NOTICE: This standard has either been superseded and replaced by a new version or withdrawn.

Contact ASTM International (www.astm.org) for the latest information

Designation: A153/A153M − 16 AmericanAssociation State Highway

and Transportation Officials Standard
AASHTO No. M232

Standard Specification for

Zinc Coating (Hot-Dip) on Iron and Steel Hardware1
This standard is issued under the fixed designation A153/A153M; the number immediately following the designation indicates the year
of original adoption or, in the case of revision, the year of last revision. A number in parentheses indicates the year of last reapproval.
A superscript epsilon (´) indicates an editorial change since the last revision or reapproval.
This standard has been approved for use by agencies of the U.S. Department of Defense.

1. Scope* 2. Referenced Documents

1.1 This specification covers zinc coatings applied by the 2.1 ASTM Standards:2
hot-dip process on iron and steel hardware. The hot-dip A90/A90M Test Method for Weight [Mass] of Coating on
galvanizing process consists of parts being immersed in molten Iron and Steel Articles with Zinc or Zinc-Alloy Coatings
zinc for a sufficient time to allow a metallurgical reaction A143/A143M Practice for Safeguarding Against Embrittle-
between iron from the steel surface and the molten zinc, ment of Hot-Dip Galvanized Structural Steel Products and
resulting in the formation of Zn/Fe alloy layers bonding the Procedure for Detecting Embrittlement
A780 Practice for Repair of Damaged and Uncoated Areas
coating to the steel surface.
of Hot-Dip Galvanized Coatings
1.2 This specification is intended to be applicable to hard- A902 Terminology Relating to Metallic Coated Steel Prod-
ware items that are centrifuged or otherwise handled to remove ucts
excess galvanizing bath metal (free zinc). Coating thickness B6 Specification for Zinc
grade requirements reflect this. B487 Test Method for Measurement of Metal and Oxide
Coating Thickness by Microscopical Examination of
1.3 This specification is applicable to orders in either Cross Section
inch-pound units (as A153) or in SI units (as A153M). B960 Specification for Prime Western Grade-Recycled
Inch-pound units and SI units are not necessarily exact (PWG-R) Zinc
equivalents. Within the text of this specification and where E376 Practice for Measuring Coating Thickness by
appropriate, SI units are shown in brackets. Each system shall Magnetic-Field or Eddy-Current (Electromagnetic) Test-
be used independently of the other without combining values in ing Methods
any way. In the case of orders in SI units, all testing and F1470 Practice for Fastener Sampling for Specified Me-
inspection shall be done using the metric equivalent of the test chanical Properties and Performance Inspection
or inspection method as appropriate. In the case of orders in SI F1789 Terminology for F16 Mechanical Fasteners
units, such shall be stated to the galvanizer when the order is
placed. 3. Terminology
1.4 This standard does not purport to address all of the 3.1 Definitions:
safety concerns, if any, associated with its use. It is the 3.1.1 The following terms and definitions are specific to this
responsibility of the user of this standard to establish appro- specification. Terminology A902 contains other terms and
priate safety and health practices and determine the applica- definitions relating to metallic-coated steel products. Terminol-
bility of regulatory limitations prior to use. ogy F1789 contains other terms and definitions relating to
mechanical fasteners.
3.2 Definitions of Terms Specific to This Standard:
3.2.1 average coating thickness, n—the average of the
specimen coating thickness values for the samples in an
inspection lot.
1
This specification is under the jurisdiction of ASTM Committee A05 on
Metallic-Coated Iron and Steel Products and is the direct responsibility of
2
Subcommittee A05.13 on Structural Shapes and Hardware Specifications. For referenced ASTM standards, visit the ASTM website, www.astm.org, or
Current edition approved Feb. 1, 2016. Published February 2016. Originally contact ASTM Customer Service at service@astm.org. For Annual Book of ASTM
approved in 1933. Last previous edition approved in 2009 as A153/A153M - 09. Standards volume information, refer to the standard’s Document Summary page on
DOI: 10.1520/A0153_A0153M-16. the ASTM website.

*A Summary of Changes section appears at the end of this standard

Copyright © ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959. United States
Copyright by ASTM Int'l (all rights reserved); Tue Jul 27 22:26:33 EDT 2021
1
Downloaded/printed by
VIKRANTH GEDDAM (Petrofac) pursuant to License Agreement. No further reproductions authorized.
 A153/A153M − 16
3.2.2 bare spots, n—uncoated areas on the surface of the 4.2 Zinc—The zinc used for the coating shall conform to
steel part that contain no measurable zinc coating. Specification B6, or Specification B960, or both, and shall be
3.2.3 dross inclusions, n—the iron/zinc intermetallics pres- at least equal to the grade designated as “Prime Western.”
ent in a galvanized coating in a form other than the layer 4.2.1 If a zinc alloy is used as the primary feed for the
growth of the coating. galvanizing bath, then the base material used to make that alloy
shall conform to Specification B6 or Specification B960, or
3.2.4 individual measurement, n—the reading from a mag-
both.
netic thickness gauge of a single coating spot thickness, or the
4.2.2 The molten metal in the working volume of the
microscopic reading of a coating thickness as seen in an optical
galvanizing bath shall contain not less than an average value of
microscope at one spot.
98.0 % zinc by weight [mass].
3.2.5 inspection lot, n—the quantity of identical parts
NOTE 1—The galvanizer may choose to add trace amounts of certain
cleaned, fluxed and galvanized together at one time in an elements (for example, aluminum, nickel, bismuth, or tin) to the zinc bath
appropriate container that is being submitted for acceptance as to help in the processing of certain reactive steels or to enhance the
a group. cosmetic appearance of the finished product. The elements can be added
to the galvanizing bath as a master feed alloy, or they can be added to the
3.2.6 malleable casting, n—a steel article that has been
bath by the galvanizer as individual feeds.
subjected to a prolonged anneal to decarburize or graphitize the
part to remove as much of the carbon as possible or to convert 4.3 Minimum Coating Weight [Mass] or Minimum Coating
the carbon to graphite, which permits plastic deformation in Thickness—The minimum coating weight [mass] or the mini-
compression without rupture. mum coating thickness shall conform to the requirements
prescribed in Table 1 for the material category and thickness of
3.2.7 sample, n—a collection of individual units of product material in which the article belongs.
from a single inspection lot selected in accordance with Section
6 and intended to represent that inspection lot for acceptance. 4.4 Threaded Articles—The zinc coating on threads shall
not be subjected to a cutting, rolling, or finishing-tool
3.2.8 specimen, n—an individual test article upon which operation, unless specifically authorized by the purchaser. In
thickness measurements or weight determinations are per- order to meet overtapping allowances, tapping the threads of
formed. nuts or tapped holes after galvanizing is not prohibited.
3.2.9 specimen coating thickness, n—the average thickness
4.5 Touch-up and Repair—Bare spots that are found on
from no less than five test measurements on a specimen, when
parts after galvanizing shall be renovated by use of the methods
each measurement location is selected to provide the widest
found in Practice A780 if the following criteria are met. The
dispersion (in all applicable directions) of locations within the
bare spots shall have an area totalling not more than 1 % of the
specimen volume.
surface area to be coated excluding threaded areas of the piece
3.2.10 threaded areas, n—the sections of a steel part that and the bare spots shall not include any threaded areas of the
have threads formed before hot-dip galvanizing. piece. The thickness of the repair shall be equal to the
surrounding galvanized coating except for repairs made by
4. Materials and Manufacture paints containing zinc dust in which case the thickness of the
4.1 Steel or Iron—Ferrous articles to be hot-dip zinc coated repair shall be 50 % greater than the thickness of the galva-
shall conform to specifications designated by the purchaser. nized coating required for the class of material, but shall not be

TABLE 1 Thickness or Weight [Mass] of Zinc Coating for Various Classes of Material
NOTE 1— Length of the piece, stated in Classes B-1, B-2, and B-3, refers to the finished dimension of the piece after fabrication.
Weight [Mass] of Zinc Coating, Coating Thickness, mils
oz/ft 2 [g/m2 ] of Surface, Minimum [microns], Minimum

Class of Material Average of Any Average of Any

Specimens Individual Specimens Individual
Tested Specimen Tested Specimen

Class A—Castings—Malleable Iron, Steel 2.00 [610] 1.80 [550] 3.4 [86] 3.1 [79]
Class B—Rolled, pressed, and forged articles
(except those which would be included under Classes C and D):
B-1—5⁄8 in. [15.88 mm] and over in thickness 2.00 [610] 1.80 [550] 3.4 [86] 3.1 [79]
and over 15 in. [381 mm] in length
B-2—under 5⁄8 in. [15.88 mm] in thickness and 1.50 [458] 1.25 [381] 2.6 [66] 2.1 [53]
over 15 in. [381 mm] in length
B-3—any thickness and 15 in. [381 mm] and under in length 1.30 [397] 1.10 [336] 2.2 [56] 1.9 [48]
Class C—Fasteners over 3⁄8 in. [9.52 mm] in diameter 1.25 [381] 1.00 [305] 2.1 [53] 1.7 [43]
and similar articles. Washers 3⁄16 in. and greater [4.76 mm and
greater] in thickness
Class D—Fasteners 3⁄8 in. [9.52 mm] and under in diameter, 1.00 [305] 0.85 [259] 1.7 [43] 1.4 [36]
rivets, nails and similar articles. Washers under 3⁄16 in. [4.76
mm] in thickness

Copyright by ASTM Int'l (all rights reserved); Tue Jul 27 22:26:33 EDT 2021
2
Downloaded/printed by
VIKRANTH GEDDAM (Petrofac) pursuant to License Agreement. No further reproductions authorized.
 A153/A153M − 16
greater than 4.0 mils [100 µm]. Repair thickness measurements 6.2 The method of selection and sample size shall be agreed
shall be made in accordance with Practice A780. The galva- upon between the galvanizer and the purchaser. Otherwise, the
nizer shall make repairs unless directed by the purchaser to sample size selected from each lot shall be as follows:
deliver items unrepaired for subsequent renovation by the
purchaser. Number of Pieces in Lot Sample Size
3 or less all
5. Workmanship, Finish, and Appearance 4 to 500 3
501 to 1200 5
5.1 The zinc-coated articles shall be free from uncoated 1201 to 3200 8
3201 to 10 000 13
areas, blisters, flux deposits, dross inclusions, and other types 10 001 and over 20
of projections that would interfere with the intended use of the
articles, or other defects not consistent with good galvanizing 6.3 A specimen that fails to conform to a requirement of this
practice. specification shall not be used to determine the conformance to
other requirements.
5.2 The zinc coating shall be reasonably smooth and uni-
form in thickness. 6.4 The method of sampling for fasteners that are required
to meet the standards of the Fastener Quality Act is described
NOTE 2—Smoothness of surface is a relative term. Minor roughness in Guide F1470. Sample quantities and definitions of terminol-
that does not interfere with the intended use of the part, or roughness that
is related to the as-received (ungalvanized) surface condition of the part,
ogy are included in the referenced specification.
shall not be grounds for rejection.
NOTE 3—Since this specification is applicable to items that are 7. Test Methods
centrifuged or otherwise handled to remove excess bath metal (see 1.2),
irregular coating distribution is not normally encountered. Drainage 7.1 Tests shall be made to ensure that the zinc coating is
problems, which manifest themselves as local excess coating thickness being furnished in accordance with this specification and as
that would interfere with function or as edge tears or spikes that present specified for the following:
a safety hazard because of their sharpness, are grounds for rejection under 7.1.1 Minimum coating weight [mass] or minimum coating
the terms of 5.1.
thickness in 4.3.
5.3 Embrittlement is a potential condition of steel that is 7.1.2 Finish and appearance in 5.1 and 5.2.
cold-worked, depending on such factors as the steel type 7.1.3 Embrittlement in 5.3 and 5.4.
(strength level, aging characteristics), thickness, degree of cold 7.1.4 Adherence in 5.5.
work, and galvanizing process. The galvanizer, the designer
and the fabricator shall take precautions against embrittlement. 7.2 Average Weight [Mass] of Coating:
The precautions to fabricate properly and prepare the material 7.2.1 The average weight [mass] of the zinc coating shall be
for galvanizing to prevent embrittlement are described in determined by weighing specimens after pickling and drying
Practice A143/A143M. and again after galvanizing unless the method described in
7.2.2 is used. The number of specimens that are used to
NOTE 4—Low service temperatures increase the risk of brittle failure of determine the average of an inspection lot shall be derived
all plain carbon steels including those which have been galvanized. This from Section 6.
temperature embrittling effect varies with type of steel. The expected
service temperature should thus be taken into account when selecting NOTE 5—This method does not take into account the weight [mass] of
steels for galvanizing. iron reacted from the article that is incorporated into the coating. It will
5.4 Malleable castings shall be of such composition as will thus underestimate coating weight [mass] by up to approximately 10 %.
Base metal reactivity will affect the extent of underestimation.
preclude the possibility that they become embrittled by the
galvanizing process, or they shall be either cooled from the 7.2.2 In the case of materials inspected after galvanizing,
anneal, or subsequently heat-treated so as to immunize them the average weight [mass] of coating shall be determined by
against embrittlement. stripping the number of specimens derived in Section 6 in
accordance with Test Method A90/A90M, and averaging the
5.5 The zinc coating shall adhere tenaciously to the surface
results of the individual specimens, unless the method de-
of the base metal.
scribed in 7.2.1 is used.
5.6 If the galvanized material covered by this specification
7.3 Average Thickness of Coating:
is bent or otherwise fabricated to the degree that causes the zinc
7.3.1 In the case of fasteners such as bolts, nuts, and screws,
coatings to stretch or compress beyond the limit of elasticity,
the determination of the thickness of coating shall be made on
any cracking or flaking of the coating resulting from the
a portion of the article that does not include any threads.
bending or fabricating shall not be cause for rejection.
7.3.2 The average thickness of coating shall be determined
5.7 High strength bolts, typically over 150,000 lb/in.2 ulti- by magnetic thickness gage in accordance with Practice E376
mate tensile strength, may be subject to hydrogen embrittle- unless the method described in 7.3.3 is used. The thickness
ment. Practices to safeguard against hydrogen embrittlement shall be measured on at least five widely separated spots on a
are described in Specification A143/A143M. specimen. No individual spot measurement shall be cause for
rejection. If an individual spot does not provide a coating
6. Sampling thickness reading, this spot must be repaired in accordance
6.1 Test specimens shall be selected at random from each with 4.5. The five or more individual coating thickness
inspection lot. measurements on a specimen must be averaged to determine

Copyright by ASTM Int'l (all rights reserved); Tue Jul 27 22:26:33 EDT 2021
3
Downloaded/printed by
VIKRANTH GEDDAM (Petrofac) pursuant to License Agreement. No further reproductions authorized.
 A153/A153M − 16
the specimen average coating thickness. The average coating 9. Rejection and Retest
thickness for the inspection lot is determined by averaging the 9.1 For all galvanized articles except those fasteners that
specimen average coating thickness values for the number of must meet the requirements of the Fastener Quality Act, the
specimens derived from Section 6. following sections are used to determine rejection and retest-
7.3.3 The thickness of coating shall be determined by cross ing.
section and optical measurement in accordance with Test
Method B487, unless the method described in 7.3.2 is used. 9.2 When partial inspection of materials to determine con-
The thickness thus determined is a point value. No less than formity with visual requirements of Section 5 warrants rejec-
five such measurements shall be made at locations on the tion of a lot, the galvanizer is not prohibited from sorting the
specimen, which are as widely dispersed as practical, so as to lot and submitting it once again for inspection.
be representative of the whole surface of the specimen. The 9.3 The number of specimens in a sample of a lot permitted
average of no less than five such measurements is the specimen to fail to conformance tests shall be agreed upon between the
average coating thickness. The average coating thickness for galvanizer and the purchaser.
the inspection lot is determined by averaging the specimen 9.4 If a set of test specimens fails to conform to the
average coating thickness values for the number of specimens requirements of this specification, two additional sets shall be
derived from Section 6. tested, both of which shall conform to the requirements in
7.4 Finish and Appearance—The test for finish and appear- every respect, or the lot of material represented by the
ance shall be conducted through visual inspection without specimens shall be rejected.
additional magnification. 9.5 Materials that have been rejected for reasons other than
7.5 Embrittlement—Hardware that is susceptible to em- embrittlement are not prohibited from being stripped,
brittlement shall be tested in accordance with Practice A143/ regalvanized, and resubmitted for test and inspection. They
A143M. The tests shall be performed through agreement shall then conform to the requirements of this specification.
between the galvanizer and the purchaser.
NOTE 6—Conformance to this specification does not guarantee “zero
7.6 Adherence—Determine adherence of the zinc coating to defects.” Depending on the size and configuration of the parts (small
the surface of the base metal by cutting or prying with the point diameter threaded parts and small washers as examples), a small amount
of “fall out” may exist in an inspection lot that is not detected during a
of a stout knife, applied with considerable pressure in a manner sample inspection. Issues include, but are not limited to, zinc build up in
tending to remove a portion of the coating. The adherence shall the threads or bonded washers. Handling of these types of issues need to
be considered inadequate if the coating delaminates in the form be negotiated between the purchaser and supplier.
of a layer of skin so as to expose the base metal in advance of
the knife point. Do not use testing carried out at edges or 10. Packaging
corners (points of lowest coating adherence) to determine 10.1 The supplier shall employ such methods of packaging
adherence of coating. Likewise, do not use removal of small zinc-coated articles as shall be required to ensure their receipt
particles of the coating by paring or whittling to determine by the purchaser in satisfactory condition, with the use to be
failure. made of the article being taken into consideration.
8. Inspection 11. Certification
8.1 The inspector representing the purchaser shall have 11.1 When specified in the purchase order or contract, the
access at all times while work on the contract of the purchaser purchaser shall be furnished certification that samples repre-
is being performed, to those areas of the manufacturer’s work senting each inspection lot have been either tested or inspected
which concern the application of the zinc coating to the as directed by this specification and the requirements have been
material ordered. The manufacturer shall afford the inspector met. When specified in the purchase order or contract, a report
all reasonable facilities to satisfy him that the zinc coating is of the test results shall be furnished.
being furnished in accordance with this specification. All
inspection and tests shall be made at the place of manufacture 12. Keywords
prior to shipments, unless otherwise specified, and shall be so 12.1 coatings, zinc; galvanized coatings; steel hardware,
conducted as not to interfere unnecessarily with the operation zinc coated; steel products, metallic coated; zinc coatings, steel
of the works. products

Copyright by ASTM Int'l (all rights reserved); Tue Jul 27 22:26:33 EDT 2021
4
Downloaded/printed by
VIKRANTH GEDDAM (Petrofac) pursuant to License Agreement. No further reproductions authorized.
 A153/A153M − 16
SUMMARY OF CHANGES

Committee A05 has identified the location of selected changes to this standard since the last issue,
A153/A153M-10, that may impact the use of this standard. (February 1, 2016)

(1) Revised values in Table 1. (3) Added Note 6.

(2) Added reference to A143/A143M in the new subsection
5.7.

ASTM International takes no position respecting the validity of any patent rights asserted in connection with any item mentioned
in this standard. Users of this standard are expressly advised that determination of the validity of any such patent rights, and the risk
of infringement of such rights, are entirely their own responsibility.

This standard is subject to revision at any time by the responsible technical committee and must be reviewed every five years and
if not revised, either reapproved or withdrawn. Your comments are invited either for revision of this standard or for additional standards
and should be addressed to ASTM International Headquarters. Your comments will receive careful consideration at a meeting of the
responsible technical committee, which you may attend. If you feel that your comments have not received a fair hearing you should
make your views known to the ASTM Committee on Standards, at the address shown below.

This standard is copyrighted by ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959,
United States. Individual reprints (single or multiple copies) of this standard may be obtained by contacting ASTM at the above
address or at 610-832-9585 (phone), 610-832-9555 (fax), or service@astm.org (e-mail); or through the ASTM website
(www.astm.org). Permission rights to photocopy the standard may also be secured from the Copyright Clearance Center, 222
Rosewood Drive, Danvers, MA 01923, Tel: (978) 646-2600; http://www.copyright.com/

Copyright by ASTM Int'l (all rights reserved); Tue Jul 27 22:26:33 EDT 2021
5
Downloaded/printed by
VIKRANTH GEDDAM (Petrofac) pursuant to License Agreement. No further reproductions authorized.