Designation: A239 − 95 (Reapproved 2009)´1

Standard Practice for

Locating the Thinnest Spot in a Zinc (Galvanized) Coating
on Iron or Steel Articles1, 2
This standard is issued under the fixed designation A239; the number immediately following the designation indicates the year of
original adoption or, in the case of revision, the year of last revision. A number in parentheses indicates the year of last reapproval. A
superscript epsilon (´) indicates an editorial change since the last revision or reapproval.
This standard has been approved for use by agencies of the Department of Defense.

´1 NOTE—Reapproved with editorial change in May 2009.

1. Scope* 1.5 This standard does not purport to address all of the
1.1 This practice covers the procedure for locating, by the safety concerns, if any, associated with its use. It is the
use of a solution of copper sulfate, the thinnest spot in a zinc responsibility of the user of this standard to establish appro-
coating (hot dipped, electroplated, or sprayed) on iron or steel priate safety and health practices and determine the applica-
articles that are coated after the shape is produced by casting, bility of regulatory limitations prior to use.
drawing, pressing, or other forming methods. Examples are:
electrical metallic tubing and rigid conduit pipe, castings and 2. Significance and Use
forgings, and structural steel; on special hardware, such as 2.1 This practice is designed to locate the thinnest portions
poleline, builder’s, and farm implement hardware; bolts, nuts, of the zinc coating on newly coated items (see Appendix X1).
screws, and other miscellaneous general hardware. Variations in coating thickness can be due to the process by
1.2 The use of this practice with zinc coating deposited which the zinc is applied (hot dipped, electroplated, or sprayed)
through different processes (such as hot dipped, electroplated, or by the geometry of the part that is coated. During hot-dip
or sprayed) requires caution in interpretation since the end galvanizing, the coating thickness is affected by the drainage
point may vary considerably between different zinc-coating pattern of the molten zinc, while during zinc spraying (metal-
systems. lizing), coating thickness can be dependent on the operator’s
manipulation of the spray nozzle. The geometry of the part can
1.3 Excluded from this practice is sheet steel from hot-dip also influence coating thickness especially during hot-dip
or electrocoating lines as the sheet products are normally galvanizing, where peaks and valleys on the part can cause
subject to additional forming after the coating process. Also molten zinc to build up or thin out. This practice is designed to
excluded from this practice are all zinc-coated wire and wire identify those areas of the part where the coating is thin.
products either continuously or batch coated before or after
forming. Warning—Past research (dating from around 1963) 3. Copper Sulfate Solution
has indicated that this practice can be influenced by operator
3.1 The copper sulfate solution shall be made by dissolving
technique. Variations can be due to the difference in hand
approximately 36 parts by weight of commercial cupric sulfate
pressure used to wipe the sample or the inability of the operator
crystals (CuSO4·5H2O) in 100 parts by weight of distilled
to recognize the end point.
water (see 3.1.1). Heat may be used to complete the solution of
1.4 The values stated in inch-pound units are to be regarded cupric sulfate crystals. If heated, the solution shall be allowed
as standard. The values given in parentheses are mathematical to cool. The solution shall then be agitated with an excess of
conversions to SI units that are provided for information only powdered cupric hydroxide (Cu(OH)2), about 0.13 oz/gal (1.0
and are not considered standard. g/L) of solution. The presence of an excess of cupric hydroxide
will be shown by the sediment of this reagent at the bottom of
the vessel. The neutralized solution shall be allowed to stand
1
This practice is under the jurisdiction of ASTM Committee A05 on Metallic- for 24 h and then filtered or decanted.
Coated Iron and Steel Productsand is the direct responsibility of Subcommittee 3.1.1 Cupric oxide (CuO), 0.11 oz/gal (0.8 g/L) may be
A05.07 on Methods of Testing.
substituted for cupric hydroxide, provided the solution is
Current edition approved May 1, 2009. Published August 2009. Originally
approved in 1940. Last previous edition approved in 2004 as A239 - 95(2004). DOI: allowed to stand not less than 48 h after this addition before
10.1520/A0239-95R09E01. decanting or filtering.
2
This practice is used to locate the thinnest spot only, and is not intended as a test
for coating weight. This practice is to be used only within the limits of Section 1, 3.2 The solution shall have a specific gravity of 1.186 at
Scope. 18°C (65°F). To adjust a solution of improper specific gravity,

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

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 A239 − 95 (2009)´1
add distilled water when the specific gravity is high, and add a 7. Procedure
copper sulfate solution of a higher specific gravity when the 7.1 Immerse the specimens in the copper sulfate solution,
solution is low in specific gravity. which shall be maintained at a temperature of 16 to 20°C (61
4. Specimen Rinse Water to 68°F). Allow the specimens to remain in a fixed position in
the solution for exactly 1 min. Do not agitate the solution
4.1 Ordinary, clean tap water may be used for rinsing during the immersion period, nor allow the specimens to touch
specimens. If no running tap water is available, the rinse water each other or the sides of the container. After each 1-min
shall be changed after each dip. The temperature of the rinse immersion, wash the specimens immediately in the rinse water,
water shall be from 15 to 21°C (60 to 70°F). and use a fiber bristle brush to remove any copper deposit that
5. Quantity of Copper Sulfate Solution may have formed on the zinc coating. Before returning the
specimens to the copper sulfate solution, drain thoroughly of
5.1 Hardware and Similar Articles— For evaluating hard- excess rinse water and wipe dry with a clean cloth.
ware and similar articles, the quantity of copper sulfate
solution required for each evaluation will depend on the 7.2 Continue successive immersions of 1 min each, washing
superficial area of the specimen being evaluated and the weight and wiping the specimens after each immersion until the end
of coating. The quantity should not be less than 1.2 qt/oz/ft2 point has been reached (see Appendix X2).
(40.5 mL/g/m2) of zinc coating on the specimen (Note 1) and NOTE 2—Zinc coatings on threads are usually difficult to test. It has
shall be sufficient to cover the specimen so that the top surface been found advantageous to saw female-threaded parts longitudinally,
of the solution is at least 1⁄2 in. (12.7 mm) above the top of the exposing the threads to full view and facilitating cleaning to remove
section of the specimen under evaluation. The solution shall be sponge copper after each immersion in the copper sulfate solution.
Brushing should be parallel to the threads.
discarded after completion of the evaluation, and fresh solution
shall be used for any additional evaluations.
8. End Point
NOTE 1—The theoretical minimum amount of copper sulfate solution
required to dissolve zinc is 0.4 qt/oz (13.5 mL/g). The quantity specified 8.1 The end point shall be recognized by the appearance of
in 5.1 is three times this minimum to ensure adequate rate of solution. bright, adherent copper deposits. However, if such a deposit
fails to form after the complete disappearance of the zinc
6. Preparation of Specimens coating, the immersion succeeding the disappearance of the
6.1 The specimens selected for evaluation shall be free of zinc shall be recognized as representing the end point.
abrasion or cuts in the zinc coating, except those which may 8.2 Confirm adherence of the bright copper deposit by a
occur during manufacture of the specimen. Where the area of peeling test. If it is possible to remove the copper with an ink
uncoated surface to be immersed is more than 10 % of the total eraser or to peel the copper with the edge of a blunt tool such
immersed surface area, precautions, such as plugs for tubular as the back of a knife blade, and zinc appears underneath the
material, or lacquer, paraffin, or other suitable coatings for the copper, such an appearance of deposited copper shall not be
uncoated surfaces must be taken so as not to deplete the construed as an end point.
strength of copper sulfate solution.
8.3 A fine line appearance of copper on the top of screw
6.2 Clean the specimens with a suitable volatile organic threads or on sharp edges of articles, or within 1 in. (25 mm)
solvent and finally, thoroughly wash with clean water and wipe of a cut portion of a specimen, shall not be judged as an end
dry with a clean cotton cloth. Unless otherwise specified, point. Likewise, the indication of bright adherent deposits of
remove lacquer or varnish coatings with a suitable clean, copper at or adjacent to any cut or abrasion present on the
volatile organic solvent such as acetone, which will not attack original specimen shall not be considered an end point.
the zinc coating or leave a greasy or waxy deposit. Thoroughly
rinse the specimens in clean water and wipe dry with a clean
9. Supplementary Tests
cotton cloth. Bring the specimens to a temperature between 15
and 21°C (60 and 70°F) prior to the beginning of the 9.1 If at any time during the immersion procedure there is
immersion series. any doubt as to the presence of exposed base metal, as
determined by visual inspection, there are several supplemen-
6.3 Abnormal cases may arise when, by reason of unusual
tary tests described in Section 10, one or more of which may be
surface conditions, the copper sulfate solution will not act
used depending on the type of coating being evaluated.
normally on the zinc coating. For example, the solution may
have no apparent attack on all or part of the surface, or false
10. Supplementary Test for All Types of Zinc Coatings
deposits of copper may appear on the zinc coating. If there is
any question of abnormality of performance of specimens, 10.1 Microscopical Test—Section the specimen through the
discard the specimens and select new ones. Clean the new copper deposit, mount, and polish it for metallographic analy-
specimens in alcohol, rinse, and wipe dry. Then immerse for 3 sis. Etch the polished surface using an etching solution
min in a solution consisting of 1 part by volume of ammonium composed of 20 g of chromic acid, 1.5 g of sodium sulfate, and
hydroxide (sp gr 0.90) and 9 parts of water. The specimens may 100 mL of distilled water (Palmerton reagent). After etching,
be scrubbed with a cotton cloth during this immersion. After wash the specimen with alcohol. Examine the etched specimen
cleaning, wash the specimens and wipe dry, then subject them under a microscope, using a magnification of 100 diameters or
to the procedure described in Section 7. greater if necessary.

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 A239 − 95 (2009)´1
10.2 Qualitative Test for Zinc3—Apply a drop (or several be made as follows: neutralize the acid with ammonium
drops) of diluted hydrochloric acid to the area in question hydroxide, acidify with acetic acid, and pass hydrogen sulfide
(depending on its size). The presence of zinc is indicated by into the solution; a white precipitate (zinc sulfide, ZnS)
immediate vigorous effervescence (evolution of hydrogen). If confirms the presence of zinc.
no appreciable zinc is present, the effervescence will be mild.
By carefully removing the acid, a confirming test for zinc may 11. Keywords
11.1 bolts; electroplated; hardware; hot dipped; nuts;
3
Only an outline of the test is given. The details of the test may be found in screws; thinnest spot; zinc coating thickness
technical literature.

APPENDIXES

(Nonmandatory Information)

X1. APPLICATION OF THIS PRACTICE TO WEATHERED GALVANIZED WARE

X1.1 This practice is not applicable to aged or weathered ammonium hydroxide solution (1 part by volume of ammo-
material because of the corrosion film present on the zinc nium hydroxide (sp gr 0.90) to 9 parts by volume of distilled
coating. If it is desired to use this practice on such material, the water) then rinsing the specimens in clean water and wiping
corrosion film should be removed before conducting this them dry.
procedure by immersing the specimens for 3 min in an

X2. STANDARD FOR COMPARISON

X2.1 If it is desired to show the character of the bright of bare surface thus exposed, including a portion with zinc
metallic copper deposit on an exposed iron or steel surface, a coating intact, is then dipped for a few seconds in the copper
reference standard for comparison may be prepared as follows: sulfate solution at a temperature of 16 to 20°C (61 to 68°F),
Partially submerge a zinc-coated specimen in strong hydro- removed, washed, and wiped dry. This copper-coated reference
chloric acid until violent action ceases. Immediately remove standard should be prepared at the time this practice is being
the specimen, wash, and wipe it dry. The specimen with an area conducted.

X3. ACTION OF COPPER SULFATE SOLUTION ON ZINC COATINGS

X3.1 The fact that this practice cannot be used for deter- X3.2 In view of these differences in the makeup of the zinc
mining the weight of zinc coating is due to the wide variation coatings applied by the different processes, it has been found
in the rate of solubility of the various types of coating resulting by Groesbeck and Walkup4 in tests on a limited number of
from differences in the composition and structure of the samples that electroplated and flame-sprayed coatings, by
coatings. For instance, electroplated and sprayed-zinc coatings reason of their high pure-zinc content, dissolve rather rapidly
consist essentially of pure zinc; the outer part of hot-dipped in the copper sulfate solution; that the conventional hot-dip
coatings consists of nearly pure zinc; whereas, the portion next coatings dissolve only about two thirds as fast as the pure zinc
to the steel base is composed of zinc-iron alloys; in the case of coatings; and that the hot-dip coatings heated after galvanizing
hot-dipped coatings heated after galvanizing, the coating con- dissolve only about half as fast as the pure zinc coatings.
sists almost entirely of zinc-iron alloys.
4
For further information on this test method, reference may be made to the
following papers:
Walkup, H. H., and Groesbeck, E. C., “Some Factors Affecting the Preece Test
for Zinc Coatings,” Proceedings, ASTM, Vol 32, Part II, 1932, p. 453.
Groesbeck, E. C., and Walkup, H. H., “Preece Test (Copper Sulphate Dip) for
Zinc Coatings,” National Institute of Standards and Technology Journal of
Research, Vol 12, No. 6, June 1934, p. 785 (Research Paper RP688).

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 A239 − 95 (2009)´1
SUMMARY OF CHANGES

Committee A05 has identified the location of selected changes to this standard since the last issue
(A239 - 95(2004)) that may impact the use of this standard. (May 1, 2009)

(1) Editorially added 1.4 and renumbered Section 1.

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