fasteners prior to subjecting components
to test has been demoted from a general requirement to a JCB business unit level option.
Visual inspection criteria deleted (formerly in Annex A).
To add a new Type 1 zinc flake coating - Delta Protekt KL 105. None
7 20/09/2012 Minor clarification of the approval process.
Cross reference superseded coatings to latest types.
Introduce Delta Protekt KL100 as an approved Type 1 zinc flake coating. The removal of a specific brand- None
6 30/08/2010 named coating from the table for Type 1 zinc flake now makes this coating type generic rather than
specific to one brand.
To correct the inspection gauge size from g to h for coated metric male threaded fasteners, to clarify the None
5 19/11/2009 scope, to elevate zinc and yellow electroplating (Types 3 and 4) from non preferred status, to reference
current standards and to make significant editorial changes to improve document flow.
To catalogue all of the coating types used regularly on JCB products in order to clarify the details None
regarding the choices available and the performance requirements for those coatings.
4 01/09/2008
The threat of future legislation will affect the use or availability of Hexavalent Chromium (Cr6) i.e. zinc
and yellow.
To identify the two acceptable corrosion preventive zinc flake coatings that satisfies the requirements of None
3 11/2006 white aluminium (type 1) coatings specified in this standard.
First issue - the use of different types of coating systems for fasteners have become common practice 9994/1100
within JCB and this standard has been introduced to define minimum performance requirements to STD00013
control quality and consistency. 9994/0301
Where superseded coatings are referenced on drawings etc. the following alternatives from this standard 9994/0302
should be used:
1 09/2003
Superseded standard Coating type STD00017 coating type to be used:
9994/1100 zinc flake 1(silver) or 9 (black) [or 8, black]
9994/0301 zinc and yellow 3 or 4
9994/0302 zinc and yellow 3 or 4
NSS A means of accelerating corrosion by exposing components to a constant mist of salty water
(Neutral Salt Spray) at a slightly elevated temperature for a specified duration, after which corrosion on the
component is visually assessed against specified levels, which may be deemed to represent a
number of months or years of in-service life.
S&L JCB Standards & Legislation department
White Rust Corrosion of top coat resulting in a white ‘rust’ forming on the surface
Red Rust Corrosion of the base material resulting in a red/brown rust forming on the surface
References
This standard incorporates provisions from other standards. These references are cited at the
appropriate places within the text and are listed hereafter. For undated references, the latest edition
applies.
- STD00019 Tightening torques for plain threaded fasteners
- JCB 9993/0003 Hydraulic component cleanliness requirements
- BS 7371-2 Coatings on metal fasteners - Part 2: Specification for torque/clamping force relationship
- BS EN ISO 10683 Fasteners - Non-electrolytically applied zinc flake coatings
- BS EN ISO 2081 Metallic and other inorganic coatings - Electroplated coatings of zinc with supplementary
treatments on iron or steel
- ISO 105-A02 Tests for colour fastness
- ISO 898-1 Mechanical properties of fasteners made of carbon steel and alloy steel. Bolts, screws and studs
- ISO 4042 Fasteners – Electroplated coatings
- ISO 9227 Corrosion tests in artificial atmospheres - salt spray tests
- ISO 10289 Methods for corrosion testing of metallic and other inorganic coatings on metallic substrates
Rating of test specimens and manufactured articles subjected to corrosion tests
- ASTM B117 Standard Practice for Operating Salt Spray (Fog) Apparatus