SIST EN ISO 2063-1:2019

Thermal spraying - Zinc, aluminium and and their alloys - Part 1: Design considerations and quality requirements for corrosion protection systems (ISO 2063-1:2019)

This document specifies requirements for the protection of iron and steel surfaces against corrosion by
applying thermal-sprayed metallic coatings of zinc, aluminium or their alloys.
In this document, requirements for the planning of the corrosion protection system and for the
constructive design of the component to be protected are specified, where thermal spraying is intended
to be the process for the deposition of the metallic corrosion protection.
Some field-related basic terms are defined and instructions for corrosion behaviour of the zinc and
aluminium materials under different environment conditions are provided.
Characteristic properties of the coating, e.g. coating thickness, minimum adhesive strength and surface
appearance, are specified and test procedures for thermal-sprayed corrosion protection coatings of
zinc, aluminium or their alloys are determined.
This document is valid for applying thermal-sprayed zinc and aluminium protection coatings against
corrosion in the temperature range between −50 °C to +200 °C, taking into consideration the service
conditions of any sealants used. Heat-resistant protective coatings of aluminium are covered by
ISO 17834 and are not in the scope of this document.
Other corrosion protection processes, e.g. hot-dip galvanizing (galvanic coating), sherardizing,
electroplating or selection and deposition of organic coatings/paints are not in the scope of this
document.
Requirements for the manufacturing of thermal-sprayed coatings are specified in ISO 2063-2.

Thermisches Spritzen - Zink, Aluminium und ihre Legierungen - Teil 1: Bauteilgestaltung und Qualitätsanforderungen für Korrosionsschutzsysteme (ISO 2063-1:2019)

Dieses Dokument legt Anforderungen zum Schutz von Eisen  und Stahloberflächen gegen Korrosion durch Aufbringen thermisch gespritzter metallischer Schichten aus Zink, Aluminium oder deren Legierungen fest.
Dieses Dokument legt Anforderungen an die Planung des Korrosionsschutzsystems und die konstruktive Gestaltung des zu schützenden Bauteils fest, wenn thermisches Spritzen als Verfahren für das Auftragen des metallischen Korrosionsschutzes vorgesehen ist.
Einige fachgebietsbezogene Grundbegriffe werden definiert und Hinweise zum Korrosionsverhalten der Zink  und Aluminiumwerkstoffe unter verschiedenen Umgebungsbedingungen gegeben.
Charakteristische Eigenschaften der Schicht, z. B. Schichtdicke, Mindesthaftfestigkeit und Oberflächen-beschaffenheit, werden spezifiziert und Prüfverfahren für thermisch gespritzte Korrosionsschutzschichten aus Zink, Aluminium oder deren Legierungen festgelegt.
Dieses Dokument gilt für das Aufbringen thermisch gespritzter Zink  und Aluminiumschutzschichten gegen Korrosion im Temperaturbereich zwischen −50 °C und +200 °C unter Beachtung der Einsatzbedingungen von verwendeten Versiegelungsmitteln. Hitzebeständige Schutzschichten aus Aluminium werden in ISO 17834 behandelt und fallen nicht in den Anwendungsbereich dieses Dokuments.
Andere Korrosionsschutzprozesse, z. B. Feuerverzinken (galvanisches Beschichten), Sherardisieren, galva-nische Metallabscheidung oder Auswählen und Auftragen organischer Beschichtungen/Anstriche liegen nicht im Anwendungsbereich dieses Dokumentes.
Anforderungen an die Herstellung von thermisch gespritzten Schichten sind in ISO 2063 2 festgelegt.

Projection thermique - Zinc, aluminium et alliages de ces métaux - Partie 1: Considérations de conception et exigences de qualité pour les systèmes de protection contre la corrosion (ISO 2063-1:2019)

Le présent document spécifie les exigences relatives à la protection contre la corrosion des surfaces en fer et en acier par l'application de revêtements métalliques obtenus par projection thermique de zinc, d'aluminium ou de leurs alliages.
Le présent document spécifie les exigences relatives à la planification du système de protection contre la corrosion et à la conception du composant à protéger, lorsqu'un procédé de projection thermique est prévu pour le dépôt du revêtement métallique de protection contre la corrosion.
Certains termes principaux liés au domaine sont définis et des informations sont données sur le comportement à la corrosion des matériaux en zinc et en aluminium dans différentes conditions d'environnement.
Les propriétés caractéristiques du revêtement, telles que l'épaisseur du revêtement, l'adhérence minimale et l'aspect de surface, sont spécifiées et des modes opératoires d'essai des revêtements de protection contre la corrosion obtenus par projection thermique de zinc, d'aluminium ou de leurs alliages sont déterminés.
Le présent document est valable pour l'application de revêtements de protection contre la corrosion par projection thermique de zinc et d'aluminium dans la plage de températures entre ?50 °C et +200 °C en tenant compte des conditions de service de tous les produits de colmatage utilisés. Les revêtements de protection en aluminium résistant à la chaleur sont couverts par l'ISO 17834 et ne relèvent pas du domaine d'application du présent document.
Les autres procédés de protection contre la corrosion, par exemple la galvanisation à chaud (revêtement galvanique), la shérardisation, le dépôt électrolytique, ou la sélection et le dépôt de revêtements organiques/peintures, ne relèvent pas du domaine d'application du présent document.
Les exigences relatives à la fabrication de revêtements par projection thermique sont spécifiées dans l'ISO 2063‑2.

Vroče brizganje - Cink, aluminij in njune zlitine - 1. del: Projektiranje in zahteve glede kakovosti korozijskega zaščitnega sistema (ISO 2063-1:2019)

Ta dokument določa zahteve za zaščito železnih in jeklenih površin pred korozijo z vroče brizganimi kovinskimi prevlekami iz cinka, aluminija ali njunih zlitin.
V tem dokumentu so podane zahteve za načrtovanje korozijskega zaščitnega sistema in za strukturno zasnovo komponente, ki jo je treba zaščititi, pri čemer se kovinska zaščita pred korozijo predvidoma nanese z vročim brizganjem.
Določeni so nekateri osnovni pojmi, povezani s področjem uporabe, in podana so navodila za korozijsko obnašanje cinkovih in aluminijevih materialov v različnih okoljskih pogojih.
Podane so značilne lastnosti prevleke (npr. debelina prevleke, najmanjša sprijemna trdnost, površinski videz) in opredeljeni so preskusni postopki za vroče brizgane korozijske zaščitne prevleke iz cinka, aluminija ali njunih zlitin.
Ta dokument se uporablja za nanašanje vroče brizganih cinkovih in aluminijevih zaščitnih prevlek
proti koroziji v temperaturnem območju od –50 °C do 200 °C ob upoštevanju pogojev uporabe
vseh uporabljenih tesnilnih mas. Toplotno odporne zaščitne prevleke iz aluminija so zajete v standardu ISO 17834 in ne spadajo na področje uporabe tega dokumenta.
Drugi postopki korozijske zaščite, npr. vroče galvanizirane prevleke, šeradiranje, galvanizacija ali izbira in nalaganje organskih prevlek/barv ne spadajo na področje uporabe tega dokumenta.
Zahteve za izdelavo vroče brizganih prevlek so podane v standardu ISO 2063-2.

General Information

• Status: Published
• Public Enquiry End Date: 19-Dec-2018
• Publication Date: 08-Apr-2019
• ICS: 25.220.20 - Surface treatment
• ICS: 77.120.10 - Aluminium and aluminium alloys
• ICS: 77.120.60 - Lead, zinc, tin and their alloys
• Technical Committee: IPKZ - Protection of metals against corrosion
• Current Stage: 6060 - National Implementation/Publication (Adopted Project)
• Start Date: 02-Apr-2019
• Due Date: 07-Jun-2019
• Completion Date: 09-Apr-2019
• Ref Project: EN ISO 2063-1:2019 - Thermal spraying - Zinc, aluminium and and their alloys - Part 1: Design considerations and quality requirements for corrosion protection systems (ISO 2063-1:2019)

Relations

• Replaces: SIST EN ISO 2063-1:2017 - Thermal spraying - Zinc, aluminium and their alloys - Part 1: Design considerations and quality requirements for corrosion protection systems (ISO 2063-1:2017)
• Effective Date: 01-May-2019
• Replaces: SIST EN ISO 2063-1:2017 - Thermal spraying - Zinc, aluminium and their alloys - Part 1: Design considerations and quality requirements for corrosion protection systems (ISO 2063-1:2017)
• Effective Date: 08-Jun-2022

Standards Content (Sample)

SLOVENSKI STANDARD
SIST EN ISO 2063-1:2019
01-maj-2019
1DGRPHãþD
SIST EN ISO 2063-1:2017
9URþHEUL]JDQMH&LQNDOXPLQLMLQQMXQH]OLWLQHGHO3URMHNWLUDQMHLQ]DKWHYH
JOHGHNDNRYRVWLNRUR]LMVNHJD]DãþLWQHJDVLVWHPD,62
Thermal spraying - Zinc, aluminium and and their alloys - Part 1: Design considerations
and quality requirements for corrosion protection systems (ISO 2063-1:2019)
Thermisches Spritzen - Zink, Aluminium und ihre Legierungen - Teil 1: Bauteilgestaltung
und Qualitätsanforderungen für Korrosionsschutzsysteme (ISO 2063-1:2019)
Projection thermique - Zinc, aluminium et alliages de ces métaux - Partie 1:
Considérations de conception et exigences de qualité pour les systèmes de protection
contre la corrosion (ISO 2063-1:2019)
Ta slovenski standard je istoveten z: EN ISO 2063-1:2019
ICS:
25.220.20 Površinska obdelava Surface treatment
77.120.10 Aluminij in aluminijeve zlitine Aluminium and aluminium
alloys
77.120.60 Svinec, cink, kositer in Lead, zinc, tin and their
njihove zlitine alloys
SIST EN ISO 2063-1:2019 en
2003-01.Slovenski inštitut za standardizacijo. Razmnoževanje celote ali delov tega standarda ni dovoljeno.

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SIST EN ISO 2063-1:2019

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SIST EN ISO 2063-1:2019


EN ISO 2063-1
EUROPEAN STANDARD

NORME EUROPÉENNE

March 2019
EUROPÄISCHE NORM
ICS 25.220.20; 25.220.40 Supersedes EN ISO 2063-1:2017
English Version

Thermal spraying - Zinc, aluminium and and their alloys -
Part 1: Design considerations and quality requirements for
corrosion protection systems (ISO 2063-1:2019)
Projection thermique - Zinc, aluminium et alliages de Thermisches Spritzen - Zink, Aluminium und ihre
ces métaux - Partie 1: Considérations de conception et Legierungen - Teil 1: Bauteilgestaltung und
exigences de qualité pour les systèmes de protection Qualitätsanforderungen für Korrosionsschutzsysteme
contre la corrosion (ISO 2063-1:2019) (ISO 2063-1:2019)
This European Standard was approved by CEN on 8 February 2019.

CEN members are bound to comply with the CEN/CENELEC Internal Regulations which stipulate the conditions for giving this
European Standard the status of a national standard without any alteration. Up-to-date lists and bibliographical references
concerning such national standards may be obtained on application to the CEN-CENELEC Management Centre or to any CEN
member.

This European Standard exists in three official versions (English, French, German). A version in any other language made by
translation under the responsibility of a CEN member into its own language and notified to the CEN-CENELEC Management
Centre has the same status as the official versions.

CEN members are the national standards bodies of Austria, Belgium, Bulgaria, Croatia, Cyprus, Czech Republic, Denmark, Estonia,
Finland, Former Yugoslav Republic of Macedonia, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania,
Luxembourg, Malta, Netherlands, Norway, Poland, Portugal, Romania, Serbia, Slovakia, Slovenia, Spain, Sweden, Switzerland,
Turkey and United Kingdom.





EUROPEAN COMMITTEE FOR STANDARDIZATION
COMITÉ EUROPÉEN DE NORMALISATION

EUROPÄISCHES KOMITEE FÜR NORMUNG

CEN-CENELEC Management Centre: Rue de la Science 23, B-1040 Brussels
© 2019 CEN All rights of exploitation in any form and by any means reserved Ref. No. EN ISO 2063-1:2019 E
worldwide for CEN national Members.

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SIST EN ISO 2063-1:2019
EN ISO 2063-1:2019 (E)
Contents Page
European foreword . 3

2

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SIST EN ISO 2063-1:2019
EN ISO 2063-1:2019 (E)
European foreword
This document (EN ISO 2063-1:2019) has been prepared by Technical Committee ISO/TC 107 "Metallic
and other inorganic coatings" in collaboration with Technical Committee CEN/TC 240 “Thermal
spraying and thermally sprayed coatings” the secretariat of which is held by DIN.
This European Standard shall be given the status of a national standard, either by publication of an
identical text or by endorsement, at the latest by September 2019, and conflicting national standards
shall be withdrawn at the latest by September 2019.
Attention is drawn to the possibility that some of the elements of this document may be the subject of
patent rights. CEN shall not be held responsible for identifying any or all such patent rights.
This document supersedes EN ISO 2063-1:2017.
According to the CEN-CENELEC Internal Regulations, the national standards organizations of the
following countries are bound to implement this European Standard: Austria, Belgium, Bulgaria,
Croatia, Cyprus, Czech Republic, Denmark, Estonia, Finland, Former Yugoslav Republic of Macedonia,
France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta,
Netherlands, Norway, Poland, Portugal, Romania, Serbia, Slovakia, Slovenia, Spain, Sweden, Switzerland,
Turkey and the United Kingdom.
Endorsement notice
The text of ISO 2063-1:2019 has been approved by CEN as EN ISO 2063-1:2019 without any
modification.


3

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SIST EN ISO 2063-1:2019

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SIST EN ISO 2063-1:2019
INTERNATIONAL ISO
STANDARD 2063-1
Second edition
2019-02
Thermal spraying — Zinc, aluminium
and their alloys —
Part 1:
Design considerations and quality
requirements for corrosion
protection systems
Projection thermique — Zinc, aluminium et alliages de ces métaux —
Partie 1: Considérations de conception et exigences de qualité pour les
systèmes de protection contre la corrosion
Reference number
ISO 2063-1:2019(E)
©
ISO 2019

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SIST EN ISO 2063-1:2019
ISO 2063-1:2019(E)

COPYRIGHT PROTECTED DOCUMENT
© ISO 2019
All rights reserved. Unless otherwise specified, or required in the context of its implementation, no part of this publication may
be reproduced or utilized otherwise in any form or by any means, electronic or mechanical, including photocopying, or posting
on the internet or an intranet, without prior written permission. Permission can be requested from either ISO at the address
below or ISO’s member body in the country of the requester.
ISO copyright office
CP 401 • Ch. de Blandonnet 8
CH-1214 Vernier, Geneva
Phone: [phone]
Fax: [phone]
Email: [e-mail]
Website: www.iso.org
Published in Switzerland
ii © ISO 2019 – All rights reserved

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SIST EN ISO 2063-1:2019
ISO 2063-1:2019(E)

Contents Page
Foreword .v
Introduction .vi
1 Scope . 1
2 Normative references . 1
3 Terms and definitions . 2
4 Criteria for corrosion and corrosion protection by thermal-sprayed coatings .3
4.1 General . 3
4.2 Corrosivity categories and environment conditions . 3
4.3 Corrosion rate . 3
4.4 Coating materials and corrosion behaviour . 3
4.4.1 General. 3
4.4.2 Zinc and zinc alloys . 4
4.4.3 Aluminium and aluminium alloys . 4
5 Requirements for the corrosion protection systems and their planning .4
5.1 General rules — Technical requirements . 4
5.2 Used spray materials and coating thickness . 5
5.2.1 Spray materials. 5
5.2.2 Coating thickness . 5
5.3 Construction design requirements for iron and steel components for thermal spraying . 6
5.3.1 General. 6
5.3.2 Recommendations for the design of the part — Avoidance of corrosion
creating areas . 6
5.3.3 Requirements for welding in combination with thermal-sprayed
protective coatings . 6
5.3.4 Thermal spraying of corrosion protected fastenings . 6
6 Pre-conditions and requirements for the manufacturing process .6
6.1 General — Requirements . 6
6.2 Reference areas . 6
6.3 Preparation of the surface to be coated . 7
6.4 Thermal spraying . 7
6.5 Sealing of thermal-sprayed coatings . 7
6.6 Metallic coatings and additional organic top coatings . 8
6.7 Requirements for the tests — Test procedures . 8
6.7.1 General. 8
6.7.2 Visual inspection — Appearance . 8
6.7.3 Coating thickness . 8
6.7.4 Adhesion strength . . 9
6.7.5 Metallographic investigation . 9
7 Requirements for the manufacturer . 9
7.1 General . 9
7.2 Coating specification — Requirements for the spray coating .10
8 Documentation .10
Annex A (informative) Corrosivity categories — Environment conditions — Exposure.11
Annex B (informative) Summary of the corrosion behaviour of thermal-sprayed coatings of
zinc, aluminium and their alloys .13
Annex C (informative) Recommended values for the thickness of the metallic coating .15
Annex D (informative) Examples of design and explanations .17
Annex E (informative) Example test certificate for work specimen for thermal sprayer used
on-site in accordance with ISO 2063-2 .22
© ISO 2019 – All rights reserved iii

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SIST EN ISO 2063-1:2019
ISO 2063-1:2019(E)

Annex F (informative) Appearance of surfaces in different treated conditions .24
Annex G (informative) Checklist for this document — Work and test steps and connection
to relevant standards or recommendations .25
Bibliography .27
iv © ISO 2019 – All rights reserved

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SIST EN ISO 2063-1:2019
ISO 2063-1:2019(E)

Foreword
ISO (the International Organization for Standardization) is a worldwide federation of national standards
bodies (ISO member bodies). The work of preparing International Standards is normally carried out
through ISO technical committees. Each member body interested in a subject for which a technical
committee has been established has the right to be represented on that committee. International
organizations, governmental and non-governmental, in liaison with ISO, also take part in the work.
ISO collaborates closely with the International Electrotechnical Commission (IEC) on all matters of
electrotechnical standardization.
The procedures used to develop this document and those intended for its further maintenance are
described in the ISO/IEC Directives, Part 1. In particular, the different approval criteria needed for the
different types of ISO documents should be noted. This document was drafted in accordance with the
editorial rules of the ISO/IEC Directives, Part 2 (see www .iso .org/directives).
Attention is drawn to the possibility that some of the elements of this document may be the subject of
patent rights. ISO shall not be held responsible for identifying any or all such patent rights. Details of
any patent rights identified during the development of the document will be in the Introduction and/or
on the ISO list of patent declarations received (see www .iso .org/patents).
Any trade name used in this document is information given for the convenience of users and does not
constitute an endorsement.
For an explanation of the voluntary nature of standards, the meaning of ISO specific terms and
expressions related to conformity assessment, as well as information about ISO's adherence to the
World Trade Organization (WTO) principles in the Technical Barriers to Trade (TBT) see www .iso
.org/iso/foreword .html.
This document was prepared by Technical Committee ISO/TC 107, Metallic and other inorganic coatings.
This second edition cancels and replaces the first edition (ISO 2063-1:2017), of which it constitutes a
minor revision.
The changes compared to the previous edition are as follows:
— Table C.1 has been corrected;
— citations for Annex E, Annex F and Annex G have been added in the text.
A list of all the parts in the ISO 2063 series can be found on the ISO website.
Any feedback or questions on this document should be directed to the user’s national standards body. A
complete listing of these bodies can be found at www .iso .org/members .html.
© ISO 2019 – All rights reserved v

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SIST EN ISO 2063-1:2019
ISO 2063-1:2019(E)

Introduction
In order to protect iron- and steel-based structures (e.g. for steel construction, bridge construction,
steel structures for water construction, onshore and offshore wind energy constructions, petrol and
natural gas industry) against corrosion, protective coatings are usually deposited. Corresponding to
type, shape and required functionality of the part, numerous procedures are available. The deposition
of corrosion protection coatings or coating systems can be done by applying hot-dip galvanizing,
organic coatings or thermal spraying of zinc, aluminium and their alloys. Using combinations of metallic
and organic coatings, duplex corrosion protection coating systems can be produced.
Thermal-sprayed corrosion protection coatings made of zinc, aluminium and their alloys can be
sprayed onto all steels which make up the components used in the relevant industrial application. This
may be carried out on-site, as well as in the workshop, regardless of the article’s size. Due to the usually
low heat input into the surface of the part, only a slight thermal loading of the substrate occurs, so that
changes in steel properties and deformation of the part do not occur.
Corrosion protection coatings can be used as repairs or rework of defects of other coatings (e.g. uncoated
hot-dip zinc galvanized areas) or worn coatings where thermal spraying can be applied on the spot. Due
to relative low investment costs, thermal spraying can also be economically applied for single parts.
The ISO 2063 series applies to thermal-sprayed metallic coatings to protect iron and steel against
corrosion by deposition of zinc, aluminium or their alloys onto the uncoated surface to be protected.
This document targets designers of components. It covers the planning engineering of the corrosion
protection system and deals with the basic rules for planning of corrosion protection systems and for
the constructive design of the components to be protected, if the protection system is based upon a
thermal-sprayed metallic coating.
ISO 2063-2 targets manufacturers of corrosion protection systems. It deals with the requirements for
the execution of the corrosion protection works by thermal spraying in the workshop and on-site.
vi © ISO 2019 – All rights reserved

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SIST EN ISO 2063-1:2019
INTERNATIONAL STANDARD ISO 2063-1:2019(E)
Thermal spraying — Zinc, aluminium and their alloys —
Part 1:
Design considerations and quality requirements for
corrosion protection systems
1 Scope
This document specifies requirements for the protection of iron and steel surfaces against corrosion by
applying thermal-sprayed metallic coatings of zinc, aluminium or their alloys.
In this document, requirements for the planning of the corrosion protection system and for the
constructive design of the component to be protected are specified, where thermal spraying is intended
to be the process for the deposition of the metallic corrosion protection.
Some field-related basic terms are defined and instructions for corrosion behaviour of the zinc and
aluminium materials under different environment conditions are provided.
Characteristic properties of the coating, e.g. coating thickness, minimum adhesive strength and surface
appearance, are specified and test procedures for thermal-sprayed corrosion protection coatings of
zinc, aluminium or their alloys are determined.
This document is valid for applying thermal-sprayed zinc and aluminium protection coatings against
corrosion in the temperature range between −50 °C to +200 °C, taking into consideration the service
conditions of any sealants used. Heat-resistant protective coatings of aluminium are covered by
ISO 17834 and are not in the scope of this document.
Other corrosion protection processes, e.g. hot-dip galvanizing (galvanic coating), sherardizing,
electroplating or selection and deposition of organic coatings/paints are not in the scope of this
document.
Requirements for the manufacturing of thermal-sprayed coatings are specified in ISO 2063-2.
2 Normative references
The following documents are referred to in the text in such a way that some or all of their content
constitutes requirements of this document. For dated references, only the edition cited applies. For
undated references, the latest edition of the referenced document (including any amendments) applies.
ISO 1463, Metallic and oxide coatings — Measurement of coating thickness — Microscopical method
ISO 2063-2:2017, Thermal spraying — Zinc, aluminium and their alloys — Part 2: Execution of corrosion
protection systems
ISO 2178, Non-magnetic coatings on magnetic substrates — Measurement of coating thickness —
Magnetic method
ISO 4624, Paints and varnishes — Pull-off test for adhesion
ISO 8044, Corrosion of metals and alloys — Basic terms and definitions
ISO 8501-1, Preparation of steel substrates before application of paints and related products — Visual
assessment of surface cleanliness — Part 1: Rust grades and preparation grades of uncoated steel substrates
and of steel substrates after overall removal of previous coatings
© ISO 2019 – All rights reserved 1

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SIST EN ISO 2063-1:2019
ISO 2063-1:2019(E)

ISO 8501-3, Preparation of steel substrates before application of paints and related products — Visual
assessment of surface cleanliness — Part 3: Preparation grades of welds, edges and other areas with surface
imperfections
ISO 12671, Thermal spraying - Thermally sprayed coatings - Symbolic representation on drawings
ISO 14232-1, Thermal spraying — Powders — Part 1: Characterization and technical supply conditions
ISO 14916, Thermal spraying — Determination of tensile adhesive strength
ISO 14917, Thermal spraying — Terminology, classification
ISO 14919, Thermal spraying — Wires, rods and cords for flame and arc spraying — Classification —
Technical supply conditions
ISO 14923, Thermal spraying — Characterization and testing of thermally sprayed coatings
EN 10163-2, Delivery requirements for surface conditions of hot-rolled steel plates, wide flats and
sections — Part 2: Plate and wide flats
EN 10163-3, Delivery requirements for surface condition of hot-rolled steel plates, wide flats and
sections — Part 3: Sections
3 Terms and definitions
For the purposes of this document, the terms and definitions given in ISO 14917, ISO 8044 and the
following apply.
ISO and IEC maintain terminological databases for use in standardization at the following addresses:
— ISO Online browsing platform: available at https: //www .iso .org/obp
— IEC Electropedia: available at http: //www .electropedia .org/
3.1
service life
expected lifetime of a product (e.g. a structure, component or part) or the acceptable period of use
in service
Note 1 to entry: It is also the time that any manufactured item can be expected to be serviceable.
3.2
design life
period of time during which the item (e.g. a structure, component, part or product) is expected by its
designers to work within its specified parameters
Note 1 to entry: In the case of series production, it is the period of time between the putting into service of a
single item and that item’s onset of wearing out.
3.3
life to first maintenance
durability
expected life of a coating system until first maintenance
Note 1 to entry: It is also the time interval that elapses after the initial coating before coating deterioration
reaches the point that maintenance is necessary to restore protection of the base metal in accordance with
ISO 12944-1.
2 © ISO 2019 – All rights reserved

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SIST EN ISO 2063-1:2019
ISO 2063-1:2019(E)

3.4
protective coating system
sum total of the coats of metal materials and/or paints (duplex coatings) or related products which are
to be applied or which have been applied to a substrate to provide corrosion protection in accordance
with ISO 12944-1
3.5
pre-fabrication primer
fast-drying paint that is applied to blast-cleaned steel to provide temporary protection during
fabrication while still allowing welding and cutting in accordance with ISO 12944-5
Note 1 to entry: In many languages, the term “pre-fabrication primer” does not have the same meaning in English.
3.6
maintenance
sum of all measures to ensure that function of protection of the steel structure against corrosion is
maintained
Note 1 to entry: Maintenance includes, but is not limited to, paintwork. Such paintwork can be patch painting
(repair included spots/areas of the coating system), patch painting followed by over-painting of the structure or
total repairing in accordance with ISO 12944-8.
4 Criteria for corrosion and corrosion protection by thermal-sprayed coatings
4.1 General
Thermal-sprayed coatings of zinc, aluminium and their alloys can significantly increase the effectiveness
of the corrosion protection and the service life of the parts. Thermal-sprayed coatings are to be applied
preference, if a long time effective corrosion protection is required.
4.2 Corrosivity categories and environment conditions
The corrosivity category provides a basic rule for selecting materials and corrosion protection measures
in relation to requirements for the individual application, especially for the service life. Definitions of
corrosivity categories and environment conditions are given in ISO 9223 and ISO 12944-2. Additional
notes for measuring relevant environment parameters are given in ISO 9225.
Annex A contains a list of typical environments related to the estimation of corrosivity categories.
4.3 Corrosion rate
The corrosion rate of a material is given by the medium and by the exposure time of moisture, air
pollution, temperature and contamination of the surface.
ISO 9224 contains information about corrosion rates for different metals. Additional information for
metallic materials related to the likelihood of corrosion in the atmosphere environment is given in
ISO 9223.
4.4 Coating materials and corrosion behaviour
4.4.1 General
The coating material and the required coating thickness are to be selected and specified in relation to
the expected corrosivity, the required design life and construction design.
The corrosion rate of metals and alloys, are not constant over the course of the exposure time. For most
metals and alloys, it decreases with time of the exposure due to the accumulation of corrosion products
on the surface of the exposed metal.
© ISO 2019 – All rights reserved 3

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SIST EN ISO 2063-1:2019
ISO 2063-1:2019(E)

The corrosion rates of thermal-sprayed coatings are different from bulk materials and other types of
metallic coatings due to porosity of thermal-sprayed coatings.
4.4.2 Zinc and zinc alloys
Zinc possesses a high resistance to corrosion due to its passive behaviour against atmospheric attack.
However, the corrosion rate per year is affected by the composition of the atmosphere.
The rate of corrosion of zinc or zinc coatings in water depends mainly on the pH value, the carbon
dioxide value and the salt and oxygen content of the water. In neutral or slightly alkaline wat
...

SLOVENSKI STANDARD
oSIST prEN ISO 2063-1:2018
01-december-2018
9URþHEUL]JDQMH&LQNDOXPLQLMLQQMXQH]OLWLQHGHO3URMHNWLUDQMHLQ]DKWHYH
JOHGHNDNRYRVWLNRUR]LMVNHJD]DãþLWQHJDVLVWHPD,62)',6
Thermal spraying - Zinc, aluminium and and their alloys - Part 1: Design considerations
and quality requirements for corrosion protection systems (ISO/FDIS 2063-1:2018)
Thermisches Spritzen - Zink, Aluminium und ihre Legierungen - Teil 1: Bauteilgestaltung
und Qualitätsanforderungen für Korrosionsschutzsysteme (ISO/FDIS 2063-1:2018)
Projection thermique - Zinc, aluminium et alliages de ces métaux - Partie 1:
Considérations de conception et exigences de qualité pour les systèmes de protection
contre la corrosion (ISO/FDIS 2063-1:2018)
Ta slovenski standard je istoveten z: prEN ISO 2063-1
ICS:
25.220.20 Površinska obdelava Surface treatment
77.120.10 Aluminij in aluminijeve zlitine Aluminium and aluminium
alloys
77.120.60 Svinec, cink, kositer in Lead, zinc, tin and their
njihove zlitine alloys
oSIST prEN ISO 2063-1:2018 en
2003-01.Slovenski inštitut za standardizacijo. Razmnoževanje celote ali delov tega standarda ni dovoljeno.

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oSIST prEN ISO 2063-1:2018

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oSIST prEN ISO 2063-1:2018
FINAL
INTERNATIONAL ISO/FDIS
DRAFT
STANDARD 2063-1
ISO/TC 107
Thermal spraying — Zinc, aluminium
Secretariat: KATS
and their alloys —
Voting begins on:
2018-10-11
Part 1:
Voting terminates on:
Design considerations and quality
2019-01-03
requirements for corrosion
protection systems
Projection thermique — Zinc, aluminium et alliages de ces métaux —
Partie 1: Considérations de conception et exigences de qualité pour les
systèmes de protection contre la corrosion
ISO/CEN PARALLEL PROCESSING
RECIPIENTS OF THIS DRAFT ARE INVITED TO
SUBMIT, WITH THEIR COMMENTS, NOTIFICATION
OF ANY RELEVANT PATENT RIGHTS OF WHICH
THEY ARE AWARE AND TO PROVIDE SUPPOR TING
DOCUMENTATION.
IN ADDITION TO THEIR EVALUATION AS
Reference number
BEING ACCEPTABLE FOR INDUSTRIAL, TECHNO-
ISO/FDIS 2063-1:2018(E)
LOGICAL, COMMERCIAL AND USER PURPOSES,
DRAFT INTERNATIONAL STANDARDS MAY ON
OCCASION HAVE TO BE CONSIDERED IN THE
LIGHT OF THEIR POTENTIAL TO BECOME STAN-
DARDS TO WHICH REFERENCE MAY BE MADE IN
©
NATIONAL REGULATIONS. ISO 2018

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oSIST prEN ISO 2063-1:2018
ISO/FDIS 2063-1:2018(E)

COPYRIGHT PROTECTED DOCUMENT
© ISO 2018
All rights reserved. Unless otherwise specified, or required in the context of its implementation, no part of this publication may
be reproduced or utilized otherwise in any form or by any means, electronic or mechanical, including photocopying, or posting
on the internet or an intranet, without prior written permission. Permission can be requested from either ISO at the address
below or ISO’s member body in the country of the requester.
ISO copyright office
CP 401 • Ch. de Blandonnet 8
CH-1214 Vernier, Geneva
Phone: [phone]
Fax: [phone]
Email: [e-mail]
Website: www.iso.org
Published in Switzerland
ii © ISO 2018 – All rights reserved

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oSIST prEN ISO 2063-1:2018
ISO/FDIS 2063-1:2018(E)

Contents Page
Foreword .v
Introduction .vi
1 Scope . 1
2 Normative references . 1
3 Terms and definitions . 2
4 Criteria for corrosion and corrosion protection by thermal-sprayed coatings .3
4.1 General . 3
4.2 Corrosivity categories and environment conditions . 3
4.3 Corrosion rate . 3
4.4 Coating materials and corrosion behaviour . 3
4.4.1 General. 3
4.4.2 Zinc and zinc alloys . 4
4.4.3 Aluminium and aluminium alloys . 4
5 Requirements for the corrosion protection systems and their planning .4
5.1 General rules — Technical requirements . 4
5.2 Used spray materials and coating thickness . 5
5.2.1 Spray materials. 5
5.2.2 Coating thickness . 5
5.3 Construction design requirements for iron and steel components for thermal spraying . 6
5.3.1 General. 6
5.3.2 Recommendations for the design of the part — Avoidance of corrosion
creating areas . 6
5.3.3 Requirements for welding in combination with thermal-sprayed
protective coatings . 6
5.3.4 Thermal spraying of corrosion protected fastenings . 6
6 Pre-conditions and requirements for the manufacturing process .6
6.1 General — Requirements . 6
6.2 Reference areas . 6
6.3 Preparation of the surface to be coated . 7
6.4 Thermal spraying . 7
6.5 Sealing of thermal-sprayed coatings . 7
6.6 Metallic coatings and additional organic top coatings . 8
6.7 Requirements for the tests — Test procedures . 8
6.7.1 General. 8
6.7.2 Visual inspection — Appearance . 8
6.7.3 Coating thickness . 8
6.7.4 Adhesion strength . . 9
6.7.5 Metallographic investigation . 9
7 Requirements for the manufacturer . 9
7.1 General . 9
7.2 Coating specification — Requirements for the spray coating .10
8 Documentation .10
Annex A (informative) Corrosivity categories — Environment conditions — Exposure.11
Annex B (informative) Summary of the corrosion behaviour of thermal-sprayed coatings of
zinc, aluminium and their alloys .13
Annex C (informative) Recommended values for the thickness of the metallic coating .15
Annex D (informative) Examples of design and explanations .17
Annex E (informative) Example test certificate for work specimen for thermal sprayer used
on-site in accordance with ISO 2063-2 .22
© ISO 2018 – All rights reserved iii

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oSIST prEN ISO 2063-1:2018
ISO/FDIS 2063-1:2018(E)

Annex F (informative) Appearance of surfaces in different treated conditions .24
Annex G (informative) Checklist for this document — Work and test steps and connection
to relevant standards or recommendations .25
Bibliography .27
iv © ISO 2018 – All rights reserved

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oSIST prEN ISO 2063-1:2018
ISO/FDIS 2063-1:2018(E)

Foreword
ISO (the International Organization for Standardization) is a worldwide federation of national standards
bodies (ISO member bodies). The work of preparing International Standards is normally carried out
through ISO technical committees. Each member body interested in a subject for which a technical
committee has been established has the right to be represented on that committee. International
organizations, governmental and non-governmental, in liaison with ISO, also take part in the work.
ISO collaborates closely with the International Electrotechnical Commission (IEC) on all matters of
electrotechnical standardization.
The procedures used to develop this document and those intended for its further maintenance are
described in the ISO/IEC Directives, Part 1. In particular, the different approval criteria needed for the
different types of ISO documents should be noted. This document was drafted in accordance with the
editorial rules of the ISO/IEC Directives, Part 2 (see www .iso .org/directives).
Attention is drawn to the possibility that some of the elements of this document may be the subject of
patent rights. ISO shall not be held responsible for identifying any or all such patent rights. Details of
any patent rights identified during the development of the document will be in the Introduction and/or
on the ISO list of patent declarations received (see www .iso .org/patents).
Any trade name used in this document is information given for the convenience of users and does not
constitute an endorsement.
For an explanation of the voluntary nature of standards, the meaning of ISO specific terms and
expressions related to conformity assessment, as well as information about ISO's adherence to the
World Trade Organization (WTO) principles in the Technical Barriers to Trade (TBT) see www .iso
.org/iso/foreword .html.
This document was prepared by Technical Committee ISO/TC 107, Metallic and other inorganic coatings.
This second edition cancels and replaces the first edition (ISO 2063-1:2017), of which it constitutes a
minor revision.
The changes compared to the previous edition are as follows:
— Table C.1 has been corrected;
— citations for Annex E, Annex F and Annex G have been added in the text.
A list of all the parts in the ISO 2063 series can be found on the ISO website.
Any feedback or questions on this document should be directed to the user’s national standards body. A
complete listing of these bodies can be found at www .iso .org/members .html.
© ISO 2018 – All rights reserved v

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oSIST prEN ISO 2063-1:2018
ISO/FDIS 2063-1:2018(E)

Introduction
In order to protect iron- and steel-based structures (e.g. for steel construction, bridge construction,
steel structures for water construction, onshore and offshore wind energy constructions, petrol and
natural gas industry) against corrosion, protective coatings are usually deposited. Corresponding to
type, shape and required functionality of the part, numerous procedures are available. The deposition
of corrosion protection coatings or coating systems can be done by applying hot-dip galvanizing,
organic coatings or thermal spraying of zinc, aluminium and their alloys. Using combinations of metallic
and organic coatings, duplex corrosion protection coating systems can be produced.
Thermal-sprayed corrosion protection coatings made of zinc, aluminium and their alloys can be
sprayed onto all steels which make up the components used in the relevant industrial application. This
may be carried out on-site, as well as in the workshop, regardless of the article’s size. Due to the usually
low heat input into the surface of the part, only a slight thermal loading of the substrate occurs, so that
changes in steel properties and deformation of the part do not occur.
Corrosion protection coatings can be used as repairs or rework of defects of other coatings (e.g. uncoated
hot-dip zinc galvanized areas) or worn coatings where thermal spraying can be applied on the spot. Due
to relative low investment costs, thermal spraying can also be economically applied for single parts.
The ISO 2063 series applies to thermal-sprayed metallic coatings to protect iron and steel against
corrosion by deposition of zinc, aluminium or their alloys onto the uncoated surface to be protected.
This document targets designers of components. It covers the planning engineering of the corrosion
protection system and deals with the basic rules for planning of corrosion protection systems and for
the constructive design of the components to be protected, if the protection system is based upon a
thermal-sprayed metallic coating.
ISO 2063-2 targets manufacturers of corrosion protection systems. It deals with the requirements for
the execution of the corrosion protection works by thermal spraying in the workshop and on-site.
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oSIST prEN ISO 2063-1:2018
FINAL DRAFT INTERNATIONAL STANDARD ISO/FDIS 2063-1:2018(E)
Thermal spraying — Zinc, aluminium and their alloys —
Part 1:
Design considerations and quality requirements for
corrosion protection systems
1 Scope
This document specifies requirements for the protection of iron and steel surfaces against corrosion by
applying thermal-sprayed metallic coatings of zinc, aluminium or their alloys.
In this document, requirements for the planning of the corrosion protection system and for the
constructive design of the component to be protected are specified, where thermal spraying is intended
to be the process for the deposition of the metallic corrosion protection.
Some field-related basic terms are defined and instructions for corrosion behaviour of the zinc and
aluminium materials under different environment conditions are provided.
Characteristic properties of the coating, e.g. coating thickness, minimum adhesive strength and surface
appearance, are specified and test procedures for thermal-sprayed corrosion protection coatings of
zinc, aluminium or their alloys are determined.
This document is valid for applying thermal-sprayed zinc and aluminium protection coatings against
corrosion in the temperature range between −50 °C to +200 °C, taking into consideration the service
conditions of any sealants used. Heat-resistant protective coatings of aluminium are covered by
ISO 17834 and are not in the scope of this document.
Other corrosion protection processes, e.g. hot-dip galvanizing (galvanic coating), sherardizing,
electroplating or selection and deposition of organic coatings/paints are not in the scope of this
document.
Requirements for the manufacturing of thermal-sprayed coatings are specified in ISO 2063-2.
2 Normative references
The following documents are referred to in the text in such a way that some or all of their content
constitutes requirements of this document. For dated references, only the edition cited applies. For
undated references, the latest edition of the referenced document (including any amendments) applies.
ISO 1463, Metallic and oxide coatings — Measurement of coating thickness — Microscopical method
ISO 2063-2:2017, Thermal spraying — Zinc, aluminium and their alloys — Part 2: Execution of corrosion
protection systems
ISO 2178, Non-magnetic coatings on magnetic substrates — Measurement of coating thickness —
Magnetic method
ISO 4624, Paints and varnishes — Pull-off test for adhesion
ISO 8044, Corrosion of metals and alloys — Basic terms and definitions
ISO 8501-1, Preparation of steel substrates before application of paints and related products — Visual
assessment of surface cleanliness — Part 1: Rust grades and preparation grades of uncoated steel substrates
and of steel substrates after overall removal of previous coatings
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oSIST prEN ISO 2063-1:2018
ISO/FDIS 2063-1:2018(E)

ISO 8501-3, Preparation of steel substrates before application of paints and related products — Visual
assessment of surface cleanliness — Part 3: Preparation grades of welds, edges and other areas with surface
imperfections
ISO 12671, Thermal spraying — Thermally sprayed coatings - Symbolic representation on drawings
ISO 14232-1, Thermal spraying — Powders — Part 1: Characterization and technical supply conditions
ISO 14916, Thermal spraying — Determination of tensile adhesive strength
ISO 14917, Thermal spraying — Terminology, classification
ISO 14919, Thermal spraying — Wires, rods and cords for flame and arc spraying — Classification —
Technical supply conditions
ISO 14923, Thermal spraying — Characterization and testing of thermally sprayed coatings
EN 10163-2, Delivery requirements for surface conditions of hot-rolled steel plates, wide flats and
sections — Part 2: Plate and wide flats
EN 10163-3, Delivery requirements for surface condition of hot-rolled steel plates, wide flats and
sections — Part 3: Sections
3 Terms and definitions
For the purposes of this document, the terms and definitions given in ISO 14917, ISO 8044 and the
following apply.
ISO and IEC maintain terminological databases for use in standardization at the following addresses:
— ISO Online browsing platform: available at https: //www .iso .org/obp
— IEC Electropedia: available at http: //www .electropedia .org/
3.1
service life
expected lifetime of a product (e.g. a structure, component or part) or the acceptable period of use
in service
Note 1 to entry: It is also the time that any manufactured item can be expected to be serviceable.
3.2
design life
period of time during which the item (e.g. a structure, component, part or product) is expected by its
designers to work within its specified parameters
Note 1 to entry: In the case of series production, it is the period of time between the putting into service of a
single item and that item’s onset of wearing out.
3.3
life to first maintenance
durability
expected life of a coating system until first maintenance
Note 1 to entry: It is also the time interval that elapses after the initial coating before coating deterioration
reaches the point that maintenance is necessary to restore protection of the base metal in accordance with
ISO 12944-1.
2 © ISO 2018 – All rights reserved

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oSIST prEN ISO 2063-1:2018
ISO/FDIS 2063-1:2018(E)

3.4
protective coating system
sum total of the coats of metal materials and/or paints (duplex coatings) or related products which are
to be applied or which have been applied to a substrate to provide corrosion protection in accordance
with ISO 12944-1
3.5
pre-fabrication primer
fast-drying paint that is applied to blast-cleaned steel to provide temporary protection during
fabrication while still allowing welding and cutting in accordance with ISO 12944-5
Note 1 to entry: In many languages, the term “pre-fabrication primer” does not have the same meaning in English.
3.6
maintenance
sum of all measures to ensure that function of protection of the steel structure against corrosion is
maintained
Note 1 to entry: Maintenance includes, but is not limited to, paintwork. Such paintwork can be patch painting
(repair included spots/areas of the coating system), patch painting followed by over-painting of the structure or
total repairing in accordance with ISO 12944-8.
4 Criteria for corrosion and corrosion protection by thermal-sprayed coatings
4.1 General
Thermal-sprayed coatings of zinc, aluminium and their alloys can significantly increase the effectiveness
of the corrosion protection and the service life of the parts. Thermal-sprayed coatings are to be applied
preference, if a long time effective corrosion protection is required.
4.2 Corrosivity categories and environment conditions
The corrosivity category provides a basic rule for selecting materials and corrosion protection measures
in relation to requirements for the individual application, especially for the service life. Definitions of
corrosivity categories and environment conditions are given in ISO 9223 and ISO 12944-2. Additional
notes for measuring relevant environment parameters are given in ISO 9225.
Annex A contains a list of typical environments related to the estimation of corrosivity categories.
4.3 Corrosion rate
The corrosion rate of a material is given by the medium and by the exposure time of moisture, air
pollution, temperature and contamination of the surface.
ISO 9224 contains information about corrosion rates for different metals. Additional information for
metallic materials related to the likelihood of corrosion in the atmosphere environment is given in
ISO 9223.
4.4 Coating materials and corrosion behaviour
4.4.1 General
The coating material and the required coating thickness are to be selected and specified in relation to
the expected corrosivity, the required design life and construction design.
The corrosion rate of metals and alloys, are not constant over the course of the exposure time. For most
metals and alloys, it decreases with time of the exposure due to the accumulation of corrosion products
on the surface of the exposed metal.
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oSIST prEN ISO 2063-1:2018
ISO/FDIS 2063-1:2018(E)

The corrosion rates of thermal-sprayed coatings are different from bulk materials and other types of
metallic coatings due to porosity of thermal-sprayed coatings.
4.4.2 Zinc and zinc alloys
Zinc possesses a high resistance to corrosion due to its passive behaviour against atmospheric attack.
However, the corrosion rate per year is affected by the composition of the atmosphere.
The rate of corrosion of zinc or zinc coatings in water depends mainly on the pH value, the carbon
dioxide value and the salt and oxygen content of the water. In neutral or slightly alkaline water, zinc
corrodes insignificantly only.
Alloying of aluminium up to a content of 15 mass % to the zinc base metal generates a higher corrosion
resistance in maritime atmosphere compared to pure zinc metal in the case of lower pH values. It is
evidently shown that the passive protection of the aluminium due to its oxidation can be combined
with the cathodic protection of zinc.
NOTE Many applications of zinc and zinc alloys in the atmosphere indicate their favourable corrosion
behaviour, e.g. the frequent use of thermal-sprayed zinc and zinc alloys for coatings on steel structures in industrial
and marine environments and also in form of solid material for roofs and gutters and cast tubes in soils.
Details of the corrosion behaviour of zinc materials (Zn99,99 and ZnAl15) are shown in Annex B.
Further details for zinc, zinc alloys and their corrosion behaviour can be taken from ISO 14713-1.
4.4.3 Aluminium and aluminium alloys
The corrosion behaviour of aluminium materials is characterized by the protection behaviour of the
electrical isolating aluminium oxide layer, which is rebuilt spontaneously even after mechanical damage
to the surface. Aluminium shows a very high corrosion resistance in slightly acidic to slightly basic
media and is particularly suitable for the corrosion protection of steel structures in SO -containing
2
industrial atmospheres, as well as in marine environments.
Further details for aluminium, aluminium alloys and their corrosion behaviour in sea water and
maritime atmosphere are to be taken from the literature.
A summary of the details for the corrosion behaviour of aluminium materials (Al and AlMg5) are shown
in Annex B.
NOTE Aluminium coatings are successfully used in the building industry, where they are applied by
electrolytic anodizing or thermal spraying. They have been proven in industrial and marine environments, as
well as in seawater immersion.
5 Requirements for the corrosion protection systems and their planning
5.1 General rules — Technical requirements
Application of the thermal-sprayed corrosion protection system requires counter-intuitive design
considerations as compared to other coating processes such as hot-dip galvanizing, which are not in
the scope of this document. The most adequate corrosion protection system for the specific application
should be specified according to the material used and the coating process before starting the design at
any time. In the case of a more serious corrosion attack, an additional organic coating should be applied
to the spray coating (duplex system), which can increase the corrosion protection significantly.
The following points of view shall be considered and stipulated in a specification, where required.
a) The corrosion protection system, e.g. a thermal-sprayed coating, sealed and covered by an
organic coating, shall be selected in such a way that it complies with the required design life of the
component. This is especially valid for surfaces, which are not accessible after assembly. A coating
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oSIST prEN ISO 2063-1:2018
ISO/FDIS 2063-1:2018(E)

protection system, which is intended to survive the required design life of the construction with
appropriate maintenance, shall be applied.
b) If there is no protection system available that is likely to survive for the full expected design life,
the corrosion protection system shall be planned not to corrode or only corrode insignificantly
until the first ma
...