Irish Standard

I.S. EN ISO 2063-2:2017

Thermal spraying - Zinc, aluminium and their

alloys - Part 2: Execution of corrosion
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protection systems (ISO 2063-2:2017)

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 I.S. EN ISO 2063-2:2017

Incorporating amendments/corrigenda/National Annexes issued since publication:

The National Standards Authority of Ireland (NSAI) produces the following categories of formal documents:
I.S. xxx: Irish Standard — national specification based on the consensus of an expert panel and subject to public consultation.

S.R. xxx: Standard Recommendation — recommendation based on the consensus of an expert panel and subject to public consultation.
SWiFT xxx: A rapidly developed recommendatory document based on the consensus of the participants of an NSAI workshop.
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This document replaces/revises/consolidates the NSAI adoption of the document(s) indicated on the
CEN/CENELEC cover/Foreword and the following National document(s):

NOTE: The date of any NSAI previous adoption may not match the date of its original CEN/CENELEC
document.

This document is based on: Published:

EN ISO 2063-2:2017 2017-10-11

This document was published ICS number:

under the authority of the NSAI
and comes into effect on: 25.220.20
25.220.40
2017-10-29

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 National Foreword
I.S. EN ISO 2063-2:2017 is the adopted Irish version of the European Document EN ISO 2063-2:2017, Thermal
spraying - Zinc, aluminium and their alloys - Part 2: Execution of corrosion protection systems (ISO 2063-
2:2017)

This document does not purport to include all the necessary provisions of a contract. Users are responsible
for its correct application.

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Compliance with this document does not of itself confer immunity from legal obligations.
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In line with international standards practice the decimal point is shown as a comma (,) throughout this
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 I.S. EN ISO 2063-2:2017

EUROPEAN STANDARD EN ISO 2063-2

NORME EUROPÉENNE
EUROPÄISCHE NORM October 2017

ICS 25.220.20; 25.220.40 Supersedes EN ISO 2063:2005

English Version

Thermal spraying - Zinc, aluminium and their alloys - Part

2: Execution of corrosion protection systems (ISO 2063-
2:2017)
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Projection thermique - Zinc, aluminium et alliages de Thermisches Spritzen - Zink, Aluminium und ihre
ces métaux - Partie 2: Exécution des système de Legierungen - Teil 2: Ausführung von
protection contre la corrosion (ISO 2063-2:2017) Korrosionsschutzsystemen (ISO 2063-2:2017)

This European Standard was approved by CEN on 31 August 2017.

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: Avenue Marnix 17, B-1000 Brussels

© 2017 CEN All rights of exploitation in any form and by any means reserved Ref. No. EN ISO 2063-2:2017 E
worldwide for CEN national Members.
 I.S. EN ISO 2063-2:2017
EN ISO 2063-2:2017 (E)

Contents Page

European foreword....................................................................................................................................................... 3
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2
 I.S. EN ISO 2063-2:2017
EN ISO 2063-2:2017 (E)

European foreword

This document (EN ISO 2063-2:2017) 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 April 2018, and conflicting national standards shall be
withdrawn at the latest by April 2018.

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.
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This document supersedes EN ISO 2063:2005.

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 2063-2:2017 has been approved by CEN as EN ISO 2063-2:2017 without any
modification.

3
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 I.S. EN ISO 2063-2:2017

INTERNATIONAL ISO
STANDARD 2063-2

First edition
2017-09

Thermal spraying — Zinc, aluminium

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and their alloys —

Part 2:
Execution of corrosion protection
systems
Projection thermique — Zinc, aluminium et alliages de ces métaux —
Partie 2: Exécution des système de protection contre la corrosion

Reference number
ISO 2063-2:2017(E)

© ISO 2017
 I.S. EN ISO 2063-2:2017
ISO 2063-2:2017(E)

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COPYRIGHT PROTECTED DOCUMENT

© ISO 2017, Published in Switzerland
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ii  © ISO 2017 – All rights reserved

 I.S. EN ISO 2063-2:2017
ISO 2063-2:2017(E)


Contents Page

Foreword...........................................................................................................................................................................................................................................v
1 Scope.................................................................................................................................................................................................................................. 1
2 Normative references....................................................................................................................................................................................... 1
3 Terms and definitions...................................................................................................................................................................................... 2
4 Requirements for the manufacturer................................................................................................................................................. 3
4.1 General............................................................................................................................................................................................................ 3
4.2 Qualification of the manufacturer........................................................................................................................................... 3
4.2.1 Qualification of the equipment............................................................................................................................. 3
4.2.2 Qualification of supervision personnel......................................................................................................... 3
4.2.3 Qualification of spraying personnel................................................................................................................. 3
4.2.4 Qualification of test personnel.............................................................................................................................. 3
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4.3 Coating specification for the thermal-sprayed coating......................................................................................... 4

4.4 Assessment of the coating on the basis of reference areas................................................................................ 4
5 Quality assurance measures for the manufacturer........................................................................................................... 4
5.1 General............................................................................................................................................................................................................ 4
5.2 Assessment of the design to coatability............................................................................................................................. 4
5.3 Establishing the manufacturing instructions — Manufacturing sequence plan............................. 4
5.4 Establishing the thermal spray procedure specification..................................................................................... 4
5.5 Qualification of the TSPS and scope of the TSPS........................................................................................................ 5
5.6 Qualification of the TSPS by a specific job reference qualification............................................................. 5
5.7 Special job qualification by performance on mock-ups, if required.......................................................... 5
6 Manufacturing of thermal-sprayed coatings............................................................................................................................ 5
6.1 General............................................................................................................................................................................................................ 5
6.2 Preparation of the surface to be coated.............................................................................................................................. 6
6.2.1 Masking of areas not to be coated...................................................................................................................... 6
6.2.2 Preparation of the surface to be coated by blasting........................................................................... 6
6.2.3 Testing of the prepared surface........................................................................................................................... 6
6.3 Thermal spraying................................................................................................................................................................................... 6
6.3.1 General...................................................................................................................................................................................... 6
6.3.2 Spray material..................................................................................................................................................................... 7
6.3.3 Pre-conditions for the execution of thermal spraying process................................................. 7
6.3.4 Execution of thermal spraying.............................................................................................................................. 7
6.3.5 Inspection after spraying........................................................................................................................................... 7
6.4 Sealing of the coating.......................................................................................................................................................................... 8
6.5 Advice for welding in combination with thermal spraying............................................................................... 8
6.6 Thermal spraying of corrosion protected fastenings.............................................................................................. 8
7 Tests — Test procedures................................................................................................................................................................................ 9
7.1 General............................................................................................................................................................................................................ 9
7.2 Manufacturing of the accompanying specimens........................................................................................................ 9
7.3 Coating thickness................................................................................................................................................................................... 9
7.3.1 General...................................................................................................................................................................................... 9
7.3.2 Coatings with a surface below 1 m2............................................................................................................... 10
7.3.3 Coatings with surfaces greater than 1 m2................................................................................................. 10
7.3.4 Number of thickness test points...................................................................................................................... 10
7.3.5 Measurement of the coating thickness....................................................................................................... 10
7.4 Appearance of the coating surface and tests............................................................................................................... 11
7.4.1 Visual inspection............................................................................................................................................................ 11
7.4.2 Roughness............................................................................................................................................................................ 11
7.4.3 Adhesion strength......................................................................................................................................................... 11
7.4.4 Metallographic examination of the coating............................................................................................ 11
7.5 Defects in the coating and their repair............................................................................................................................. 11
7.5.1 Defects on the surface and in the coating and their repair....................................................... 11

© ISO 2017 – All rights reserved  iii

 I.S. EN ISO 2063-2:2017
ISO 2063-2:2017(E)


7.5.2 Reasons for the rejection of a defective sprayed coating............................................................ 12

8 Health and safety and environment protection.................................................................................................................12
9 Additional requirements for working on-site......................................................................................................................12
9.1 General......................................................................................................................................................................................................... 12
9.2 Supervision of spraying on-site.............................................................................................................................................. 12
9.3 Job reference qualification for spray personnel working on-site.............................................................. 12
9.4 Execution of spray works in the case of planned work on-site or not planned
repairs on new manufactured parts................................................................................................................................... 13
9.4.1 General................................................................................................................................................................................... 13
9.4.2 Surface preparation..................................................................................................................................................... 13
9.4.3 Masking.................................................................................................................................................................................. 13
9.4.4 Thermal spraying.......................................................................................................................................................... 13
9.4.5 Spraying of accompanying specimens........................................................................................................ 13
9.4.6 Sealing..................................................................................................................................................................................... 13
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10 Execution of spray works on-site in the case of planned maintenance of a service

operated coating.................................................................................................................................................................................................14
10.1 General......................................................................................................................................................................................................... 14
10.2 Pre-inspection for assessment of the repair possibility applied by thermal spraying........... 14
10.3 Execution of repair-works by thermal spraying...................................................................................................... 14
10.3.1 General................................................................................................................................................................................... 14
10.3.2 Quality control after repair................................................................................................................................... 14
11 Tests — Test procedures.............................................................................................................................................................................14
12 Documentation of the procedure and tests in the case of maintenance..................................................15
13 Health and safety and environment protection on-site.............................................................................................15
Annex A (normative) Adhesion testing using the pull-off test in accordance with ISO 4624..................16
Annex B (informative) Documentation of the applied maintenance procedure, the thermal
spray procedure and test results in the case of a planned maintenance.................................................18
Annex C (informative) Documentation of the applied thermal spray procedure and test
results in the case of a new manufacturing............................................................................................................................21
Annex D (informative) Test certificate for job reference qualification for thermal sprayers
working on-site in accordance with ISO 2063-2................................................................................................................23
Annex E (informative) Test specimens — Spray positions..........................................................................................................25
Annex F (informative) Assessment of the coatability.......................................................................................................................28
Annex G (informative) Bend test and its execution.............................................................................................................................29
Annex H (informative) Additional information for surface preparation.....................................................................31
Annex I (informative) Further details for sealing.................................................................................................................................32
Annex J (informative) Further instructions for safety and activities on-site...........................................................33
Annex K (informative) Repair procedures of service loaded coatings and recommended
repair procedures.............................................................................................................................................................................................34
Bibliography.............................................................................................................................................................................................................................. 35

iv  © ISO 2017 – All rights reserved

 I.S. EN ISO 2063-2:2017
ISO 2063-2:2017(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).
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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 on 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 the following
URL: www.iso.org/iso/foreword.html.
This document was prepared by Technical Committee ISO/TC 107, Metallic and other inorganic coatings.
This document, together with ISO 2063-1:2017, cancels and replaces ISO 2063:2005, which has been
technically revised.
A list of all the parts in the ISO 2063 series can be found on the ISO website.

© ISO 2017 – All rights reserved  v

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I.S. EN ISO 2063-2:2017
 I.S. EN ISO 2063-2:2017

INTERNATIONAL STANDARD ISO 2063-2:2017(E)

Thermal spraying — Zinc, aluminium and their alloys —

Part 2:
Execution of corrosion protection systems

1 Scope
This document specifies requirements for corrosion protection of steel structures, components or
parts, which are coated by thermal spraying of zinc, aluminium or their alloys.
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This document specifies requirements for coating manufacturers of surface preparation, thermal
spraying, testing and post treatments, e.g. sealing of the coating. This document applies to metallic
corrosion protection coatings in the case of new fabrication in the workshop, as well as on-site and for
repair on-site after assembly.
Requirements for coating thickness, minimum adhesive strength and surface conditions, specified in a
coating specification, are given.
Recommendations are given for suitable process steps and quality assurance measures for new
production and maintenance and for supervising of corrosion protection works.
This document covers the application of thermal-sprayed zinc, aluminium and their alloys for protection
against corrosion in the temperature range between –50 °C to +200 °C. Heat-resistant protective
coatings of aluminium are covered by ISO 17834 and are not in the scope of this document.
This document specifies requirements for the equipment, the working place and the qualification of the
spray and testing personnel.
NOTE ISO 2063-1:2017 is addressed to the designer and to the planning engineer of corrosion protection
system.

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 2063-1, Thermal spraying —Zinc, aluminium and their alloys — Part 1: Design considerations and
quality requirements for 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 8501-1:2007, 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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