BS 443

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British Standard

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19 March 2004

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BRITISH STANDARD

Specification for

Licensed Copy: lbocvzr lbocvzr, University of Loughborough, 19 March 2004, Uncontrolled Copy, (c) BSI

Testing zinc coatings on


steel wire and for
quality requirements

UDC 669.58:669.14-426

BS 443:1982
Incorporating
amendment No. 1

BS 443:1982

Cooperating organizations

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The Iron and Steel Standards Committee, under whose direction this British
Standard was prepared, consists of representatives from the following:
British Constructional Steelwork Association
British Internal Combustion Engine Manufacturers Association
British Ironfounders Association
British Railways Board
British Steel Corporation
British Steel Industry*
British Steel Industry (Wire Section)*
Concrete Society Limited
Council of Ironfoundry Associations
Department of Industry (National Physical Laboratory)
Electricity Supply Industry in England and Wales
Engineering Equipment Users Association
Federation of Civil Engineering Contractors
Institute of Quality Assurance*
Institution of Production Engineers
Institution of Structural Engineers
International Tin Research Institute
Lloyds Register of Shipping
National Association of Drop Forgers and Stampers
Oil Companies Materials Association
Process Plant Association
Royal Institute of British Architects
Society of Motor Manufacturers and Traders Limited
Steel Casting Research and Trade Association
Water-tube Boilermakers Association
The organizations marked with an asterisk in the above list, together with the
following, were directly represented on the Technical Committee entrusted
with the preparation of this British Standard:
This British Standard, having
been prepared under the
direction of the Iron and
Steel Standards Committee,
was published under the
authority of the Board of
BSI and comes
into effect on
26 February 1982.

British Wire Netting Association


Fencing Contractors Association
Society of Chain Link Fencing Manufacturers

BSI 12-1998
First published March 1932
First revision November 1939
Second revision January 1961
Third revision January 1969
Fourth revision February 1982
The following BSI references
relate to the work on this
standard:
Committee reference ISM/26
Draft for comment 80/71262 DC
ISBN 0 580 12612 9

Amendments issued since publication


Amd. No.

Date of issue

Comments

6158

December 1989 Indicated by a sideline in the margin

BS 443:1982

Contents

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Cooperating organizations
Foreword
Section 1. General
1
Scope
2
Reference
3
Metallurgical quality of coating
4
Test pieces
5
Test pieces from fabricated wire products
6
Surface condition
7
Uniformity and adherence

1
1
1
1
1
1
1

Section 2. Test methods


8
Determination of mass of coating
9
Test for uniformity of coating (Preece dip method)
10 Adhesion of coating

2
5
6

Section 3. Standard coating


11 Thickness and quality

Appendix A Conversion factors

Figure 1 Apparatus for determining coating mass by


gas-volumetric method

Table 1 Length of test piece


Table 2 Correction factors for temperature and barometric
pressure used in calculating mass of coating
Table 3 Ratio of mandrel diameter to wire diameter
Table 4 Minimum mass of coating and number of dips
Standards publication referred to

BSI 12-1998

Page
Inside front cover
ii

3
5
6
7
Inside back cover

BS 443:1982

Licensed Copy: lbocvzr lbocvzr, University of Loughborough, 19 March 2004, Uncontrolled Copy, (c) BSI

Foreword
This British Standard has been prepared under the direction of the Iron and Steel
Standards Committee. This edition has been technically up-dated in detail
although the major technical concepts have not been altered significantly.
BS 443:1969 is now withdrawn.
With the emphasis on adoption of international standards in national standards,
there is the future possibility that some British Standards may not refer to the
standard values for coating thickness given in section three of this standard, or
may not require the dip test. Ease of cross-reference will, therefore, be improved
by separation of test methods and general quality requirements.
The standard coatings specified in section three are intended for a wide variety of
wire applications in which medium/long term protection of the steel against
corrosion is desired. It is emphasized that the protection afforded by the zinc is
sacrificial and the duration of the protection is therefore dependent on the
conditions in which the zinc coated wire will be expected to function.
The dip test has been retained as a standard requirement but it is not intended
as an indirect measurement of the mass of coat. It is intended only to reveal any
serious eccentricity of a coating that could lead to failure over a portion of the
circumference, even though the total mass of coat may be in accordance with the
standard.
Following international practice which is becoming established, the term zinc
coated rather than galvanized has been adopted in this standard. The terms
are synonymous.
Factors for converting coating mass from imperial to metric units and for
converting coating mass to coating thickness are included in appendix A.
A British Standard does not purport to include all the necessary provisions of a
contract. Users of British Standards are responsible for their correct application.
Compliance with a British Standard does not of itself confer immunity
from legal obligations.

Summary of pages
This document comprises a front cover, an inside front cover, pages i and ii,
pages 1 to 8, an inside back cover and a back cover.
This standard has been updated (see copyright date) and may have had
amendments incorporated. This will be indicated in the amendment table on the
inside front cover.
ii

BSI 12-1998

Section 1

BS 443:1982

Section 1. General
1 Scope

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This British Standard specifies the methods of


testing zinc coated steel wires and products
fabricated from them to determine the nominal
mass of the zinc coating, its uniformity and its
adhesion.
In addition, requirements are specified
(see section three) for mass, uniformity and
adhesion of coating on steel wires of circular section
in diameters from 0.23 mm to 10.0 mm. These
requirements are not applicable to articles made
from wire which have been coated after fabrication.
NOTE Coatings in accordance with section three are not
necessarily available in every combination of wire size and
tensile strength grade and reference should be made to the
appropriate British Standard for the type of wire.

4.2 In removing the test pieces care shall be taken to


avoid surface damage. Portions of wire which are
obviously damaged shall not be used.
4.3 For all the tests a piece of total length of at
least 500 mm will usually be needed
(see 8.2.2, 8.3.4, 9.4 and clause 10).

5 Test pieces from fabricated wire


products
If the test pieces have been taken from a product
fabricated from zinc coated wires, then unless
otherwise stated in the product standard, the
specified minimum coating mass shall be reduced
by 5 % and the specified dips shall be reduced by one
half-minute dip.

2 Reference

6 Surface condition

The title of the standards publication referred to in


this standard is given on the inside back cover.

The coating on wire shall be continuous and


reasonably smooth. It is recognized that thick
coatings produced by the final hot dip process may
exhibit some surface irregularities, but the coating
shall be free from imperfections, such as gross dross
contamination, not consistent with good coating
practice.

3 Metallurgical quality of coating


The metallurgical quality of the coating is
dependent on the quality of the zinc used. Wire shall
be coated in a bath using zinc of purity not less than
grade Zn 3 of BS 3436.

4 Test pieces
4.1 The number and basis of selection of test pieces
shall be that specified in the standard for the
product. In the absence of such a standard the
degree of sampling shall be agreed between the
manufacturer and the purchaser.

BSI 12-1998

7 Uniformity and adherence


The coating on wire shall be reasonably uniform, as
judged by the copper sulphate solution dip test, and
shall be adherent to the steel under the conditions of
the adhesion wrap test (see clause 10).

Section 2

BS 443:1982

Section 2. Test methods


8 Determination of mass of coating

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8.1 General. The mass of coating shall be


determined by either a gravimetric or volumetric
method. The latter has an acceptable degree of
accuracy and has the advantage of rapidity. It is
therefore the preferred method for routine testing of
all the sizes of wire which can be conveniently
accommodated in the measuring apparatus. In any
case of dispute, the gravimetric method shall be
accepted as the referee method.

8.2.4 Determination. The mass of zinc coating


in g/m2 of steel surface is given by the formula
( W ZS WS )
------------------------------------ d 1962
WS
where
Wzs is the mass (in g) of the zinc coated steel
wire.
Ws is the mass (in g) of the bare steel wire.
d is the diameter (in mm) of the bare steel wire.

NOTE The methods of test contained in this standard do not


necessarily detail all precautions necessary to meet the
requirements of the Health and Safety at Work etc., Act 1974.
Attention should be paid to any appropriate precautions and the
methods should be operated only by trained personnel.

NOTE The expression is derived from the relationship between


the curved surface area and the volume of a cylinder and the
density of steel (7 850 kg/m3).

8.2 Gravimetric method

8.3.1 Principle. The volumetric method of


determining the mass of coating depends on the fact
that a metal dissolved in acid always releases a
quantity of hydrogen proportional to the amount of
metal dissolved, i.e. the chemical equivalent of the
metal in question.

8.2.1 Reagents. The following reagents are used.


Antimony chloride solution. Dissolve 20 g antimony
trioxide or 32 g antimony trichloride in 1 000 ml
hydrochloric acid, of relative density of
between 1.16 and 1.18.
Stripping solution. Add 5 ml of the antimony
chloride solution to every 100 ml hydrochloric acid,
of relative density of between 1.16 and 1.18.
8.2.2 Test piece. For wires of diameter 3 mm and
larger, the length of the test piece should not be less
than 100 mm. As a guide to the length for smaller
sizes of wire, this should be such that the mass in
grams is numerically not less than approximately
four times the diameter in millimetres.
After cleaning the test piece in a suitable organic
solvent, e.g. methylated spirit, wipe the wire dry
with a clean, soft cloth and weigh it to the
nearest 0.01 g.
8.2.3 Stripping the zinc. Strip the coating from the
steel wire by complete immersion of the test piece in
any convenient volume of the stripping solution.
NOTE The same solution may be repeatedly used, without
further additions of antimony chloride solution, until the time of
stripping becomes inconveniently long.

The temperature of the stripping solution should


not be allowed to exceed 38 C and the number of
test pieces immersed at any one time shall not
exceed 3 per 100 ml of solution.
As soon as the violent chemical action has ceased,
remove the wire from the acid, wash it thoroughly in
running water and wipe dry. The diameter of the
wire shall then be determined to the
nearest 0.02 mm by taking the average of two
measurements at right angles to each other. Weigh
each piece of stripped wire to the nearest 0.01 g.

1)

8.3 Gas volumetric method

1 g of zinc releases 343 ml of hydrogen at a


temperature of 0 C and a pressure of 1 014 mbar1).
NOTE With very large wires problems of test piece preparation
and damage to the glass burette may be introduced. This method
of determination is therefore usually limited to wires of
maximum diameter 5 mm.

8.3.2 Reagent. The same stripping solution as


specified in 8.2.1 is used, subject to the following
qualifications. Acid concentration may affect the
result in the volumetric method, strong acid giving
slightly high results and weak acid giving low
results. Assuming a 36 % mass content of HCl in the
concentrated acid (relative density 1.18), 70 parts by
volume should be mixed with 30 parts by volume of
water to give a mass concentration of
approximately 25 % HCl (relative density
approximately 1.13).
NOTE The stripping solution should be replaced when the acid
concentration is reduced to a level where, for example, vigorous
evolution of gas lasts longer than about 80 s with a zinc mass
of 230 g/m2.

8.3.3 Apparatus. The apparatus consists of a 100 ml


glass burette fitted with a stopcock at the top and
bottom and connected at the bottom with a rubber
tube to a reservoir. The apparatus is shown
in Figure 1(a) set up for the commencement of a test.
The 100 ml burette should be graduated to at
least 0.5 ml subdivisions.
NOTE Where small sizes of wire, say less than 1.5 mm
diameter, are regularly tested, it may be found useful to use
a 50 ml burette of about the same length and graduated to at
least 0.2 ml subdivisions.

1 mbar = 100 N/m2 = 0.1 kPa.

BSI 12-1998

BS 443:1982

8.3.4 Test pieces. From a straightened and


undamaged length of wire, test pieces of the
required length are accurately cut (error no more
than 1 %). The most suitable length of test piece
depends upon the size of burette, diameter of wire
and expected mass of coating. The lengths indicated
in Table 1 will usually be found convenient.
Table 1 Length of test piece

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Zinc coated wire diameter

Length of test piece

Over

Up to and
including

for a 100 ml
burette

for a 50 ml
burette

mm

mm

mm

mm

0.45

0.85

200

0.85

1.06

200

150

1.06

1.8

100

75

1.8

3.6

75

3.6

5.0

50

8.3.5 Procedure. Pour the acid reagent into the


reservoir C until it completely fills the burette
leaving a small portion in the reservoir when in the
elevated position.
To carry out a test, adjust the height of the reservoir
C so that the acid reagent just fills the burette up to
the stopcock A with the bottom stopcock B closed.
Drop the test piece, cut to the specified length, into
the burette and immediately close the stopcock A.
NOTE Where long test pieces are necessary, rapid entry into
the burette may be difficult and it may be more convenient to
drop two short pieces simultaneously through the stopcock.

BSI 12-1998

The zinc coating rapidly dissolves and liberates


hydrogen and the test is continued until evolution of
hydrogen, but for a few fine bubbles, has ceased.
Then lift the reservoir from its supporting ring and
place alongside the burette until the levels of the
acid reagent in the burette and the reservoir are the
same, as shown in Figure 1(b), then read off the
volume of hydrogen on the burette scale.
When the test is concluded open stopcock A and
draw all acid reagent from the burette by lowering
the reservoir to a position below stopcock B. Then
open stopcock B to eject the test piece and close
again. The procedure given above may then be
repeated for a succeeding test.
The stripped wire shall then be washed, wiped dry
and the diameter measured.
8.3.6 Determination. The mass of zinc coating is
calculated from the formula:
V
Mass of coating/unit area of steel surface = ------ f
dl
where
V is the volume of hydrogen evolved in millilitres
(ml)
d is the stripped wire diameter
l is the length of test piece
Where length and diameter are in millimetres,
f = 872, to give a mass of zinc coating in g/m2.
NOTE In practice the mass of zinc (in g/m2) is read directly
from tables relating mass of zinc to diameter of stripped wire and
volume of hydrogen.

Licensed Copy: lbocvzr lbocvzr, University of Loughborough, 19 March 2004, Uncontrolled Copy, (c) BSI

BS 443:1982

Figure 1 Apparatus for determining coating mass by gas-volumetric method


8.3.7 Correction for temperature and barometric
pressure. The factor (f) has been calculated for a
temperature of 18 C and a barometric pressure
of 1 014 mbar. If the atmospheric pressure is
outside the range 987 mbar to 1 040 mbar or if the
temperature is outside the range 16 C to 20 C,
apply the appropriate correction factor
from Table 2. If the combination of pressure and
temperature results in a correction factor
within 0.02 of unity (see outlined zone in Table 2),
then the factor need not be applied to the calculated
mass of zinc or to that obtained from tables.

NOTE 1 Where the test result is within 5 g/m2 of the specified


minimum value, it is desirable to check the atmospheric pressure
and temperature, in case a negative correction is necessary.

Where climate or altitude cause permanent


divergence from standard conditions, the formula
shall be corrected to suit prevailing conditions. If
tables are used these shall be corrected.
NOTE 2 At high altitudes it will be found convenient to have a
burette of greater capacity than 50 ml or 100 ml.

BSI 12-1998

BS 443:1982

9 Test for uniformity of coating


(Preece dip method)

9.4 Test pieces. The test piece should be not less


than 150 mm in length and shall be undamaged as
far as possible. The test piece may be hand
straightened and shall be cleaned with an organic
solvent, e.g. methylated spirit, and then wiped dry
with a clean soft cloth.

9.1 General. The uniformity of the coating shall be


tested by the method described below.

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9.2 Reagent. The following reagent is used.

9.5 Temperature. At the commencement, and


during the progress of the test, the temperature of
the test pieces and of the solution shall not vary
outside the limits of 18 2 C.

Copper sulphate solution. Dissolve


approximately 36 g of crystalline copper sulphate
(CuSO4.5H2O) in each 100 ml of distilled or
deionized water. The water may be heated to aid
solution of the crystals; but if heated, the solution
shall be allowed to cool before neutralizing.
For neutralization, shake the solution with an
excess of basic cupric carbonate (1 g/l to 2 g/l of
solution) and allow it to stand, preferably for at
least 24 h, before filtering or decanting the solution
from the sediment.

9.6 Procedure. It is preferable that not more than


three test pieces be immersed in the solution at one
time. The test pieces shall not touch one another.
During the immersion the test pieces shall not be
disturbed, and the solution shall not be agitated.
The test piece or test pieces shall be subjected to
successive dips of exactly 1 min. After each dip
remove the sample and immediately rinse it in clean
running water and wipe dry with a clean soft cloth.
If running water is not available, the rinse water
shall be changed frequently so that there is no
obvious contamination with copper sulphate
solution.
Half-minute dips, where specified, shall be given
after the completion of all the one-minute dips.

NOTE Analytical reagent quality copper sulphate is not


essential. The pH of the solution is initially 3.0 to 2.7 and after
neutralization with basic cupric carbonate the pH is 3.7 to 3.5,
and it appears to be consistent over a period of time. If cupric
oxide is used for neutralization with a recommended standing
time of 48 h, the pH will be in the range 3.6 to 3.3 and may vary
with time. For these reasons only the basic cupric carbonate is
specified as the neutralizing agent.

The relative density of the test solution shall


be 1.186 at 18 C. Adjustment may be made by
adding distilled (or de-ionized) water or solution of
higher relative density, as appropriate.
The solution shall be discarded and replaced with
fresh solution after six samples have been tested.

9.7 Examination. After the specified number of


dips, the final rinsing and wiping dry, the test piece
shall not show any adherent bright deposit of
metallic copper on the steel. Any deposit of metallic
copper within 25 mm of the cut end shall be
disregarded.

9.3 Apparatus. The following apparatus is


required.
Glass or plastics container of internal diameter not
less than 50 mm for wires of 2.8 mm diameter and
smaller or 75 mm for larger wires. It should be filled
with copper sulphate solution to a depth of at
least 100 mm.

Table 2 Correction factors for temperature and barometric pressure used in calculating mass
of coating
Atmospheric pressure, mbar

Temperature
C

693

720

747

773

800

827

853

880

907

933

960

987

10

0.703

0.730

0.758

0.784

0.811

0.839

0.866

0.892

0.920

0.947

0.974

1.001

1.028

1 014

1.055

1 040

1.082

1 067

12

0.698

0.725

0.752

0.779

0.806

0.833

0.860

0.886

0.914

0.940

0.967

0.994

1.021

1.048

1.075

14

0.694

0.720

0.747

0.774

0.800

0.827

0.854

0.880

0.908

0.934

0.960

0.988

1.014

1.040

1.068

16

0.689

0.715

0.742

0.768

0.795

0.822

0.848

0.874

0.901

0.927

0.954

0.981

1.007

1.033

1.060

18

0.684

0.710

0.737

0.763

0.789

0.816

0.842

0.868

0.895

0.921

0.947

0.974

1.000

1.026

1.053

20

0.679

0.705

0.732

0.758

0.783

0.810

0.836

0.862

0.889

0.915

0.940

0.967

0.993

1.019

1.046

22

0.674

0.700

0.727

0.752

0.778

0.805

0.830

0.856

0.882

0.908

0.934

0.960

0.986

1.012

1.038

24

0.670

0.696

0.722

0.748

0.773

0.800

0.825

0.851

0.877

0.903

0.928

0.955

0.980

1.005

1.032

26

0.666

0.691

0.717

0.742

0.769

0.794

0.819

0.845

0.871

0.896

0.921

0.947

0.973

0.998

1.025

28

0.661

0.687

0.713

0.738

0.763

0.789

0.814

0.839

0.865

0.891

0.916

0.942

0.967

0.992

1.018

30

0.657

0.682

0.708

0.732

0.757

0.783

0.808

0.833

0.859

0.884

0.909

0.935

0.960

0.985

1.011

520

540

560

580

600

620

640

660

680

700

720

740

760

780

800

Height of barometer, mmHg

BSI 12-1998

BS 443:1982

10 Adhesion of coating
For wires of 7.5 mm and smaller the adhesion of the
zinc shall be tested by wrapping the wire at least six
close turns round a cylindrical mandrel. Larger
wires shall be bent through an angle of at
least 90 round the mandrel. The ratio of mandrel
diameter to wire diameter (d) shall be in accordance
with Table 3.
Table 3 Ratio of mandrel diameter to wire
diameter

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Wire diameter (d)

Mandrel diameter

mm

Up to and including 3.8

4d

Over 3.8

5d

The zinc shall remain firmly adherent to the steel


and shall not crack or flake to such an extent that
any flakes of zinc can be removed by rubbing with
bare fingers.

BSI 12-1998

Section 3

BS 443:1982

Section 3. Standard coating


11 Thickness and quality

The coating shall be adherent in accordance with


the adhesion wrap test (see clause 10).

When tested in accordance with clauses 8 and 9, the


zinc coating mass and the number of dips in the
copper sulphate solution when testing for
uniformity of coating shall comply with the
requirements given in Table 4.
Table 4 Minimum mass of coating and number of dips
Nominal diameter of coated
wire

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Over

Wire of tensile strength


less than 540 N/mm2

Up to and
including

Minimum
mass of
coating

mm

g/m2

mm

Number of dips
Minute

Half minute

Wire of tensile strength


540 N/mm2 and above
Minimum
mass of
coating

Number of dips
Minute

Half minute

g/m2

0.23
0.33
0.40

0.33
0.40
0.46

45
60
75

no test
no test
1

45
60
75

0.46
0.53
0.63

0.53
0.63
0.75

90
105
120

0.75
0.85
0.95

0.85
0.95
1.06

1.06
1.18
1.32

1
1
1

90
105
120

1
1
1

135
150
170

1
1
2

1
1

135
140
150

1
1
1

1
1
1

1.18
1.32
1.55

185
200
215

2
2
2

160
170
180

2
2
2

1.55
1.8
2.24

1.8
2.24
2.72

230
240
260

2
3
3

200
215
230

2
2
2

2.72
3.15
3.55

3.15
3.55
4.25

275
275
290

3
3
3

1
1
1

240
250
260

3
3
3

4.25
5.0
8.0

5.0
8.0
10.0

290
290
305

3
3
4

1
1

275
290
305

3
3
4

1
1

BSI 1998

no test
no test
1

BS 443:1982

Appendix A
Conversion factors
From

oz/ft

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Mass of coat

To

g/m

Multiply by

305.152

Average radial thickness of coat

1 oz/ft2

42.926 m (micrometres)

1 g/m2

0.1407 m (micrometres)

BSI 12-1998

Licensed Copy: lbocvzr lbocvzr, University of Loughborough, 19 March 2004, Uncontrolled Copy, (c) BSI

BS 443:1982

Standards publication referred to

BS 3436, Ingot zinc.

BSI 12-1998

Licensed Copy: lbocvzr lbocvzr, University of Loughborough, 19 March 2004, Uncontrolled Copy, (c) BSI

BSI
389 Chiswick High Road
London
W4 4AL

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BSI British Standards Institution


BSI is the independent national body responsible for preparing British Standards. It
presents the UK view on standards in Europe and at the international level. It is
incorporated by Royal Charter.
Revisions
British Standards are updated by amendment or revision. Users of British Standards
should make sure that they possess the latest amendments or editions.
It is the constant aim of BSI to improve the quality of our products and services. We
would be grateful if anyone finding an inaccuracy or ambiguity while using this
British Standard would inform the Secretary of the technical committee responsible,
the identity of which can be found on the inside front cover. Tel: 020 8996 9000.
Fax: 020 8996 7400.
BSI offers members an individual updating service called PLUS which ensures that
subscribers automatically receive the latest editions of standards.
Buying standards
Orders for all BSI, international and foreign standards publications should be
addressed to Customer Services. Tel: 020 8996 9001. Fax: 020 8996 7001.
In response to orders for international standards, it is BSI policy to supply the BSI
implementation of those that have been published as British Standards, unless
otherwise requested.
Information on standards
BSI provides a wide range of information on national, European and international
standards through its Library and its Technical Help to Exporters Service. Various
BSI electronic information services are also available which give details on all its
products and services. Contact the Information Centre. Tel: 020 8996 7111.
Fax: 020 8996 7048.
Subscribing members of BSI are kept up to date with standards developments and
receive substantial discounts on the purchase price of standards. For details of
these and other benefits contact Membership Administration. Tel: 020 8996 7002.
Fax: 020 8996 7001.
Copyright
Copyright subsists in all BSI publications. BSI also holds the copyright, in the UK, of
the publications of the international standardization bodies. Except as permitted
under the Copyright, Designs and Patents Act 1988 no extract may be reproduced,
stored in a retrieval system or transmitted in any form or by any means electronic,
photocopying, recording or otherwise without prior written permission from BSI.
This does not preclude the free use, in the course of implementing the standard, of
necessary details such as symbols, and size, type or grade designations. If these
details are to be used for any other purpose than implementation then the prior
written permission of BSI must be obtained.
If permission is granted, the terms may include royalty payments or a licensing
agreement. Details and advice can be obtained from the Copyright Manager.
Tel: 020 8996 7070.

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