Is 4759-1996 (Ra2021)

(Reaffirmed
PPLIED BY BOOK SUPPLY BUREAU UNDER THE LICENSE FROM BIS FOR SJVN LIMITED - SHIMLA ON 16/11/2022 17:12:37 2013)
(117.239.0.10) VALID UPTO31/05/20
IS(Reaffirmed
4759 : 1996
2012)
(Reaffirmed
( Reaffirmed 2001)
2006 )
Edition 4.1
(2002-05)
SUPPLIED BY BOOK SUPPLY BUREAU UNDER THE LICENSE FROM BIS FOR SJVN LIMITED - SHIMLA ON 16/11/2022 17:12:37 (117.239.0.10) VALID UPTO31/05/2023
(Reaffirmed 2011)
(Reaffirmed 2016)
(Reaffirmed 2021)
(Reaffirmed 2010)
(Reaffirmed 2015)
(Reaffirmed 2009)
(Reaffirmed 2014)
Indian Standard (Reaffirmed 2008)
HOT-DIP ZINC COATINGS ON (Reaffirmed 2013)

STRUCTURAL STEEL AND OTHER ALLIED
(Reaffirmed 2007)
PRODUCTS — SPECIFICATION (Reaffirmed 2012)
( Third Revision ) (Reaffirmed 2006)
(Reaffirmed 2011)
(Incorporating Amendment No. 1)
(Reaffirmed 2005)
ICS 25.220.40;77 : 140.20 (Reaffirmed 2010)
(Reaffirmed 2009)
(Reaffirmed 2008)
(Reaffirmed 2007)
(Reaffirmed 2006)
© BIS 2002
(Reaffirmed 2005)
BUREAU OF INDIAN STANDARDS
MANAK BHAVAN , 9 BAHADUR SHAH ZAFAR MARG
NEW DELHI 110002
Price Group 3
PPLIED BY BOOK SUPPLY BUREAU UNDER THE LICENSE FROM BIS FOR SJVN LIMITED - SHIMLA ON 16/11/2022 17:12:37 (117.239.0.10) VALID UPTO31/05/20
Metallic and Non-Metallic Finishes Sectional Committee, MTD 20
FOREWORD
This Indian Standard (Third Revision) was adopted by Bureau of Indian Standards, after the draft
finalized by the Metallic and Non-Metallic Finishes Sectional Committee had been approved by
the Metallurgical Engineering Division Council.
This standard was initially published in 1968 and was subsequently revised in 1979 and 1984.
While reviewing the standard the committee decided to revise the same. The following
modifications have been made in this revision :
a) Additional grade of zinc has been specified;
b) Guidelines on the properties of the articles to be coated that affect the results of Hot-Dip
Coatings have been incorporated;
c) A new clause on information to be given by the purchaser to the galvanizer have been added;
and
d) Requirements of 3.2 of IS 4759 : 1984 have been covered in 4.2 of this standard.
In this revision assistance has also been derived from Doc CEN/TC, 262/SCI/WG2/N27—‘Hot Dip
Coatings on Fabricated Ferrous Products’, issued by European Committee for Standardization.
This edition 4.1 incorporates Amendment No. 1 (May 2002). Side bar indicates modification of the
text as the result of incorporation of the amendment.
For the purpose of deciding whether a particular requirement of this standard is complied with,
the final value, observed or calculated expressing the result of a test or analysis, shall be rounded
off in accordance with IS 2 : 1960 ‘Rules for rounding off numerical values ( revised )’. The number
of significant places retained in the rounded off value should be the same as that of the specified
value in this standard.
IS 4759 : 1996
Indian Standard
HOT-DIP ZINC COATINGS ON
STRUCTURAL STEEL AND OTHER ALLIED
PRODUCTS — SPECIFICATION
( Third Revision )
1 SCOPE 5 INFORMATION TO BE SUPPLIED BY
THE PURCHASER TO THE HOT-DIP
1.1 This standard specifies requirements for GALVANIZER
zinc coating applied by hot-dip galvanizing on
iron and steel products, fabricated or 5.1 Essential Information
assembled from cast, rolled, pressed and forged The following information shall be supplied by
shapes, such as structural steel sections, plates the purchaser to the hot-dip galvanizer :
and bars. a) Number of this Indian standard, and
1.2 This standard makes no reference to the b) The composition and any properties of the
quality of iron and steel itself before hot-dip base metal that may affect hot-dip
galvanizing. However guidance on the galvanizing.
condition of the base material which may affect NOTE — Any other information like:
the result of hot-dip galvanizing are given in i) Designation of steel;
Annex A. ii) Description regarding size length, etc;
iii) Condition of delivery;
iv) Any special requirement; and
2 REFERENCE v) Test report (if required) may be supplied by the
purchaser to the hot-dip galvanizer.
The Indian Standards listed at Annex B are 5.2 Additional Information
necessary adjuncts to this standard.
The following information may be required for
particular purpose and if so shall be specified
3 SUPPLY OF MATERIAL by the purchaser:
General requirements relating to the supply of a) An identification of significant surfaces,
material shall conform to IS 1387 : 1993. for example by drawings or by the
provision of suitably marked samples.
4 GENERAL REQUIREMENTS b) A drawing or other means of identifying
surface unevenness; for example round
4.1 Quality of Zinc drops or contact marks, will make the
coated article unacceptable for its
Zinc used for galvanizing shall conform to any intended purpose.
of the grades specified in IS 209 : 1992 ‘Zinc c) A sample or other means of showing the
ingot’ or IS 13229 : 1991 ‘Zinc for Galvanizing’. finished required.
d) Any special thickness of coating ( see
4.2 Galvanizing Bath Annex A ).
NOTE — Any other information like:
The molten metal in the galvanizing bath shall
i) Designation of steel;
contain not less than 98.5 percent by mass of ii) Description regarding size, length, etc;
zinc, but where there is a special user iii) Condition of delivery;
requirement, levels or addition of impurities in iv) Any other special requirements; and
the bath or in the coating may be specified by v) Test report (if required) may be supplied by the
purchaser to the hot-dip galvanizer.
the purchaser.
6 COATING REQUIREMENTS
4.3 Galvanizing
6.1 Mass of Zinc Coating
The steel products may, as far as practicable, Requirements for the mass of the coating for
be galvanized in accordance with IS 2629 : different classes of materials are given in
1985. Table 1.
1
IS 4759 : 1996
Table 1 Mass of Zinc Coating 8.1.2 Each lot shall be tested separately for the
( Clause 6.1 ) various requirements of the specification. The
number of units to be selected from each lot for
Sl Product Minimum Value
No. or Average Mass this purpose shall be as given in Table 2.
of Coating (g/m2)
(1) (2) (3) Table 2 Scale of Sampling
i) Castings-grey iron, malleable iron 610
ii) Fabricated steel articles: No. of Units No. of Units to be Acceptance
in the Lot Selected in a Sample No.
a) 5 mm thick and over 610
b) Under 5 mm, but not less 2 mm 460 (1) (2) (3)
c) Under 2 mm, but not less than 340
Up to 25 3 0
1.2 mm
iii) Threaded work other than tubes 26-100 5 0
and tube fittings: 101-150 8 1
a) 10 mm dia and over 300 151-500 13 1
b) Under 10 mm dia 270
501-1 000 20 2
NOTES
1 001-10 000 32 3
1 The requirements for the minimum mass of coating
10 001 and above 50 5
are for normal or rural atmosphere. In case of special
atmosphere like marine and industrial atmosphere, the NOTES
minimum mass of coating shall be increased as agreed 1 The units shall be selected at random. For this
to between the galvanizer and the purchaser. purpose, reference may be made to IS 4905 : 1968.
2 In case of fabricated steel structures, plates, etc, the 2 For details of acceptance number reference may be
coating mass is defined in terms of grams per square made to IS 2500 (Part 1) : 1992.
meter of the total surface area.
6.2 Freedom from Defects 8.2 Number of Tests

The zinc coating shall be uniform, adherent, 8.2.1 The sample selected according to col 1 and
reasonably smooth and free from such 2 of Table 2, shall be tested for visual
imperfections as flux, ash bare patches, black requirements as per 6.2.
spots, pimples, lumpiness, runs, rust stains, 8.2.2 The sample found conforming to the
bulky white deposits and blisters. above requirements shall then be tested for
6.3 Steel Embrittlement mass of zinc coating. For this purpose, suitable
test specimen shall be selected. If the material
The design of the products and the selection of is of inconvenient length, shorter pieces of the
the steel for its suitability to withstand normal same section under the same steel composition,
galvanizing operations without embrittlement not less than 90 cm length may be taken as test
or the method of fabrication shall be the specimen. Three test specimens shall be cut
responsibility of the fabricator. from each sample for the determination of mass
NOTE — Recommended precautions to properly design, of zinc coating as described in 9.2.
fabricate and prepare the material for galvanizing to
prevent embrittlement are given in IS 6158 : 1984. 8.3 Criteria for Conformity
7 POST-TREATMENT 8.3.1 Each sample shall be tested by testing one
Most galvanized products do not require any test specimen prepared as prescribed in 9.2.2.
post-treatment. Wherever required by the In case a test specimen representing a sample
purchaser, treatment such as chromating or unit fails to conform to the requirements
phosphating may be applied to reduce the risk specified in 9.2 with respect to the mass of zinc
of wet storage staining or assist subsequent coating the second and the third specimen shall
painting respectively. be tested. If any one of the second or third
specimen fails to conform to the requirements,
8 SAMPLING AND CRITERIA FOR the sample unit shall be called a defective unit.
CONFORMITY If the number of defective units in a lot exceeds
Unless otherwise agreed to, the following the acceptance number as specified in col 3 of
sampling plan shall be followed for ascertaining Table 2, the lot shall be rejected, else accepted.
the conformity of galvanized coating on 8.3.2 The material in the lot which have been
structural steel and other allied products. rejected may be stripped, galvanized and again
8.1 Sampling submitted for the test and inspection. Samples
shall be taken in accordance with Table 2.
8.1.1 Lot
8.4 Test for Visual Inspection
All the material of the same type in a coating
bath having uniform coating characteristics 8.4.1 Visual inspection of the material in a lot
shall be grouped together to constitute a lot. shall be made to determine the conformity with
2
IS 4759 : 1996
the requirements of 6.2. If the inspection shall then be calculated by multiplying

warrants rejection of the lot, the galvanizer the thickness in millimetres by a
may segregate the good pieces of the lot and factor 7 047.
submit it once again for inspection.
9.2.2 In the case of long pieces when test
8.4.2 If the lot inspected for visual inspection specimens are not available, the mass of the
passes then it shall be declared as conforming coating shall be the average of the
to the requirements of 6.2. determination made at each end and the
9 TEST PROCEDURE middle of the article. In the case of composite
assemblies, each part shall be tested separately
9.1 Test Specimen as they may fall in different classification.
9.1.1 Test specimens shall be selected from the
material galvanized but if the material is of 9.3 Determination of Uniformity of
inconvenient length, shorter pieces of the same Galvanizing Coating
section and of the same steel composition, not Where practicable, the uniformity of
less than 90 cm long, may be introduced as test galvanizing coating shall be determined by
specimen. preece test as prescribed in IS 2633 : 1972. The
9.1.2 All test specimens shall be treated in the article should withstand 4 one minute dips.
same manner, in the same bath and at the NOTES
same time as the material, whose coating 1 The use of the Preece test should be agreed to between
characteristics they intend to represent. the purchaser and the galvanizer.
9.1.3 Three representative specimens may be 2 In the case of large articles of inconvenient length, the
selected from each lot for carrying out the mass determination of coating thickness as done in 9.2.1(b)
may be taken as a uniformity test.
of coating as described in 9.2.
9.2 Mass of Galvanized Coating 9.4 Adhesion of Galvanized Coating
9.2.1 The mass of zinc coating shall be The coating shall withstand the pivoted
determined in accordance with IS 6745 : 1972. hammer and knife tests as prescribed in
The methods (a) and (b) as given below may IS 2629 : 1985 for testing adhesion of zinc
also be used subject to agreement between the coatings on fabricated products and hardware
purchaser and the galvanizer. However, the respectively.
method (a) gives the actual mass of zinc
coating, hence the average mass per unit area 10 MARKING
by this method is realistic:
10.1 The galvanized articles may be marked
a) Mass before and after galvanizing — The legibly and indelibly with the name or
mass of coating may be determined by trade-mark of the manufacturer.
weighing the article before and after
galvanizing, subtracting the first mass 10.1.1 BIS Certification Marking
from the second and dividing the result by
the surface areas. The first mass shall be 10.1.2 The articles may also be marked with
determined after pickling, rinsing and the Standard Mark.
drying, the second after cooling to ambient 10.1.3 The use of Standard Mark is governed
temperature. by the provisions of Bureau of Indian
b) The magnetic or microscopic methods as Standards Act, 1986 and Regulation made
prescribed in IS 3203 : 1982 or eddy thereunder. The details of conditions, under
current methods as prescribed in which a licence for the use of the Standard
IS 6012 : 1992 may also be employed to Mark may be granted to manufacturers or
determine the thickness of coating. The processors may be obtained from the Bureau of
mass of coating in grams per square meter Indian Standards.
3
IS 4759 : 1996
ANNEX A
( Clause 1.2 )
PROPERTIES OF THE ARTICLES TO BE COATED THAT AFFECT
THE RESULT OF HOT-DIP GALVANIZING (FOR INFORMATION ONLY)
A-1 BASE METAL strain age-embrittlement if the steel is

susceptible.
A-1.1 Composition
NOTE — Strain age-hardening and the risk of
Unalloyed carbon steel, low alloy steels and embrittlement is principally caused by the nitrogen
content of steel, which in turn is largely dependent on
grey and malleable cast iron are suitable for the steel making process. As a general guide, the
hot-dip galvanizing; while sulphur-containing problem does not occur in modern steel making
free-cutting steels are particularly unsuitable practices and the basic steels are generally least
for hot-dip galvanizing. susceptible to strain age-hardening.
To avoid risk of embrittlement, use a steel
A-1.2 Surface Condition which is not susceptible to strain
The surface of the base metal should be clean age-hardening. If a susceptible steel must be
before dipping into the molten zinc. Pickling is used, avoid severe cold work if possible. If
the recommended method of cleaning the severe cold work cannot be avoided, stresses
surface. Surface contaminants which cannot be should be relieved by heat-treatment before
removed by pickling for example oil, grease, hot-dip galvanizing.
paint, welding slags and similar impurities Heat treated or cold worked steels may be
must be removed prior to pickling. tempered by the heat in the hot-dip galvanizing
bath and lose some of the increased strength
Castings should be as free as possible from obtained by heat treatment or cold working.
surface porosity and shrinkage. The holes
should be cleaned by grit blasting, electrolytic Hardened steels may have tensile stresses of
pickling or other methods specially suitable for such a magnitude that zinc may penetrate into
grain boundaries causing the steel to crack in
castings.
the hot-dip galvanizing bath. The risk of
A-1.3 The Influence of Steel Surface cracking can be avoided by stress relieving.
Roughness on the Hot-Dip Galvanized Usual structural steels are not normally
Coating Thickness embrittled by the absorption of hydrogen
during pickling. With structural steels, any
The surface roughness of the steel surface has
absorbed hydrogen is discharged during hot-dip
an influence on the thickness and the structure
galvanizing. Hardened steels may, however, be
of the coating. embrittled due to hydrogen absorbed, if they
A rough steel surface as obtained by grit are harder than approximately 34 HRC, 340
blasting, coarse grinding, etc, prior to pickling HV or 325 HB.
gives a thicker coating than a surface which is Where experience shows that specific steels,
obtained by pickling alone. pretreatments, thermal and mechanical
treatments and hot-dip galvanizing procedures
A-1.4 The influence of reactive elements in the
have been satisfactory, the information serves
base metal on the zinc coating thickness and as an indication that an embrittlement problem
appearance. is not to be expected for the same combination
Several reactive elements affect galvanizing, of steels, pretreatments, thermal and
for example, silicon (Si) and phosphorus (P) in mechanical treatments and galvanizing
the steel. The steel surfaces have an influence procedures.
on the thickness and appearance of the zinc A-1.6 Larger or Thicker Steels
coating. At certain levels, they can give uneven, Longer handling times are needed in the
bright and/or dull dark grey coatings which galvanizing bath for larger articles and this as
may be brittle and thick. well as the metallurgical properties of thicker
A-1.5 Stresses in the Base Metal steels due to normal manufacturing methods
may cause thick coatings to form because the
Stresses in the base metal are relieved during thickness of the coatings is normally a function
the hot-dip galvanizing process and this may of the immersion time in the galvanizing bath.
cause deformation of the coated article.
A-2 DESIGN
Steel that is cold worked may become brittle,
A-2.1 General
depending on its type and the degree of cold
work. As hot-dip galvanizing is a form of heat The design of the articles to be hot-dip
treatment also, it may accelerate the onset of galvanized should be appropriate for the
4
IS 4759 : 1996
process of hot-dip galvanizing. The purchaser is before galvanizing, or if hot-rolled steels

recommended to seek the advice of the hot-dip containing more than 0.3 percent silicon are
galvanizer before designing or making a used.
product which is subsequently to be hot-dip
galvanized, as it may be necessary to adpot the A-4 THE HOT-DIP GALVANIZING BATH
construction of the article for the hot-dip
galvanizing process. The alloying elements of the zinc in the bath
vary with different hot-dip galvanizing
A-2.2 Effect of Process Heat processes. Normally the zinc content in the
No materials which will be adversely affected working area of the bath should be not less
by the heat of the hot-dip galvanizing bath than 98.5 percent by mass but where there is a
(typically 440°C but up to 470°C in high special user requirement, levels of additions or
temperature hot-dip galvanizing) should be impurities in the bath or in the coating may be
hot-dip galvanized. specified by the purchaser.
A-2.3 Enclosed Cavities A-5 AFTER TREATMENT
It is essential for both safety and process Hot-dip galvanised articles may be left to cool
reasons that means for venting and draining in air after withdrawal from the hot-dip
enclosed cavities be provided by the purchaser, galvanizing bath or may be quenched in water.
or after the consent of the purchaser, by the
hot-dip galvanizer. Small articles dipped in bulk in baskets or on
CAUTION — It is essential to avoid enclosed cavities jigs may be centrifuged immediately after
as these can cause explosions during hot-dip withdrawal from the zinc to remove any
galvanizing. surplus metal [ see 4.2(e) ].
A-3 RELATION BETWEEN LENGTH OF To retard the possible formation of wet storage
TIME OF CORROSION PROTECTION stain on the surface, the articles can be given a
AND HOT-DIP GALVANIZED COATING suitable surface treatment, like chromating,
THICKNESS after hot-dip galvanizing.
The length of time of corrosion protection of If the articles are to be painted or powder
hot-dip galvanized coatings (whether light grey coated after galvanizing the customer should
or dull grey) is approximately proportional to advise the galvanizer accordingly.
the coating thickness and the surface condition
of the material to be galvanized. A-6 RENOVATION OF UNCOATED OR
DAMAGED AREAS
For extremely aggressive conditions and/or an
exceptionally long service life, thicker coatings Areas of surface that are uncoated when
may be required. The specification of the galvanized may be renovated by zinc spraying
coating is subject to mutual agreement between (after cleaning and removal of mill scale), by
the galvanizer and the purchaser. Some zinc-rich paint (normally minimum 90 percent
increase in coating thickness may be obtained, m/m metallic zinc content of dry film) or by a
for example, if steel surface are grit-blasted low-melting-point zinc alloy.
5
IS 4759 : 1996
ANNEX B
( Clause 2 )
LIST OF REFERRED INDIAN STANDARDS
IS No. Title IS No. Title

209 : 1992 Zinc ingot ( fourth revision ) 3203 : 1982 Methods of testing local
thickness of electroplated
1387 : 1993 General requirements for the coatings ( first revision )
supply of metallurgical materials
( second revision ) 4905 : 1982 Methods of random sampling
6012 : 1982 Measurement of coating
2500 (Part 1) : Sampling inspection procedure : thickness by eddy current
1992 Part 1 Attribute sampling plans methods ( first revision )
indicated by acceptable quality
level (AQL) for lot inspection 6158 : 1984 Recommended practice for
( second revision ) safeguarding against
embrittlement of hot-dipped
2629 : 1985 Recommended practice for galvanized iron and steel
hot-dip galvanizing of iron and products ( second revision )
steel ( first revision ) 6745 : 1972 Method for determination of
2633 : 1986 Methods of testing uniformity of mass of zinc coating on zinc
coating on zinc coated articles coated iron and steel articles
( second revision ) 13229 : 1991 Zinc for galvanizing
6
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Enquiries relating to copyright be addressed to the Director (Publications), BIS.
Review of Indian Standards

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Indian Standards should ascertain that they are in possession of the latest amendments or edition by
referring to the latest issue of ‘BIS Catalogue’ and ‘Standards : Monthly Additions’.
This Indian Standard has been developed from Doc : No. MTD 20 (4155).
Amendments Issued Since Publication

Amend No. Date of Issue
Amd. No. 1 May 2002
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(Reaffirmed

Indian Standard (Reaffirmed 2008)

HOT-DIP ZINC COATINGS ON (Reaffirmed 2013)

Metallic and Non-Metallic Finishes Sectional Committee, MTD 20

6.2 Freedom from Defects 8.2 Number of Tests

the requirements of 6.2. If the inspection shall then be calculated by multiplying

A-1 BASE METAL strain age-embrittlement if the steel is

process of hot-dip galvanizing. The purchaser is before galvanizing, or if hot-rolled steels

IS No. Title IS No. Title

Bureau of Indian Standards

Review of Indian Standards

Amendments Issued Since Publication

BUREAU OF INDIAN STANDARDS

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