INTERNATIONAL ISO

STANDARD 2063-2

First edition
2017-09

Thermal spraying — Zinc, aluminium

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
ISO 2063-2:2017(E)


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 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
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

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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
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

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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 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.

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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.
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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ISO 8503-1, Preparation of steel substrates before application of paints and related products — Surface
roughness characteristics of blast-cleaned steel substrates — Part 1: Specifications and definitions for ISO
surface profile comparators for the assessment of abrasive blast-cleaned surfaces
ISO 14916, Thermal spraying — Determination of tensile adhesive strength
ISO 14917, Thermal spraying — Terminology, classification
ISO 14918, Thermal spraying — Approval testing of thermal sprayers
ISO 14922-1, Thermal spraying — Quality requirements of thermally sprayed structures — Part 1: Guidance
for selection and use
ISO 14923, Thermal spraying — Characterization and testing of thermally sprayed coatings

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:
— IEC Electropedia: available at http://www.electropedia.org/
— ISO Online browsing platform: available at http://www.iso.org/obp
3.1
minimum local thickness
lowest value of the local thickness found on surface of a single article
3.2
dew point
temperature to which a volume of humid air should be cooled, at constant barometric pressure, for
water vapour to condense into liquid water on a solid surface
3.3
local repair
restoring of the thermal-sprayed metallic corrosion protection coating by applying a suitable corrosion
protection system on small defective areas, such as are caused by damage on transport, erection or by
destructive tests
3.4
manufacturing sequence plan
manufacturing and test operations listed step by step
3.5
job control record
JCR
manufacturing sequence plan used for control that each single operation step is really carried out
3.6
job reference specimen
JRS
specimen simulating production conditions and which represents the part to be coated and is
comparable in material and size
3.7
job reference qualification
JRQ
qualification of an application or of a thermal sprayer applying a job reference specimen for the test

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3.8
pre-production spraying test
thermal spraying test having the same function as a spray procedure test, but is based on a job reference
specimen (non-standard test piece, simulating production conditions)

4 Requirements for the manufacturer

4.1 General
The manufacturer of thermal spray coating shall possess a quality management system, which can
fulfil the necessary quality requirements in accordance with this document or to the quality assurance
system in accordance with ISO 14922-1 (A, B or C), shall employ qualified personnel, is responsible to
keep the function of the spray and necessary ancillary equipment in proper condition and shall fulfil
applicable requirements concerning health and safety and environment protection. For that purpose,
the instructions and information provided by the CEN/TR 15339 series may be helpful.

4.2 Qualification of the manufacturer

4.2.1 Qualification of the equipment

The manufacturer shall provide blasting and spraying equipment and ancillary equipment which is fit
for the purpose. The continued proper functioning of the equipment shall be proven through inspection
reports or results of successfully applied tests (e.g. if a component related procedure qualification has
passed). Testing may be carried out in accordance with the appropriate part of the standard series
EN 1395-1 to EN 1395-3, EN 1395-6 or EN 1395-7.
The manufacturer is also responsible for providing an adequate calibration and validation of the
instruments for measuring, testing and for supervision. The results of the tests, calibration and
maintenance shall be documented.

4.2.2 Qualification of supervision personnel

The manufacturer of the thermal-sprayed coating shall employ qualified supervisors according to the
requirements of the component and of the required quality in accordance with ISO 2063-1 and to this
document. The education and qualification of the supervisor should be carried out in accordance with
ISO 12690.
When an additional coating with organic materials is part of the order, an adequate qualified person
shall be available for supervision of this part of the corrosion protection, e.g. with the scope of
responsibility in accordance with ISO 12944-7.

4.2.3 Qualification of spraying personnel

In case of manual spraying, the manufacturer of the thermal-sprayed coating shall employ qualified
thermal sprayers in accordance with ISO 14918 or sprayers who are instructed and trained adequately
(e.g. with long lasting and proved experience in thermal spraying). This requirement shall be in
accordance with the requirements of the component, the quality assurance system in accordance with
ISO 14922-1 and of this document or of the contract.

4.2.4 Qualification of test personnel

The manufacturer of the thermal-sprayed coating shall only employ inspectors who possess the
required qualification for the test procedure concerned in accordance with the requirements of the
component and the required quality in accordance with ISO 2063-1 and this document.

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When an additional coating with organic materials is part of the order, an adequate qualified person
shall be available for supervision of this part of the corrosion protection, e.g. with the responsibility in
accordance with ISO 12944-7.

4.3 Coating specification for the thermal-sprayed coating

The manufacturer of the thermal-sprayed coating of a component shall fulfil any requirements, which
are stipulated in the contract and/or coating specification. If neither a coating specification is present
nor rated values of the minimum coating thickness, minimum tensile adhesive strength, admissible
imperfections, post treatments, e.g. sealing, and tests and their scope are specified in the coating
specification or in the manufacturing instructions, they shall be agreed upon between the contracting
parties or be taken from this document.
Test specifications shall be prepared by the manufacturer of the coating, if required in agreement with
the contractor, when they are not part of the coating specification.

4.4 Assessment of the coating on the basis of reference areas

If in the case of a thermal-sprayed coating for very large surfaces, representative areas can be coated.
Location and size of the areas shall be unambiguously defined and documented.

5 Quality assurance measures for the manufacturer

5.1 General
This clause describes the measures that shall be taken by the coating manufacturer, in order to ensure
an adequate order management, quality assurance and reproducibility of manufacturing.

5.2 Assessment of the design to coatability

In the frame of the contract and design review, the coatability of the component shall be checked.
Checking is necessary for working in the workshop, as well as for working on-site and repairs, in the
case of maintenance work. If the main principles are considered when executing the constructive design
(dealt in ISO 2063-1) and the questions of the check list (see Annex F) can be positively answered, the
work piece would be considered coatable.

5.3 Establishing the manufacturing instructions — Manufacturing sequence plan

The manufacturer of spray coatings shall establish manufacturing instructions, detailing all single
work and test steps listed in chronological order, including the surface preparation, thermal spraying,
post-treatments, e.g. smoothing or sealing of the coating and establishing the documentation. Spray
procedure specifications necessary for each single process shall be indicated. This manufacturing
sequence plan can be used as a job control record (JCR).

5.4 Establishing the thermal spray procedure specification

The coating manufacturer is responsible for establishing and following the thermal spray procedure
specification (TSPS). This procedure should include information on the coating specification and to the
manufacturing instructions, as well as parts lists, substrate and spray materials data, drawings and
test instructions. All relevant information should be available for the thermal sprayer in written form,
if appropriate.
The TSPS shall contain all parameters of the procedure required for the spray process.
The required spray parameters shall be determined using sprayed specimens or can be taken from
similar applications. The TSPS can be qualified by a procedure qualification in accordance with

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EN 15648, if this is required by the quality management system of the manufacturer generally, or by
the contractor.
The preparation of the surface to be coated shall be specified in the TSPS, together with the required
cleanliness level. For further instructions, see 6.2.
Any changing of a parameter or the spray materials, ancillary substances, the design, the spray
procedure or the spray equipment requires a checking of the coating quality. If necessary, the TSPS
shall be corrected or prepared again.

5.5 Qualification of the TSPS and scope of the TSPS

Coating manufacturers can achieve qualification of the TSPS by a component-related procedure
qualification in accordance with EN 15648 or by testing on test sheets, if the requirements are fulfilled,
which are stipulated in the coating specification for the respective part.
The scope can also be agreed upon by the contracting parties for similar parts, if the substrate material
is comparable in its technological, metallurgical, physical and chemical properties. Comparability is
given to the level of difficulty for the thermal spraying.

5.6 Qualification of the TSPS by a specific job reference qualification

Due to shape and dimension of very large components the qualification of a spray procedure
specification (TSPS) by a component related qualification maybe too complicated and expensive. A
job reference qualification (JRQ) can be used to assess the suitability of the application process. By
that way job reference specimens (JRSs) shall represent the spray positions to be performed and shall
be comparable to the level of difficulty on preparation and thermal spraying of the component. The
procedure shall be agreed upon between contracting parties.

5.7 Special job qualification by performance on mock-ups, if required

If required by the contractor, a referencing mock-up shall be manufactured to simulate the angles for
steel assemblies exhibiting acute angles between structural members to be sprayed after welding or
assembly. Details of the acceptance criteria should be agreed upon.

6 Manufacturing of thermal-sprayed coatings

6.1 General
This clause deals with the operations and measures of the applicator of the spray coating, which belong
to a conforming manufacturing route for the deposition of a thermal-sprayed coating. This procedure
applies to the component as well as to accompanying specimens, if they are required.
It may be helpful to check accessibility for preparation, spraying, post treatments and testing, and
to follow the design considerations of the area to be sprayed according to general requirements, e.g.
EN 15520. A useful checklist is presented in Annex F.
If possible, very large surfaces should be separated into sectors to be coated, in order to fulfil the
requirement to start with the thermal spraying immediately without any delay after finishing the
surface preparation.
NOTE 1 The term “immediately without any delay” means without any culpable delay.

NOTE 2 Usually, such a section would not exceed 40 m2 to 45 m2. In some cases, such a sectioning will be
impossible, especially in long beams. The surface preparation in overlapping zones needs special attention so as
not to damage the coating already partially applied by blasting of the next section. Usually, a time period of 4 h is
adequate in zones with temperate climate.

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For climate zones with a high continuous humidity, this rule is not valid. In such cases, the size of sections and
the 4 h period should be significantly reduced and special measures for drying should be applied. Otherwise,
thermal spraying cannot be applied without loss in quality.

6.2 Preparation of the surface to be coated

6.2.1 Masking of areas not to be coated

Areas of the part that are not to be coated shall be masked prior to blasting and prior to spraying.
The masking material should withstand the grit when blasting and the hot spray particles when
spraying. Otherwise, separate masking should be applied for each process.
Precautionary measures should be taken to avoid contamination of the surfaces to be coated by a
masking material.

6.2.2 Preparation of the surface to be coated by blasting

EN 13507 (or similar) should be followed in the preparation of the surface to be coated when no
instructions are stipulated in the TSPS. The blasting parameter shall be determined using a plate as a
test specimen if no parameter is stipulated in the TSPS or in the manufacturing instructions.
NOTE Important parameters are type and grain size of the blasting material, state of wear (sharp or rounded
edges), blasting time, distance and angle, air pressure and type of the spray equipment.

The surface to be prepared, including occasional weld areas (if available) shall be cleaned and blasted
using pressurized air blast equipment and an adequate blasting material, until the part’s surface gives
a metallic appearance with uniform structure in accordance with ISO 8501-1, Sa 2 ½ G for Zn/ZnAl15
and Sa 3 G for Al/AlMg5. This state shall be confirmed by visual comparison to the reference sample G
(grit) in accordance with ISO 8503-1, if no other commitment is agreed upon between the contracting
parties.
Usually, surface roughness (Rz) should be in the range of 50 µm to 100 µm, depending on the spray
process and spray material.
Safe access and sufficient lighting of the surface to be blasted and adequate work conditions (low
humidity, sufficient temperature of environment and component for instance not falling below the
dew point, protection against ice, rain and wind) shall be ensured for blasting and subsequent testing.
Specific measures shall be taken in the case of working on-site.
The blasting material shall be adequately stored and protected from pollution.
Sufficient cleaning of the blasted surface from grit residues should be carried out in accordance with
EN 13507 (or similar). For further details, see Annex H.
After blasting, spraying shall be started as soon as possible to avoid any contamination and build-up of
moisture on the surface.

6.2.3 Testing of the prepared surface

The condition of the surface to be coated shall be checked for cleanliness in accordance with ISO 8501-1
and to the desired uniform roughness by visual comparison. Reference samples in accordance with
ISO 8503-1 are adequate aids.

6.3 Thermal spraying

6.3.1 General

Before spraying, the surface prepared for coating shall be visually checked. If imperfections on the
surface to be coated are visible the surface preparation shall be repeated.

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6.3.2 Spray material

The spray material stipulated in the TSPS shall be applied. Proof shall be delivered on the conformity
of the spray material by comparison with the accompanying supply instructions and designations. The
instructions of the manufacturer/supplier for storage and use of the spray material shall be considered.

6.3.3 Pre-conditions for the execution of thermal spraying process

When the spray equipment is not in operation, checking of the parameter setting should be carried out.
Applying a bend test (or, if required, an adhesion test in accordance with ISO 4624) can be helpful. For
details, see Annex G.
After finishing the surface preparation (blasting and masking, if appropriate, and testing) spraying
shall be started immediately. The spray coating shall be produced using the parameter stipulated in the
TSPS in one manufacturing step without interruption.
An assessment of the atmospheric conditions (humidity, dew point and ambient air temperature) shall
be carried out and recorded before thermal spray application begins. When large components are to
be thermally coated, these conditions shall be checked in adequate periods of time while spraying is
running. Spraying should not be performed unless the ambient requirements for thermal spraying
or sealing are met. If the general climate conditions allow (temperate climate zones), the following
environmental conditions should be present prior to thermal spraying:
— surface temperature: > 3 °C above the dewpoint of the air (determined in accordance with
ISO 8502-4);
— relative humidity: < 85 %;
— air temperature: > 5 °C (determined in accordance with ISO 8502-4).

6.3.4 Execution of thermal spraying

Thermal spraying shall be carried out according to the instructions of the TSPS. For further details,
see 5.4.
The following spraying parameters shall be supervised in adequate periods of time by the spray
coordinator/supervisor or the sprayer:
— values of current, voltage, gas flows;
— motion rate in the case of mechanical spraying;
— component’s surface temperature;
— right use of the spray material applied;
— dimensional and visual inspection of the coating.
Spray dust shall be exhausted, as thoroughly as possible. Entrapment of dust in the coating shall be
minimized. An intermediate cleaning of the sprayed layers during interruption of the spray process
may be necessary, especially when spraying in vertical or downward position. In that way, dust and
loose particles can be removed by exhausting or blowing oil-free and dry compressed air.

6.3.5 Inspection after spraying

The as-sprayed coating and the accompanying specimen, if applicable, shall be inspected according to
the following aspects:
— measuring of the coating thickness (see 7.3);

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— measuring of the adhesion strength by pull-off testing in accordance with ISO 4624 on accompanying
specimens, if possible and required;
— visual inspection to coating defects, e.g. cavities, score marks, cracks, overspray not removed,
damages, or spalling (see 7.4.1);
— checking the surface roughness (see 7.4.2), if required;
— other specified requirements, e.g. on accompanying specimens.
Any testing shall be indicated in the JCR and any test results in a test report.
If defects are found, such as de-bonding, spalling, cracks or other unacceptable imperfections (defects),
as a minimum, the coating shall be completely removed from the defect zone. The spray procedure,
including surface preparation and thermal spraying, shall be repeated. In the case of general or
systematic defects, the TSPS shall be revised or a new one shall be prepared and qualified. For further
details, see 7.5.
The sprayed coating can be released for the next operation step (sealing) when the inspection of the
thermal-sprayed coating shows no unacceptable imperfections (defects).
When no other proof is delivered or commitments are taken between the contracting parties, the spray
coordinator/supervisor is responsible for applying the required tests in accordance with the rules. The
testing shall be executed by a qualified person and the test results documented in a test report.

6.4 Sealing of the coating

The thermal-sprayed metallic coating (TSMC) should be sealed. The sealing shall be started immediately
after finishing the spraying process and cooling down of the sprayed coating before visible oxidation
of the surface occurs and in order to avoid a contamination of the sprayed coating surface by dirt or
moisture.
A thorough cleaning of the sprayed surface from spray dust and loose spray particles is necessary prior
to deposit the sealant.
The spray coordinator/supervisor is responsible for following the manufacturer’s instructions for
storage and use of the sealant and for the disposal of superfluous sealant. For further details, see
Annex I.

6.5 Advice for welding in combination with thermal spraying

Welding works shall be done prior to thermal spraying in the workshop when they are not intended to
be applied on-site.
Prior to thermal spraying, slag, alkali residues and other welding residues shall be removed from the
area to be coated. The welds shall be free of undercuts, open pores, craters and spatters on or next
to the weld. Such imperfections shall be removed by blasting or grinding. Moreover, prime coats (if
available) or their leavings near the weld shall be removed prior to thermal spraying.
If weld bevels on a component are prepared for welding on-site, the areas next to the weld shall be
covered on a width of approximately 100 mm, measured from the weld bevel, prior to thermal spraying
in the workshop.

6.6 Thermal spraying of corrosion protected fastenings

Zones where fastenings are applied, which are already protected against corrosion, shall be corrosion
protected by thermal spraying after assembly by bonding or by welding according to the manufacturing
instructions or agreements between the contracting parties.

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7 Tests — Test procedures

7.1 General
Tests and their scope shall be specified in the coating specification or in the manufacturing instructions.
Test specifications shall be prepared by the applicator of the spray coating, if required, by mutual
agreement with the contractor.
When test methods are not specified in the coating specification nor agreed upon between the
contracting parties, tests shall be carried out in accordance with this document.
Whenever possible, the required tests shall be performed on the component. If this is not possible,
accompanying specimens shall be subjected to such tests.
Tests and scope of testing shall be representative for the component.

7.2 Manufacturing of the accompanying specimens

Accompanying specimens shall be provided for tests that cannot be carried out non-destructively on
the component. This is predominantly applicable when testing the pull-off strength in accordance with
ISO 4624, especially the tensile adhesive strength in accordance with ISO 14916 and for metallographic
investigations. Adequate dimensions of the specimens are described in E.4.
The accompanying specimens shall be sprayed using the same parameters as stipulated for the
component itself. Different spray positions (horizontal, overhead, vertical down), the deposition method
(carried out manually or mechanically) and the general spray conditions (in the workshop or on-site)
shall be considered.

7.3 Coating thickness

7.3.1 General

The coating thickness shall be non-destructively measured on the component.

If measuring on the component is not possible due to geometrical or material reasons, the coating
thickness should be checked on accompanying specimens.
When the frequency of measuring the coating thickness is not specified in the manufacturing
instructions, the frequency shall be determined according to the size of the coating’s surface.
Applying an adequate selection of number and location of the measuring points, the test result shall be
representative for the whole coated surface of the component. When selecting the measuring points,
the method of applying the coating, manually or mechanically, shall be considered.
The arithmetic mean value of three readings of the coating thickness measured within an area of 1 cm2
according to Figure 1 shall be called local coating thickness. Its value represents the result of one
measuring point.

Figure 1 — Distribution of measurement points in the reference square centimetre

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ISO 2063-2:2017(E)


7.3.2 Coatings with a surface below 1 m2

In the case of thermal-sprayed coatings with a surface below 1 m2, the local thickness shall be measured
at an adequate reference surface of 1 dm2, at measuring points distributed corresponding to Figure 2.
Five measuring points shall be taken in the case of manual spraying and three measuring points in the
case of mechanical spraying.

Figure 2 — Distribution of measurement points on the coated surface and used as reference
square decimetre

7.3.3 Coatings with surfaces greater than 1 m2

In the case of coatings with surface areas larger than 1 m2, the thickness of the coating measured at
any point shall be called local thickness, when it is measured on a reference square of about 1 dm2. That
way, the local thickness is defined to be the arithmetic mean value of three with five measuring points,
according to Figure 2. Regarding the number of the measuring points, see 7.3.4.

7.3.4 Number of thickness test points

When location and number of the measuring points are not specified or agreed upon, the selection of
these points is left to the discretion of the applicator. In the case of coating surfaces larger than 1 m2
up to 45 m2, two locations per m2 shall be chosen in minimum where measurements according to the
reference square decimetre (dm2) and also distributed according to Figure 2 shall be applied.
The spray method (manual or mechanical) shall be considered to determine the number of
measurements of each reference square. For larger surfaces to be coated, the number of reference
squares related to the size of the surfaces to be coated shall be agreed upon.

Table 1 — Number of thickness measurements

Number of thickness Surface to be thermally sprayed (m2)
measurements <1 1 to 5 5 to 10 10 to 45 45 to 90 > 90
Number of reference squares to be agreed
2 3 4 6 8
(test area) upon

7.3.5 Measurement of the coating thickness

Measurement of the thickness shall be carried out by means of electromagnetic measuring methods in
accordance with ISO 2178. The measuring instrument shall be calibrated prior to use; the instructions
of the producer/supplier are to be considered.

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Due to the often high roughness of the coating’s surface, measuring the coating thickness might create
some problems and doubt. Measurements taken on roughened thermal-sprayed coating on roughened
substrates will therefore be higher than the real value of the coating thickness above the peaks of
the profiles. The thickness of the coating above the peaks of the profile is defined as the measuring
instrument reading minus an appropriate correction value.

7.4 Appearance of the coating surface and tests

7.4.1 Visual inspection

The surface of the coating shall be of uniform in appearance, without blisters or bare patches, and free
from non-adhering particles and defects. In the case of a visual inspection, an assessment of the surface
characteristics shall be carried out in accordance with ISO 14923. Visual inspection at 100 % shall be
applied after finishing the coating, even if it is not specified in the manufacturing instructions.

7.4.2 Roughness

The desired roughness may be stipulated in the coating specification or committed by agreement.
The roughness to be achieved in the as-sprayed condition depends on the spray process, the spray
parameter and the spray method (manual or mechanical). The necessary or desired roughness depends
on the subsequent treatments:
— only sealing: less roughness;
— with additional organic coating: higher roughness required.
Roughness values of flame spraying coatings are usually lower by comparing with the values of arc
spraying.

7.4.3 Adhesion strength

If required, the tensile adhesive strength for acceptance criteria shall be determined on accompanying
specimens by pull-off tests in accordance with ISO 4624 and as described in A.1, when no other test
procedure had been agreed upon between the contracting parties.
Typical values for adhesive strength can be found in Table A.1.
A tensile adhesive test in accordance with ISO 14916 should only be applied when this measurement
is required by the contractor, e.g. for qualification purposes. The number of accompanying specimens
should be agreed upon.

7.4.4 Metallographic examination of the coating

If the coating thickness shall be determined by a metallographic examination, a cross-section of a

specimen shall be taken and the examination carried out in accordance with ISO 1463. Ten measurements
shall be equally distributed along one side of the cross-section on a length of approximately 20 mm to
determine the mean value.

7.5 Defects in the coating and their repair

7.5.1 Defects on the surface and in the coating and their repair

Small local defects, e.g. short cracks, bare patches, inclusions and damages due to assembly works or
caused by destructive tests, which can impair the corrosion protection, can be repaired using organic
coatings, e.g. zinc powder coatings, after an adequate surface preparation, if there are no specific
agreements against this procedure. However, the entire defective surface should not exceed 1 % of the
entire coating’s surface and a single defect shall not exceed 10 cm2.

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In the case of larger flat defects, the defective coating shall be removed entirely or partially and renewed
by thermal spraying. Longer cracks or bare patches on and next to the weld shall be cleaned according
to level Sa 2 ½ G for Zn/ZnAl15 and Sa 3 G for Al/AlMg5 in accordance with ISO 8501-1:2007 and
roughened in accordance with ISO 8503-1 and protected by thermal spraying. The quality requirements
for the corrosion protection of such coating areas shall correspond to those of the component itself.
In each individual case the availability of specific guidelines or agreements for removal of defects shall
be checked and considered.

7.5.2 Reasons for the rejection of a defective sprayed coating

If a sprayed coating or the accompanying specimens do not fulfil the requirements specified in the test
specification, the spray coating concerned shall be removed. After cleaning and surface preparation,
the spray coating can be applied again using the existing TSPS. If it is noticeable that the requirements
of the coating specification cannot be fulfilled by the existing TSPS, it shall be corrected or a new TSPS
shall be prepared and qualified again.
The tests and their scope shall be carried out as stipulated in the test specification.

8 Health and safety and environment protection

For the manufacturing of thermal-sprayed corrosion protection coatings, applicable requirements
concerning health and safety and environment protection shall be fulfilled. For further details, see
Annex J.

9 Additional requirements for working on-site

9.1 General
When working on-site, negative influences of the environment to a safe work are to be expected. The
employer shall avoid or minimize them by organizational and technical measures.

9.2 Supervision of spraying on-site

For operations on-site, the conditions defined in 4.2.2 apply. A supervisor for thermal spraying shall
be present on-site during the course of the manufacturing. This spray coordinator/supervisor shall
supervise the qualified thermal sprayers working on-site and ensure that the required tests are carried
out according to current manufacturing steps.
Where no supervisor is nominated by the producer, the spray coordinator shall be responsible for
health and safety and environment protection matters.

9.3 Job reference qualification for spray personnel working on-site

Before the thermal sprayer begins to work on-site, the thermal sprayer shall, if required by the TSPS,
be qualified by a job reference qualification applying a specimen, which shall be coated in the most
challenging position required. By applying an adequate job reference specimen (JRS) the thermal
sprayer can get permission for the employment on-site, if all quality requirements are fulfilled when
testing.
The qualification shall be carried out under leadership and in response of the spray
coordinator/supervisor.
The specimens defined in Annex E can be used for the sprayer’s qualification so that the required spray
position can be covered. For details, see Table E.1. This personnel qualification can also be executed
using a plate for a JRS according to 5.6.

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9.4 Execution of spray works in the case of planned work on-site or not planned repairs
on new manufactured parts

9.4.1 General

An execution of thermal spraying planned to be carried out on-site can be necessary due to the
component’s dimension or transport capacity or unplanned work in the case of repair of damages that
occurred during transportation or assembly. Such damages shall be identified by the inspector and
repaired according to available specifications or commitments.
Welding shall be carried out prior to thermal spraying. Generally, the details given in 6.5 apply also for
works on-site.
The spraying coordinator or supervisor is responsible for ensuring that the works follow the
manufacturing sequence plan and the instructions for manufacturing and testing, as required.

9.4.2 Surface preparation

The surface preparation shall be carried out according to 6.2.

If the zone next to a weld is protected by a primer, this primer shall be removed prior to blasting for
surface preparation.
Furthermore, it shall be ensured that no residues of former coatings remain on the surface to be coated
and the cleaned and prepared surface will not be contaminated, e.g. not to be touched with bare hands
or not to fall below dew point, and kept be free of any contaminants.

9.4.3 Masking

Masking shall be carried out according to 6.2.1.

The masking material shall be stored safely and dry and the masking itself protected from condensation
of moisture.

9.4.4 Thermal spraying

Thermal spraying shall be carried out according to 6.3.

Due to the weather and usual climate conditions on-site, a higher risk of rusting can be expected. The
spraying supervisor shall ensure that the period of time between blasting and thermal spraying is as
short as possible.
The spraying supervisor or the sprayer shall take care that the dew-point of the air is known and the
surface temperature of the component in the area to be coated can be kept constantly to at least 3 °C
above the dew-point. If this is not possible, thermal spraying should not be carried out.

9.4.5 Spraying of accompanying specimens

For manufacturing and testing, 7.2 applies. Size and number of specimens depend on the test procedures,
which are required for the investigation. If testing of the zone next to a weld is required, this test shall
be applied on a welded accompanying specimen, e.g. according to Figure E.2.

9.4.6 Sealing

Sealing should be carried out according to 6.4.

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10 Execution of spray works on-site in the case of planned maintenance of a

service operated coating

10.1 General
Deterioration and damage of the TSMC can occur by impact with other objects, abrasion and corrosion.
A repair can vary from entire replacement of the coating to minor touch-up depending on the extent of
the damage.
NOTE Maintenance is usually applied if a metallic or organic coating looks shabby or the coating thickness
is reduced. Local repair can be carried out if rust did not occur. Rusting of the metal surface can be ruled out
when the rest of the metallic coating not attacked by rust is more than 50 μm in thickness. Since such rusting
of the metal surface is not easy to recognize, this procedure can only be partly recommended. Renewing of the
coating is required, where rust appeared on the substrate and the required design life of the component will not
be reached. Usually, such work is carried out on-site.

Welding planned to be carried out on-site or which was found to be necessary in the case of maintenance
of a service loaded structure and coating shall be carried out prior to thermal spraying. Generally, the
details specified in 6.5 shall be kept for working on-site too.

10.2 Pre-inspection for assessment of the repair possibility applied by thermal spraying
Usually, a pre-inspection is required, if a weathered, strongly attacked coating shall be maintained. A
report of the actual status shall be established.

10.3 Execution of repair-works by thermal spraying

10.3.1 General

All the works for thermal spraying shall be carried out according to the status report, as described in
10.2 and 10.3 and stipulated in the order. The procedures as specified in Clause 9 shall be considered,
when they are applicable in the specific case.
If the substrate is already rusty, the substrate shall be repaired at first like a corroded but uncoated or
only organic coated steel by blasting, grinding, or welding. Further details can be taken from Annex K.

10.3.2 Quality control after repair

During and after the execution of repair works by thermal spraying, quality control measures shall be
applied (control and testing, e.g. according to 6.2, 6.3, 7.3 and 7.4), if required. This includes control of
adequate ambient air and environment conditions, surface temperature, surface cleanliness, adhesion
strength, thickness of the metallic coating, sealant and sealing; and thickness of painted coats, if
applying of the organic top coat belongs to the order.
The criteria for repairs shall be applied according to 7.5.

11 Tests — Test procedures

The tests shall be carried out on the component when possible. If no other test procedures are agreed
upon between the contracting parties, the tests shall be carried out according to 7.1 to 7.4.
The test results shall be indicated in a report (e.g. according to Annex B). If all requirements are fulfilled,
release for further manufacturing is given by this report. If the requirements are not fulfilled, rejection
of the coating is given by the report and correcting measures will be required. For details, see 7.5. If
necessary, further conditions are to be agreed upon between the contracting parties.

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12 Documentation of the procedure and tests in the case of maintenance

Annex B provides a test report form for the documentation of the manufacturing steps applied. The
thermal spraying process and the test results shall be indicated. The form is intended to the case of a
planned maintenance. It can be used for activities in a workshop, as well as on-site.

13 Health and safety and environment protection on-site

Generally the instructions and determinations from Clause 8 apply also for thermal spraying on-site.
Due to the different weather and climate conditions that can be expected on-site, measures are required
to protect the environment when surface preparation, thermal spraying, sealing, testing and organic
coating is carried out, if appropriate.

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Annex A
(normative)

Adhesion testing using the pull-off test in accordance with

ISO 4624

A.1 General requirements

In the case of acceptance control, the tensile adhesive strength tests shall be carried out in accordance
with ISO 4624 using accompanying specimens prepared according to 7.2. The number of the
accompanying specimens to be tested according to E.4 shall be taken from the manufacturing or testing
instructions (in accordance with ISO 4624, minimum of six test pieces). If no instructions for testing
and for minimum values of the tensile adhesive strength are stipulated in the coating specification or
contract, the instructions of this document apply.
If the pull-off test is carried out on the component itself and is applied until rupture occurs, the local
damage shall be repaired. The location of testing shall be representative for the sprayed coating.

A.2 Preparation of the test dolly (pull stub)

Remnants from previous tests (former coating or adhesive) shall be removed from the test dolly. The
dolly shall be degreased with an adequate solvent such as alcohol.

A.3 Preparation of the coating

The TSMC surface is sufficient for bonding, usually. If necessary, the metal coating may be slightly
abraded with a grit paper. Afterwards, it shall be degreased and any lose material removed.

A.4 Applying adhesive

The bond strength of the adhesive shall be higher than the bond strength at the coating substrate
interface.
Due to the spray procedure, related porosity adhesives with a higher viscosity (paste type) are
preferred. If the adhesive penetrates the coating to the substrate, the adhesive strength value will
be remarkably influenced. If appropriate, a comparison test should be applied for the selection of an
adequate adhesive.
When selecting the adhesive, the kind and roughness of the sprayed coating should be considered. The
quantity of the adhesive should cover the bond area of the test dolly evenly and even out the roughness.
The dolly shall be pressed by hand straight down without any bending or torsion momentum onto the
test surface. The pressure shall be kept constantly for about half a minute. This will cause the air to be
displaced and will evenly spread out the thickness of the adhesive. Around the border of the specimen
a slight bulge will be created that should be removed as soon as possible. The adhesive shall then cure.
Instructions for applying the adhesive from the manufacturer or supplier shall be considered.

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A.5 Before tension test

When nothing to the contrary is agreed upon between the contracting parties, a sharp edged tool shall
be used to carefully cut around the periphery of the dolly to remove excess adhesive. The cut shall
penetrate to the substrate.
NOTE Because the cutting eliminates the lateral bond within the coating, cracks can be introduced, which
then undermine the dolly, resulting in a lower breaking stress.

A.6 Tensile test

The suspension on tensile test equipment or a pneumatically or hydraulically working tester shall be
placed in such a way that the tensile force can be applied vertically and free of bending and torsion
momentum. The force on the dolly (pull stub) shall be gradually increased until the bond breaks. For
details, see ISO 4624.

A.7 Assessment
The exact fracture location shall be determined in order to specify the mode of failure:
— failure along the interface between coating and substrate;
— failure in the glue;
— cohesive failure within the applied coating;
— mixed fracture with portions of interfacial failure and adhesive or cohesive fail.
The test results shall be indicated in the test report, together with additional details to coating
thickness, type of adhesive, test instrument and whether cut around the dolly or not.

A.8 Typical values of adhesion strength of thermal spray coatings

See Table A.1.

Table A.1 — Typical values of the pull-off strength in accordance with ISO 4624 of unsealed TSMCs
Pull-off strength (min. MPa)a
Spray material
Wire flame spraying/Arc spraying
Zn, ZnAl15 Zinc, 85/15 Zinc-Aluminium 4
Al, AlMg5 Aluminium, 95/5 Aluminium-Magnesium 4,5
a) If the coating is not cut, 20 % to 25 % higher values are typical.
NOTE 1      If the measured values are remarkably lower than the typical ones, an insufficient coating quality (surface
preparation included) can be expected.
NOTE 2     Values are influenced by
—   sealing:
—   not cut around the dolly;
—   mechanically sprayed;
—   insufficient spray position (overhead and vertically down);
—   on-site conditions;
—   surface preparation, blasting material.
NOTE 3     The pull-off test can be interrupted, when the minimum value of the specified adhesion strength is reached. This
method avoids the necessity of repair in the areas damaged by the test. The bonded dolly can be removed by softening of
the adhesive through heating and by beating to the side of the dolly. This test method may only be executed in the case of
quality assurance measures in the manufacturing sequence. The coating quality can be impaired.

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Annex B
(informative)

Documentation of the applied maintenance procedure, the

thermal spray procedure and test results in the case of a planned
maintenance

B.1 Sample documentation

This form may be copied by the user of this document regardless of copyright.

Manufacturer: Contractor:
Reason for maintenance:
Location: workshop/on-site
if on-site, where: countryside/town/near to coast
Component description:
Substrate material:
Function of coating: corrosion protection /......................................
Existing coating system
     metallic bond coat: type: ...................................... sealed/unsealed
     synthetic top coat: type: ......................................
No. of inspection report about actual conditions of coating system
     Existing synthetic top coat to be removed: entirely/partially
     Existing metallic bond coat to be removed: entirely/partially/remaining
     Re-sealing necessary: yes/no
     Welding repair required: yes/no
Welding procedure specification (WPS), if required:
Thermal spray procedure specification (TSPS):
Method of preparation and cleaning:
Surface preparation
Programme no. (if mechanical): ......................................
Blasting procedure: ......................................
Type of grit: ...................................... Grain size: ......................................
Blasting pressure: bar Blasting distance/angle:
Visual inspection: Cleanliness, uniformity, e.g. as per ISO 8501-1:
Masking (if necessary)
     Imperfections: existing: yes/no Removed: yes/no
     Intermediate cleaning by extraction/blowing Done: yes/no
Masking material:
Time period between blasting, masking and spraying:
Environment conditions: Temperature/dew-point: / °C degrees above dew-point: °C

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Spray procedure, generally (if not specified or no TSPS available)

Spray material: designation acc. with ISO 14919: Wire diameter:
Preheating: yes/no Preheating temperature: °C
Required coating thickness: as sprayed: μm
Spray procedure to be applied: manual/mechanical
Spraying distance:                       mm Spraying positions:
Spraying sequences: up and down; left to right direction/crossing right-angled
Spray procedure, specific data applied (if not specified or no TSPS available)
Spraying procedure (per ISO 14917): Arc spraying
Arc spraying system:
Type of nozzle: closed arc/open arc
Current (A): Voltage (V):
Atomizing gas pressure (MPa): Arc jet pressure (MPa):
Spraying procedure (per ISO 14917): Wire flame spraying
Flame spraying system:
Type of nozzle:
Wire feed rate/adjustment:
Oxygen flow/adjustment:
Fuel type: Flow setting:
Compressed air adjustment:
Spraying procedure (per ISO 14917): Powder flame spraying
Flame spraying system:
Powder feed rate/setting:
Oxygen flow/setting:
Type of fuel: Flow setting:
Pressured air setting:
Thermal sprayers, qualified acc. with ISO 14918 and/or by a job reference qualification (JRQ):
Name/Personal no.:

B.2 Inspection and test results

Inspection/ Required Executed Record Test results

Specification Remarks
Test Yes/No by: No. Passed Failed
Visual inspection ISO 14923
Coating thicknessa ISO 2178
Determination
of the pull-off ISO 2063-2/ISO 4624
strengthb
a Single values are to be taken from the report.
b Single values and positions of the tests are to be taken from the report.

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ISO 2063-2:2017(E)


Date of issue: .........................................

Spraying coordinator: Inspector:

Signature: .......................................... Signature: ..........................................

Name: ............................................... Name: ...............................................

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Annex C
(informative)

Documentation of the applied thermal spray procedure and test

results in the case of a new manufacturing

C.1 Sample documentation

This form may be copied by the user of this document regardless of copyright.

Manufacturer: Contractor:
Location: workshop/on-site
if on-site, where: countryside/town/near to coast
Component description:
Substrate material:
Function of coating: corrosion protection /......................................
Welding procedure specification (WPS), if required:
Thermal spray procedure specification (TSPS):
Method of preparation and cleaning:
Surface preparation
Programme no. (if mechanical): ......................................
Blasting procedure: ......................................
Type of grit: ...................................... Grain size: ......................................
Blasting pressure: bar Blasting distance/angle:
Visual inspection: Cleanliness, uniformity, e.g. as per ISO 8501-1:
Masking (if necessary)
     Imperfections: existing: yes/no Removed: yes/no
     Intermediate cleaning by extraction/blowing Done: yes/no
Masking material:
Time period between blasting, masking and spraying:
Environment conditions: Temperature/dew-point: / °C degrees above dew-point: °C
Thermal spray procedure specification, generally (if not specified or no TSPS available)
Spray material: designation acc. with ISO 14919: Wire diameter:
Preheating: yes/no Preheating temperature: °C
Required coating thickness: as sprayed: μm
Spray procedure to be applied: manual/mechanical
Spraying distance:                       mm Spraying positions:
Spraying sequences: up and down; left to right direction/crossing right-angled
Spray procedure, specific data applied (if not specified or no TSPS available)
Spraying procedure (per ISO 14917): Arc spraying
Arc spraying system:
Type of nozzle: closed arc/open arc

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ISO 2063-2:2017(E)


Current (A): Voltage (V):

Atomizing gas pressure (MPa): Arc jet pressure (MPa):
Spraying procedure (per ISO 14917): Wire flame spraying
Flame spraying system:
Type of nozzle:
Wire feed rate/adjustment:
Oxygen flow/adjustment:
Fuel type: Flow setting:
Compressed air adjustment:
Spraying procedure (per ISO 14917): Powder flame spraying
Flame spraying system:
Powder feed rate/setting:
Oxygen flow/setting:
Type of fuel: Flow setting:
Pressured air setting:
Thermal sprayers, qualified acc. with ISO 14918 and/or by a job reference qualification (JRQ):
Name/Personal no.:

C.2 Inspection and test results

Inspection/ Required Executed Record Test results

Specification Remarks
Test Yes/No by: No. Passed Failed
Visual inspection ISO 14923
Coating thicknessa ISO 2178
Determination
of the pull-off ISO 2063-2/ISO 4624
strengthb
a Single values are to be taken from the report.
b Single values and positions of the tests are to be taken from the report.

Date of issue: .........................................

Spraying coordinator: Inspector:

Signature: .......................................... Signature: ..........................................

Name: ............................................... Name: ...............................................

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Annex D
(informative)

Test certificate for job reference qualification for thermal sprayers

working on-site in accordance with ISO 2063-2

D.1 Sample documentation

This form may be copied by the user of this document regardless of copyright.

Name of thermal sprayer: Personal no.

Date of birth: Place of birth: Country:
Employed in company:
Location of company:
Thermal sprayer, qualified acc. with ISO 14918: Spray process: manually/mechanically
Validity of testing until:
Trained and instructed by spray coordinator:
Test standard for JRS: ISO 2063-2
Test location: on-site:

Spray procedure
Thermal spray process: e.g. WFS (wire flame spraying):
Application method: e.g. manual:
Spray procedure specification: TSPS: state of revision:

Test designation:
For example: JRS ISO 2063‑2–manual–ISO 14919:2015-2.3 (ZnAl15)

D.2 Tests and test results

Readings in different positions
Inspection/ Direction spray jet/ Test result
Specification Inspector
Test direction motion
V/H H/V O/H R P F
Visual inspection ISO 14923
Coating thickness ISO 2178
Roughness test ISO 8501-1
Determination of adhe-
ISO 2063-2/ISO 4624
sive tensile strength
Positions: V = vertical H = horizontal O = overhead R = Radius (r = 6mm)
Test result: P = passed F = failed

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ISO 2063-2:2017(E)


Date of JRS spraying: ......................................... on-site: .........................................

Date of JRS testing: ......................................... on-site: .........................................

Test certification: ......................................... valid until: .........................................

Date of issue: .........................................

Valid for site: .........................................

Signatures

Responsible spray supervisor: Inspector/employment/test body:

......................................... .........................................

(Name in printed letters) (Name in printed letters)

The acceptance for spraying is extended for the site: .........................................

Signature

Responsible spray supervisor/coordinator:

.........................................

(Name in printed letters)

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Annex E
(informative)

Test specimens — Spray positions

E.1 Specimen’s arrangement and spray positions for job reference specimens

Table E.1 — Specimen’s arrangement and spray positions for job reference specimens
Type of Arrangement
Positions for spraying
specimen of specimen
Overhead
Horizontal Flat (vertically down)
Plate (vertically up)
Vertical Horizontally
Flat, vertically down Horizontally onto a
Horizontal onto a horizontal surface vertical surface of the Overhead
L-profile of the L-profile L-profile
(65 × 115 × 6) Horizontally onto a
mm Horizontally onto a
vertical surfaces of the
Vertical vertical surface of the
L-profile inclusive a
L-profile
radius

E.2 Example for JRS — Test specimen for operation on-site

Dimensions in millimetres

TS – X = vertically onto horizontal surface

TS – Y = horizontally onto vertical surface
TS – Z = overhead
a Masked.

Figure E.1 — Specimen: L-Type profile steel (65 × 115 × 6) mm for sprayers qualification for
different working positions

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ISO 2063-2:2017(E)


E.3 Example for welded JRS for assessment and testing of the coating next to
the weld
Dimensions in millimetres

Figure E.2 — Welded JRS

E.4 Example for accompanying specimen for destructive testing of the coating
Dimensions in millimetres

Figure E.3 — Accompanying specimen

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E.5 Spray positions

The spray position represents the position of the spray gun or spray torch in front of the substrate to be
coated. The spray gun or spray torch should be used in such a way that the spray jet strikes the surface
of the part at a right angle. The striking angle of the spray jet to the surface to be coated should be
around 90° and no less than 45°.
The spray distance shall be taken from the TSPS. It varies depending on the spray process and spray
parameter. It should be kept in the stipulated range of tolerance.
The horizontal position is recommended for spraying, see Figure E.4 for details. Other spray directions
can be applicable; for example, in the case of large components or twisty structures, spraying in flat
position (vertical down) and/or overhead position may be needed. Coating quality shall be guaranteed
in any direction.
In general, spraying onto flat or cylindrical surfaces shall be applied, crossing at right-angle. An
adequate overlapping of the spray traces is necessary in any case.

a) Horizontal position b) Flat position c) Overhead position

(vertically down) (vertically up)
Key
1 substrate
2 spray torch

Figure E.4 — Spray positions: horizontal — flat, vertical down — overhead (e.g. wire flame
spraying)

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ISO 2063-2:2017(E)


Annex F
(informative)

Assessment of the coatability

Table F.1 — Example checklist

No Item Yes/No
1 Is access possible for the surface preparation by cleaning and blasting, for removal
of grit residues, for the thermal spraying and the sealing and, if appropriate, for the
removal of worn coatings or of further organic coatings?
2 Can the blasting material or the spray material meet the surface as vertically as
possible?
3 Can a striking angle of > 45° be kept?
4 Is the minimum distance of about 300 mm to the surface available for motion of the
sprayer when spraying manually resp. for motion of spray gun with the hose assembly
when spraying mechanically?
5 Are narrow gaps, recesses, deep pockets, sharp edges and acute angles avoided?
6 Are open L-, wide U- or T-profiles intended for reinforcements?
7 Are edges intended to be rounded or chamfered?
8 Have inner corners and inner radii adequate radii values?
9 Is a smooth surface designed, that residues of moisture and dirt can drain away and
supervision, cleaning and maintenance can easy be applied?
10 Are thin walled plates or profiles reinforced designed in such a way, that they cannot
be unacceptable deformed when blasting?
11 Do close spaces, e.g. container and tanks, contain sufficient openings as for manholes
and for exhausting of dust, smoke and gases?
12 Is a free opening for ventilation available?
13 Can the considerable volume of dust resp. metal dusts and heat created by blasting and
spraying effectively be exhausted?
14a Can intermediate walls, bulkheads, fittings, etc. inside of tanks and hollow bodies be
disassembled?
14b If this is not possible, will a reduced quality be accepted?
14c Is thermal spraying the adequate process?
15 Are expansion and shrinkage minimized by the design in the case of sudden tempera-
ture change, if applicable?
16 Are areas to be coated marked specifying the minimum thickness in accordance
with the instructions of ISO 12671 or unequivocally described in the manufacturing
instructions?
17 Can the required legal work and environment conditions be kept?

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Annex G
(informative)

Bend test and its execution

G.1 Bend test to evaluate equipment set up

The bend test is a qualitative test used to confirm that the equipment is in proper working condition.
At any time where the thermal spray equipment is to be used, the bend test can be applied using test
panels and standard parameter of the intended spray process. The test result should be in accordance
with the requirements. The results of the bend test should be recorded and the test panels labelled and
saved. The bend test can also be applied to reach a qualification of the TSPS.

G.2 Performance of the bend test

G.2.1 General
The coating should be applied to prepared test panels and the bend test conducted. The test consists of
bending coated steel panels around a cylindrical mandrel and examining the coating for cracking.

G.2.2 Test panels

The test panels should be a cold rolled steel measuring (75 × 150 × 1,25) mm (3 × 6 × 0,050) in. The
panels should be cleaned and blasted in the same fashion as will be used for the job.

G.2.3 Application of the thermal spray coating

The thermal spray coating should be applied to five test panels using the identical spray parameters, the
same number of overlapping spray passes in a cross hatch pattern and the average specified thickness
that will be used for the job. The coating thickness should be measured to confirm that it is within the
specified range.

G.2.4 Bend test to be conducted

Test panels are bent 180° around a steel mandrel of a specified diameter 12,5 mm (0,5 in.). Pneumatic
and manual mechanical bend test apparatus may be used to bend the test panels.

G.2.5 Bend test panels to be examined

Test panels should be examined visually without magnification. The bend test is deemed to be accepted
if the coating shows no cracks or exhibits only minor cracking with no lifting of the coating from the
substrate. If the bend test fails and the coating lifts from the substrate, corrective measures of the spray
parameter and/or on the spraying equipment should be taken. Figure G.1 depicts representative bend
test results.

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ISO 2063-2:2017(E)


Figure G.1 — Results of bend tests

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Annex H
(informative)

Additional information for surface preparation

Advice for surface preparation for degreasing, cleaning and blasting can also be taken from ISO 12679.
The cleanliness of the blasting material should be ensured by adequate dust extraction where the
blasting material is used again in equipment with material circulation. If the grit particles are rounded
the spray material should be changed.
The pressurized air used when blasting should be sufficient, clean and free of oil and moisture. Adequate
conditions can be reached by using oil and water separators.
When nothing is specified in the TSPS, a blocky blasting material with a size distribution of 0,5 mm to
1,5 mm should be applied. The following blasting materials are recommended:
— hematite chilled cast iron grit in accordance with ISO 11124-2;
— copper refinery slag in accordance with ISO 11126-3;
— coal furnace slag in accordance with ISO 11126-4;
— aluminium oxide grit in accordance with ISO 11126-7;
— almandine garnet grit in accordance with ISO 11126-10.
The blasted surface shall not be contaminated (e.g. not to be touched with bare hands). If necessary, the
blasted surface should be protected against contamination and moisture.
Sufficient post cleaning of the blasted surface from residues of blasting material can be carried out by
exhausting or blowing off using, preferably, oil-free and dry pressurized air.
Qualitative tests are carried out to assess the surface roughness. A quantitative roughness test can
be applied with support of the profile method in accordance with ISO 4288 or the replica method in
accordance with ISO 8503-5. The surface should not be impaired by the measurement. The surface
roughness, Rz, should be in a range between 50 µm and 100 µm.
ISO 8502-3 provides guidance on the assessment of the surface roughness.

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ISO 2063-2:2017(E)


Annex I
(informative)

Further details for sealing

I.1 General
Cleaning of the sprayed surface from dust and overspray can be carried out by vacuuming or blown off
using oil-free dry pressurized air.
The sealant should penetrate the sprayed coating to a depth of 40 µm to 75 μm, depending on the
coating thickness. The sealant should be mixed according to the manufacturer’s instruction, using an
adequate thinner.
NOTE Solvent-free sealants and thinner are preferable to mitigate environmental impact.

The treatment of the sealant should be carried out considering the instructions of the data sheet and the
instructions of the manufacturer. The entire thickness of the coating should not significantly increase
and by not more than 40 μm after applying the sealer.
Conventional or airless spray procedures are used for the deposition of the sealant. Rolling is not
suitable.
Recommendations for selection and treatment of the sealant may be taken from ISO 12944-5 and
ISO 12944-7 and ISO 2063-1.

I.2 Notes
The sealing material selected for this purpose should also be a suitable coating material. The selected
sealant should be compatible with the thermally sprayed coatings and also with the subsequent
coatings (if applicable).
The required sealant thickness varies according to the amount of thinner added and, in addition, may
be affected by the sealing spray position. A higher concentration of thinner will improve the flow
behaviour of the sealant in the thermally sprayed coating. This will also affect the thickness of the
sealant and the adhesive strength of the system of thermally sprayed coating/sealant.
The dry film thickness (DFT) of the sealant decreases with the increase in the amount of thinner added.
The thickness of the thermal-sprayed coating should also be considered. Apply the sealer evenly until
no more is absorbed.
The sealant has mostly a positive impact on the adhesion of the thermally sprayed coating. It increases
the adhesion strength values for thermally sprayed coatings with a thickness above 100 µm; for thick
thermally sprayed coatings is the increase mostly insignificant.
The coater should assess in advance of carrying out the sealing processes the quality of the thermally
sprayed coating to be sealed, e.g. thickness, roughness.

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Annex J
(informative)

Further instructions for safety and activities on-site

J.1 Safety
Noise, dust and smoke of zinc, aluminium and their alloys created by thermal spraying can injure
and adversely affect the health of personnel and the environment. Technical or organizational
countermeasures should be taken.
In the case of manufacturing of thermal-sprayed aluminium and aluminium alloys in closed spaces,
measures against ignition and fire should be taken.
Instructions for the enclosure of the spray process for workshop manufacturing against dust, smoke,
gases and noise are given in CEN/TR 15339-6. Safety requirements are provided in CEN/TR 15339-3
for spray gun or torch and power supply equipment and in CEN/TR 15339-5 for spray material feeders.

J.2 Measures in the case of working on-site

Due to the more difficult weather and climate conditions on-site, contrary to those in a workshop,
additional requirements for performance and employees should be established to ensure quality. The
most important conditions are as follows:
— impairment by climate conditions, e.g. rain, snow, intensive sun shine;
— impairment by the environment, e.g. near to the coast, rivers, main roads, residential areas;
— difficulties of protection against distribution of noise, intensive light, risk of fire;
— difficulties when collecting rebounded spray material and overspray of thermal spraying and of
drained organic coating material;
— working in closed spaces, e.g. in large containers or tanks;
— working in unusual height secured by special devices against fall, e.g. on pylons, wing structures,
bridges, columns for wind wheels;
— working in uncomfortable positions when blasting, spraying and applying further coatings, e.g. in
the overhead position.

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Annex K
(informative)

Repair procedures of service loaded coatings and recommended

repair procedures

In addition to the status report, the following items should be considered in the assessment of the
necessity to repair the thermal-sprayed coating:
a) identification of the type of the sealant originally applied when spraying the coating;
b) identification of sealer defects (difficult to identify if no topcoat is present);
c) identification of defects in a thermal-sprayed sealed or unsealed coating, which can include
general or localized thickness reductions, the presence of rust and bare steel, cracked, blistered, or
delaminated coating areas.
Reports from the original manufacturing or former repairs can contain the necessary information.
Test methods for quantifying the coating deterioration are provided in the following:
— ISO 4624;
— ASTM F1130;
— ASTM D61 0.
Defects like dis-bondment from the substrate, cracking or mechanical damages can reduce the service
life of the thermal-sprayed coating. Discoloration does not indicate damage on the substrate; however,
it can indicate possible exposure of the substrate.
It is important to know
— which organic coating should be replaced entirely or partially only, and
— if the metallic coating is already corroded.
Areas without visible damage on the coating should be inspected carefully to locate the rusty zone of
the metallic coating. If the corroded zone is not limited to a small extent, the whole organic coating
should be removed and the metallic coating should be renewed by thermal spraying after removing the
rusty zones in accordance with Clause 10.
ISO 12944-4 provides guidance in choosing an adequate procedure to remove primers or for repair.

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Bibliography

[1] ISO 2064, Metallic and other inorganic coatings — Definitions and conventions concerning the
measurement of thickness
[2] ISO 4288, Geometrical Product Specifications (GPS) — Surface texture: Profile method — Rules and
procedures for the assessment of surface texture
[3] ISO 8501-2, Preparation of steel substrates before application of paints and related products —
Visual assessment of surface cleanliness — Part 2: Preparation grades of previously coated steel
substrates after localized removal of previous coatings
[4] 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
[5] ISO 8502-3, Preparation of steel substrates before application of paints and related products —
Tests for the assessment of surface cleanliness — Part 3: Assessment of dust on steel surfaces
prepared for painting (pressure-sensitive tape method)
[6] ISO 8502-4, Preparation of steel substrates before application of paints and related products —
Tests for the assessment of surface cleanliness — Part 4: Guidance on the estimation of the
probability of condensation prior to paint application
[7] ISO 8503-2, Preparation of steel substrates before application of paints and related products —
Surface roughness characteristics of blast-cleaned steel substrates — Part 2: Method for the grading
of surface profile of abrasive blast-cleaned steel — Comparator procedure
[8] ISO 8503-3, Preparation of steel substrates before application of paints and related products —
Surface roughness characteristics of blast-cleaned steel substrates — Part 3: Method for the
calibration of ISO surface profile comparators and for the determination of surface profile —
Focusing microscope procedure
[9] ISO 8503-4, Preparation of steel substrates before application of paints and related products —
Surface roughness characteristics of blast-cleaned steel substrates — Part 4: Method for the
calibration of ISO surface profile comparators and for the determination of surface profile — Stylus
instrument procedure
[10] ISO 8503-5, Preparation of steel substrates before application of paints and related products —
Surface roughness characteristics of blast-cleaned steel substrates — Part 5: Replica tape method
for the determination of the surface profile
[11] ISO 11124-2, Preparation of steel substrates before application of paints and related products —
Specifications for metallic blast-cleaning abrasives — Part 2: Chilled-iron grit
[12] ISO 11126-3, Preparation of steel substrates before application of paints and related products —
Specifications for non-metallic blast-cleaning abrasives — Part 3: Copper refinery slag
[13] ISO 11126-4, Preparation of steel substrates before application of paints and related products —
Specifications for non-metallic blast-cleaning abrasives — Part 4: Coal furnace slag
[14] ISO 11126-7, Preparation of steel substrates before application of paints and related products —
Specifications for non-metallic blast-cleaning abrasives — Part 7: Fused aluminium oxide
[15] ISO 11126-10, Preparation of steel substrates before application of paints and related products —
Specifications for non-metallic blast-cleaning abrasives — Part 10: Almandite garnet
[16] ISO 12671, Thermal spraying - Thermally sprayed coatings - Symbolic representation on drawings
[17] ISO 12679, Thermal spraying — Recommendations for thermal spraying

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ISO 2063-2:2017(E)


[18] ISO 12690, Metallic and other inorganic coatings — Thermal spray coordination — Tasks and
responsibilities
[19] ISO 12944-1, Paints and varnishes — Corrosion protection of steel structures by protective paint
systems — Part 1: General introduction
[20] ISO 12944-2, Paints and varnishes — Corrosion protection of steel structures by protective paint
systems — Part 2: Classification of environments
[21] ISO 12944-3, Paints and varnishes — Corrosion protection of steel structures by protective paint
systems — Part 3: Design considerations
[22] ISO 12944-4, Paints and varnishes — Corrosion protection of steel structures by protective paint
systems — Part 4: Types of surface and surface preparation
[23] ISO 12944-5, Paints and varnishes — Corrosion protection of steel structures by protective paint
systems — Part 5: Protective paint systems
[24] ISO 12944-6, Paints and varnishes — Corrosion protection of steel structures by protective paint
systems — Part 6: Laboratory performance test methods
[25] ISO 12944-7, Paints and varnishes — Corrosion protection of steel structures by protective paint
systems — Part 7: Execution and supervision of paint work
[26] ISO 14232, Thermal spraying — Powders — Composition and technical supply conditions
[27] ISO 14713-1, Zinc coatings — Guidelines and recommendations for the protection against corrosion
of iron and steel in structures — Part 1: General principles of design and corrosion resistance
[28] ISO 14919, Thermal spraying — Wires, rods and cords for flame and arc spraying — Classification —
Technical supply conditions
[29] ISO 17834, Thermal spraying — Coatings for protection against corrosion and oxidation at elevated
temperatures
[30] ISO 19840, Paints and varnishes — Corrosion protection of steel structures by protective paint
systems — Measurement of, and acceptance criteria for, the thickness of dry films on rough surfaces
[31] EN 1395-1, Thermal spraying — Acceptance inspection of thermal spraying equipment — Part 1:
General requirements
[32] EN 1395-2, Thermal spraying — Acceptance inspection of thermal spraying equipment — Part 2:
Flame spraying including HVOF
[33] EN 1395-3, Thermal spraying — Acceptance inspection of thermal spraying equipment — Part 3:
Arc spraying
[34] EN 1395-6, Thermal spraying — Acceptance inspection of thermal spraying equipment — Part 6:
Manipulator systems
[35] EN 1395-7, Thermal spraying — Acceptance inspection of thermal spraying equipment — Part 7:
Powder feed systems
[36] EN 13507, Thermal spraying — Pre-treatment of surfaces of metallic parts and components for
thermal spraying
[37] EN 15520, Thermal spraying — Recommendations for constructional design of components with
thermally sprayed coatings
[38] EN 15648, Thermal spraying — Component related procedure qualification
[39] CEN/TR 15339-1, Thermal spraying — Safety requirements for thermal spraying equipment —
Part 1: General requirements

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 ISO 2063-2:2017(E)


[40] EN 15339-2, Thermal spraying — Safety requirements for thermal spraying equipment — Part 2:
Gas control units
[41] CEN/TR 15339-3, Thermal spraying — Safety requirements for thermal spraying equipment —
Part 3:Torches for thermal spraying and their connection and supply units
[42] CEN/TR 15339-4, Thermal spraying — Safety requirements for thermal spraying equipment —
Part 4: Gas and liquid fuel supply
[43] CEN/TR 15339-5, Thermal spraying — Safety requirements for thermal spraying equipment —
Part 5:Powder and wire feed units
[44] CEN/TR 15339-6, Thermal spraying — Safety requirements for thermal spraying equipment —
Part 6: Spray cabin, handling system, dust collection, exhaust system, filter
[45] ASTM D61 0, Test method for evaluating degree of rusting on painted steel surfaces
[46] ASTM F1130, Standard practice for inspecting the coating of a ship

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ISO 2063-2:2017(E)


ICS 25.220.20; 25.220.40

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© ISO 2017 – All rights reserved