AS 1650—1989 Australian Standard® Hot-dipped galvanized coatings on ferrous articles Fat pulses ip part as AS KSI—1942 cond eden 1900 Si ea et st pubic 1 fand AS 1650-—i974 revised, amalgamated od redesignated AS 1680-181. ‘Third edition 1988, PUBLISHED BY STANDARDS AUSTRALIA (STANDARDS ASSOCIATION OF AUSTRALIA) 7 THE CRESCENT, HOMEBUSH, NSW 2140 ISBN 0 7282 S848 0AS 1650-1989 2 PREFACE ‘This Standard was prepared by Standards Australia’s Committee on Metal Finishing to supersede AS 1650--1981, Galvanized coatings. In this edition the section on fasteners has been deleted. It is considered that this is adequately covered by AS 1214, Hot~dip galvanized coatings on threaded fasteners (USO metric coarse thread series). ‘The Preece Test for uniformity of coating is not included in the Standard since it is recognized, both in Australia and overseas, that it has many drawbacks which make it highly suspect in a pass/fail situation. © Copyright ~ STANDARDS AUSTRALIA sas of Sands te rminded tat copyright sbi all Sidads Ania puss and software, Except where the Copyright Act allows and exept where provid Tor below no publieations or software produced by Siandards Awtcae a) sored, ordi eile py farmer rave ay meas it pt perms aii am Sans Satan Petsson onditonal'on an appropiate royalty paymeat, Requests for permission and intrmation on 3 mm 00 Steet ihiskness 3 2 mm < $ mm 450 Steel, thickness < 2 mn 350 Castings Giron and steel) 600 $00 Gentrifuged work * Lao comting mass = 0.14 um coating thickness (for information on, copreasnrAPPENDIX A PURCHASING GUIDELINES (This Appendix does not form an integral part of this Standard.) AT GENERAL. Australian Standards are intended to include the technical provisions necessary for the supply of products referred to in the particular Standard but do not purport to comprise all the necessary provisions of a contract. This Appendix contains advice, and recommendations on the information to be supplied by the purchaser at the time of enquiry or order. Its aims are to avoid misunderstanding, and to result in the purchaser receiving satisfactory products and services. A2_ INFORMATION TO BE SUPPLIED BY THE PURCHASER. The purchaser should supply the following information at the time of enquiry and order: (@) Reference to this Australian Standard, i.e, AS 1650. (b) The nature of the product to be galvanized and its end use (a drawing and sample are useful). (©) Any requirement in regard to drilling, etc (see Clause 1.4.0). (@) Coating class, in the case of sheet and wire. (©) Whether a one-surface coating mass is required for hollow sections (ee Clause 3.3.1). (©) Any special requirements for frequency of testing, (@) Whether a chromate conversion coating is required, and if so, the applicable type (ee AS 1791). (b) Whether removal of surplus zine on threads is required (see Clause 1.5.2). @ Whether an additional test for uniformity of the coating is required. Details of ‘test requirements should be included. @_ Whether a test report covering coating mass and adhesion is required. (k) Requirements for independent testing if applicable. (Whether itis the intention of the purchaser to inspect the coated product at the galvanizer’s works. (mm) Any special or supplementary requirements, e.g. special finish, post treatment, (2) Instructions for renovation of damaged or uncoated areas (see Appendix F), COPYRIGHT AS 1650—1989AS 16501989 APPENDIX B DETERMINATION OF COMPLIANCE OF A BATCH (This Appendix does not form an integral part of this Standard.) Bi AUSTRALIAN STANDARDSMARK. |The general purpose of the Australian StandardsMark is to provide an independent assurance reinforcing the claim by the ‘manufacturer that articles comply with an Australian Standard. ‘An essential feature of the scheme is that it does not rely merely upon initial type tests and subsequent check tests, but places on the manufacturer the onus of ‘maintaining an effective system of quality control. Its aim is to ensure that the manu- facturer makes his product ‘right first ume’, so that faulty production is avoided and the interest of the consumer in obtaining reliable products, fit for their purpose in terms of the Standard, is safeguarded. B2_ ASSESSMENT OF COMPLIANCE ON THE BASIS OF STATISTICAL SAMPLING. Where compliance with this Standard is to be assessed on the basis Of statistical sampling and inspection, the sampling plan should be in accordance with either AS 1199 (Waking into account the guidance given in AS 1399), or AS 2490, The designation of an acceptable quality level does not imply that the supplier has the right to knowingly supply any defective item or unit of production. B3 ASSURANCE OF COMPLIANCE ON THE BASIS OF SUPPLIER'S QUALITY SYSTEM. Where compliance with this Standard is to be assured on the basis of a supplier's quality system, the acceptance procedures should include provision for— (a) type testing, type approval and maintenance of type approval; and (b) the customer to specify the level of the system in accordance with the requirements .of the relevant Standard from cithcr AS 1821-23 or AS 3901-03. In doing so, ‘cognizance should be taken of the guidance given in AS 2000 or in AS 3900 and AS 3904, a5 appropriate. B4_ OTHER MEANS OF ASSESSMENT. B4.1 General. Where the above approaches are not considered practicable in their ‘entirety and some other method coupled with the manufacturer's guarantee of compliance is desired, consideration may be given to the results of testing, based on the alternative sampling schedule set out in Table BI, in the assessment of compliance. NOTE: The designation of an acceptable level or alow test frequency does not imply that che supplier ‘na the rian fo Knowingly supply defective ems or units of Drodction. B4.2. Compliance. Each batch shall be deemed to comply with the Standard if all of the samples tested give results which are within the specified limits. If any of the properties of the tested samples give results outside the specified limits, the requirements of Paragraph B4.3 shall apply. B4.3_Retesting. Should any test piece first selected fail to pass the relevant tests specified in this Standard, retest samples shall be selected in accordance with the requirements of AS 2483. Should any one of these additional samples or areas fail, the batch or consignment represented by the test samples shall either be rejected, or be egalvanized and tested in accordance with this Standard. aie 7 C+ WU 3 TABLE BI AS 16501989 ALTERNATIVE SAMPLING SCHEDULE FOR ASSESSMENT ‘OF COMPLIANCE, Type | Testmetnos | Prope under test Minimum fequeacs Steet 7 ating mass ‘One sample shall be seleted 10 ‘Gee Seaton 294 Appendix H__| Costing represent the product from each batch Clause 2.5 [Adherence of coating | of 25 t or part thercor Hrotow ‘One samele shall be seleaed from each sections | Appendix H__| Coating mass batch of $00 hollow sections or part Gee Sesion 3] Clause 3.4 [Adherence of conag | thereat, Continanus montering Wie oF ‘Sampling plans for iexing should be in circular Appendix H_ | Coating mass secure wh he product Sana rosssetion 7 In the absence of a product Standard, fer Secionsy| Camera | Adherence of contng | cece maybe ade a AS 388 for Sampling plans. General | Appendix | Coating mass ‘Sampling plans for teiing should be in artes “a = Fag | ascordance with the product Standard. Gee Secon 5)| Clause 53 | Adherence of coating COPYRIGHTAS 1650—1989 4 APPENDIX C RECOMMENDED PROCEDURES FOR DESIGN AND PREPARATION OF MATERIALS PRIOR TO GALVANIZING (This Appendix does not form an integral part of this Standard.) Cl GENERAL. This Appendix contains advice for the designer and fabricator ‘on factors which may affect the galvanizing process. €2_ SIZE AND SHAPE. Before design and fabrication, the dimensional limitations ‘on size and shape imposed by the galvanizing facilities should be determined. (See Appendix D.) NOTE: Information on facies of galvariers in Avstalia is available from the Galvaniers Association ‘of Australia, 124 Exhibition Street, Melbourne, 3000 C3 OVERLAPPING OR CONTACTING SURFACES. Wherever possible, gaps should be avoided between surfaces which are sufficiently close to prevent penetration of zine during galvanizing yet allow the ingress of liquor ducing pickling. Wherever such gaps cannot be avoided, they should be sealed by a pinhole-free continuous weld, x vented in the area of overlap by one hiole of approximately 6 mm diameter for every 100 em* of overlap area. C4 SHEET STEEL IN CONTACT WITH OTHER SURFACES. Sheet steel should not be in contact with other surfaces. All oil, grease, paint or lacquer should be removed from contact surfaces before assembly. C5 WELDING. Any recognized welding procedure may be used. The supplier should remove ail welding slags prior to delivery to the galvanizer. It should be noted that some weld metal can have a higher silicon content than the adjacent metal, causing sharp changes in appearance and thickness of the galvanized coating at welds. 5 VENTING AND DRAINING. 6.1 General. Structures which incorporate enclosed sections should have mn for adequate venting and draining (or filling) during galvanizing. At galvanizing temperatures, any moisture present in closed sections is rapidly converted to superheated steam capable of generating explosive forces if venting to the atmosphere is not provided. I is recommended that before components are fabricated, and preferably while the design is stil on the drawing board, the purchaser confer with the galvanizer regarding Yenting and draining (r fling) requirements. In this way, the galvanizer's experience can often assis: the purchaser to design for satisfactory coatings, while at the same time reducing danger to operators in the galvanizer’s plant. €6.2. Hollow sections. On welded hollow section assemblies, itis preferable to use full open-mnitre joints. If this is not possible, vent and drain (or fill) holes should be drilled in accordance with the’ following: (@) Hollow sections such as pipe columns with base plates and caps, handrails, etc, should have hole diameters at least 25 percent of the diameter or diagonal dimensions, with a minimum of 10mm, except for light fabrications, e.g. packracks, where hole diameters may be 6 mm minimum, (b) Tenks and closed vessels should have one, vent and one drain (or fill) hole of 50 mm diameter minimum for each 0.5 m' of enclosed volume, at appropriate locations. Baffles should be corner cut to a minimum of 75 mm. CT ASSEMBLIES. Where steels of widely differing surface conditions are combined in a single assembly, the entire assembly should be abrasive-biast cleaned to produce a uniform finish. ‘The supplier should not deliver items to the galvanizer in an assembled condition requiring break-up prior to galvanizing. C8 MOVABLE PARTS. The designer and fabricator should allow a minimum of | mm radial clearance on parts requiring free movement after galvanizing. C9 LABELS AND MARKINGS. For temporary identification the supplier should QO use either water-soluble marking paints or detachable metal labels. For permanent * identification, figures should be heavily punched or embossed by the supplier.Is C10 HANDLING. Work should be designed to provide for any special handling requirements. CLL CASTINGS. To produce high quality galvanized coatings on castings, it is necessary 10 have sound, stress-free castings with a good surface finish. To produce these castings, the following practices are recommend (a) Castings should be designed with uniform section thickness wherever possible. (®) Large fillet radii and large pattern numbers should be used; deep recesses and sharp corners should be avoided. (©) Large grey iron castings should be stress relieved by the supplier. Castings should be abrasive-blast cleaned by the supplier following heat treatment and prior to galvanizing. COPYRIGHT AS 1650—1989AS 1650—1989 APPENDIX D. DIMENSIONAL STABILITY (This Appendix does not form an integral part of this Standard.) Fabricated assemblies may be liable to distortion:at the galvanizing temperature by stresses induced during manufacture of the steel and subsequent fabricating operations, ‘These stresses may be compounded by bad design, e.g. the use of parts of unequal thickness, or parts having non-symmetrical sections. Where appropriate, the likeliood of buckling may be reduced by the use of suitable jigs and jigging procedures, but designers should observe the following guidelines in order to minimize distortion: (a) Avoid designs which require double-end dipping into the galvanizing bath. It is preferable to build assemblies and sub-assemblies in suitable units so that they can be immersed quickly and fully in a single dip. (b) Use symmetrical sections in preference to angles and channels. (©) Use sections of near equal thickness at joints. (@) Bend members to the largest acceptable radii. (©) Accurately preform parts to avoid the need for force or restraint during joining. () Continuously weld joints if possible, using balanced welding techniques to reduce tuneven thermal stresses. It should be noted that acid seepage may occur in staggered weld fabrications. (g) Design castings to comply with the guidelines listed above (see also Appendix C, Paragraph C11(c)). ryAPPENDIX E EMBRITTLEMENT OF STEEL (This Appendix does not form an integral part of this Standard.) EI EMBRITTLEMENT OF STEEL. E1.1 Introduction, For steel to be in an embrittled condition after galvanizing is rare, since the occurrence of embrittlement depends on a combination of factors. Under certain conditions, some steels can lose their ductile properties and exhibit a degree of embrittlement. Several different types of embrittlement can occur but only one, strain-age embritclement, can be aggravated by the hot-dip galvanizing process. The information which follows is given as guidance for critical applications. E1.2 Factors which may cause embrittlement of galvanized steel. E121 Susceptibility 0 strain-age embrittlement. Stcain-age embrittlement is caused by cold working of certain steels followed by ageing at temperatures less than 600°C or by warm working steels below 600°C. All structural steels may become embrittled to some extent. The extent of ‘embrittlement depends on the amount of strain, time at ageing temperature and steel composition. Aluminium-killed steels are less susceptible to strain-age embrittlement than semi-killed, silicon-killed or rimming steels. ‘The hot-dip galvanizing process involves immersion in a bath of molten zinc for up to 5 min at a temperature of about 450°C. This heat treatment can accelerate the ‘onset of strain-age embrittlement in susceptible steels which have been cold worked. ‘No other aspect of the galvanizing process is significant. E122 Embrittlement resulting from cold-working operations. _Cold-working jing of holes, shearing and bending, carried out before galvanizing may give rise to embrittlement of susceptible steels, Steels having thicknesses less than 3 mm are unlikely to be severely affected by these operations. E1.2.3 Hydrogen embrittlement, Hydrogen can be absorbed into a steel during acid pickling, but is rapidly expelled at the temperature of galvanizing and is not a problem with components free from internal stress. However, some steels which hhave been cold worked or stressed prior to pickling can be affected by hydrogen embrittlement to the extent that cracking can occur prior to the galvanizing process. Stress relieving before pickling, as described in Paragraph E1.3.3 will prevent cracking during the pickling operation. E124 Ageing of low carbon and medium carbon galvanized wire. Low carbon and medium carbon soft galvanized wire will, in time, exhibit changes in mechanical properties after manufacture, particularly changes in elongation and tensile strength. ‘The mechanical property changes result from a phenomenon known as ageing, of age hardening, and are evidenced by lower elongation and slightly higher tensile strength than that of the wire immediately after gelvanizing. In the manufacture of such soft galvanized wire, it is customary to make tests immediately after manufacture. At ordinary temperatures, the ageing will proceed slowly and many weeks may pass before ageing is complete. Therefore, results of tests performed by the purchaser may be at variance with those reported by the manufacturer. E13 Minimizing the extent of embrittlement, E1.3.1 General. The following recommendations should be followed to minimize the extent of embrittlement: (@) A steal with low susceptibility to strain-age embrittlement should be used if possible (see Paragraph E1.2.1). (b) Where cold working is carried out, the practices given in Paragraph E1.3.2 should be followed. E132 Recommended practices. The colé-working operations of punching, shearing and bending have limitations. The following practices should be observed: ‘COPYRIGHT AS 1650-1989AS 16501989 18 (@) Punching. The fabricator should be aware of the limitations of making fully-punched holes in structural steelwork and should consult AS 1250 and AS 1511 prior to making such holes. Material of any thickness may be punched at least 3 mm undersize and then be reamed, or drilled. Good shop practice in relation to ratios of punched hole diameter to plate thickness and punch/die diametral clearance to piate thickness should be observed. For static loading, holes may be punched full size in material up to 4500/R mm. thick, where R is material yield strength or proof stress up to 360 MPa. (©) Shearing, Edges of steel sections which will be subject to tensile forces may be ‘cut by shearing for thicknesses up to 16 mm. Sections greater than £6 mm thick should be machined or machine flame cut. Sheared edges subject to subsequent fabrication by: bending should have stress-raising features (burrs or flame gouges) removed and the corners radiused. over the arc of bend. At least 1.5 mm should be removed from a sheared edge over the arc of bend before radiusing corners. (©) Bending. Bending should be carried out over a smooth former having @ minimum. radius of 3 times the material thickness. E13.3 Critical applications. Its better to avoid cold working (punching, shearing cr bending) of structural steels over 6 mm thick, where the item is to be galvanized and subsequently subjected to tensile stress. A practical embrittlement test should bbe carried out where this is unavoidable (sce ASTM A 143). Where consequences of failure are severe, and cold working cannot be avoided, it is advisable to stress relieve at a minimum temperature of 650°C before pickling. £2 EMBRITTLEMENT OF MALLEABLE AND SPHEROIDAL GRAPHITE IRON. When malleable or spheroidal graphite cast irons are galvanized, embrittlement related to the chernical composition of the material may occur. A low phosphorus content will reduce the probability of embrittlement; alternatively, where Feasible, the casting can be heated to 650°C and quenched in water before galvanizing. cea( 9 APPENDIX F RENOVATION OF DAMAGED OR UNCOATED AREAS (This Appendix forms an integral part of this Standard.) ‘Where areas of galvanized surface have been uncoated or damaged by welding, cutting or by excessively rough treatment during transit or installation, renovation by the application of at least two coats of good quality zine-rich paint (see AS 2204), or in some circumstances, by blast cleaning and zinc metallizing, may be carried out. Each method of repair requires adequate surface preparation, and sufficient material ‘should be applied to provide a zinc coating at least equal in thickness to the galvanized layer. Areas of exposed steel situated within 1 mm of a substantial zinc layer should receive sacrificial protection from corrosion attack, For objects galvanized after fabrication, the sum total of the uncoated areas which have been made good individually, or the sum total of defective areas, shall not exceed 0.1 percent of the total surface area of the object of 250 cm*, whichever is the lesser, and no individual defective area shall exceed 40 cm”, However uncoated areas greater than 40.cm* which have been caused by air locks during the galvanizing operation are deemed to be acceptable. COPYRIGHT AS 16501989‘AS 1650-~1989 a APPENDIX G TRANSPORT AND STORAGE OF GALVANIZED ARTICLES (This Appendix does not form an integral part of this Standard.) Attention should be paid to the conditions of transport, shipment and storage to avoid the possibility of wet-storage stain. A. corrosion product known as ‘white rust”, can ‘occur on freshly galvanized articles which are transported or stored under damp, badly ventilated conditions. The attack is frequently superficial despite the bulkiness of the corrosion product and may be unattractive, but is not usually detrimental t0 the ‘other properties of the coating. If itis desired to retain the initial bright appearance of the galvanized coating, dry storage conditions are necessary. Post-treatments such as chromating applied immediately after galvanizing can avoid or reduce the formation of these white marks. Galvanized articles should never be stored in contact with cardboard or paper products, cinders, clinkers, unseasoned timber or harmful chemicals. If the galvanized coating is subjected to excessively rough treatment, some damage ‘may occur in the course of transit and erection; small areas damaged in this way may be renovated by the procedures described in Appendix F. oy .)C a APPENDIX H. DETERMINATION OF COATING MASS (This Appendix forms an integral part of this Standard.) H1 GENERAL. This Appendix sets out five alternative procedures for determining {he mass of the zine coatiag on galvanized articles specified in Sections 2 to 5, as Follows: (a) Gravimetric determination (see Paragraph H2). (b) Volumetric determination (see Paragraph H3). (© Mass-on-mass method (See Paragraph H4), (@) Magnetic method (see Paragraph H5). (©) Beta-backscatter method (see Paragraph H6) H2 GRAVIMETRIC METHOD. 2.1 Method. The method used shall be the strip and weigh (dissolution of coating) ‘method in accordance with Method A of AS 2331.2.1, with the following exceptions: (@) The test piece(s) are weighed to within an accuracy of 1 percent of the presumed coating mass. (©) Where necessary, the surface area (4) of the exposed surface is determined to within an accuracy of 1 percent. 2.2. Preparation of specimen for the determination of coating mass on one surface only. Where itis required to determine the coating mass on one surface only of a sheet or a hollow section, it is necessary to protect the other surface from the effects Of the stripping solution, This may be carried out by the application of e protective film which is easily removable, or by the use of seals to protect the internal coating of a hollow section. NOTE: Quick crying i-celuone ager an clan cons vinyl adhesives ave een found stable for wie se proeaive fins H2.3_Caleulation of coating mass. The coating mass shall be calculated using the Sollowing equation: rig = MLE ye sof -H2.3(1) where ‘ma = coating mass, in grams per square metre ‘my = mass of specimen before stripping, in grams mass of specimen after stripping, in grams surface area, in square millimetres NOTES: 1. Surface area (A) in Equation H2.34) refers the surface area of the uncoated specimen, whereas forthe thickness eleulations in AS 2551.2.1, iris the area ofthe coated surface. 2, The basic equation has been further develope a follows: (@) For an area of 2000 min?— ss = (m= m3) % 500 es ooH2.32) () For wire of circular erote-seetion— my =P x 19600 #23) where 4 = sstipped wire dlameter, in mllineres 43 VOLUMETRIC DETERMINATION. 3.1 Method. ‘The method used shail be either the hydrogen evolution method for zinc coatings given in AS 2331.2.3, or, for wire, the volumetric method described in BS 443, H3.2_Calculation of coating mass. The coating mass shall be calculated using the following equations: (@) Wire— net 1H3.2(1 m= Hx an 3.2(1) COPYRIGHT. AS 16501999AS 16501989 (b) Other articles— m = ¥ x 2139 =. -HB.2@) ‘mig, = coating mass, in grams per square metre = volume of hydrogen evolved, in millilitres d= stripped wire diameter, in millimetres 1 = length, in millimetres A = area of specimen, in square millimetres NOTES: |. The above equations are based on measurement of the hydrogen volume at 100 ¢Pa and 18°C. 2. Surface ara (4) in Equation H3.2Q) refers othe susface ares ofthe unvonted specimen, whereas forthe thekwen calclaions it AS SOLS, A te sete eomad sures 4 MASS-ON-MASS METHOD, ‘The coating mass (in grams per square metre) shall be determined by weighing the articles before and after galvanizing and dividing the difference by the surface area. ‘The mass before galvanizing shall be determined after pickling and drying, and the ‘mass after galvanizing when the article has cooled to ambient temperature. HS MAGNETIC METHOD. HS.1_General, The method used shall be in accordance with AS 2331.1.3 and AS 2331.1.4. H5.2_ Calculation of coating mass. The coating mass shall be calculated by raultiplying the thickness (in micrometres) by 7.15. 6 BETA-BACKSCATTER METHOD. The method used shall be in accordance with AS 2331.1.5. 7 TEST REPORT. A test report shall include the following information: (@) Name of testing authority. (b) Report number and date of issue. (©) Batch number and details of the material under test. @) Test method used. (©) Location and details of test sampies and test specimens. (©) Results of the test, and a statement of compliance or otherwise with the requirements of this Standard. (g) Results of any retests carried out. (h) Reference to this test method, i.e. AS 1650, Appendix H. ‘The test results shall be rounded to the requirements of AS 2706. oO2B (@LANK) AS 16501999AS 1650-1989 4 BLANO)