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HUBBELL POWER SYSTEMS
PURCHASING SPECIFICATION

HOT DIP GALVANIZING

1.0 Purpose

This document describes the requirements for hot dip galvanized (HDG) zinc coatings on
steel and iron hardware.

2.0 Scope

This document applies to the quality, uniformity, weight and thickness of hot dip
galvanize (HDG) zinc coatings for parts used within all operating companies of Hubbell
Power Systems.

3.0 Definitions

3.1 Galvanize - A primarily zinc coating applied by immersion in a molten zinc bath.
Its purpose is corrosion protection. Its common acronym is HDG.

3.2 Rc - Rockwell hardness measured on the 'c' scale.

3.3 Pickle - An acid bath used to remove surface oxides and clean the part in
preparation for galvanizing. Pickling is also used to remove a previous galvanize
coating in case of rework.

4.0 Reference Documents/Forms

4.1 ASTM A 153 (latest revision) - Specification for Zinc Coating (Hot-Dip) on Iron
and Steel Hardware.

4.2 ASTM A 143 (latest revision) - Recommended Practice for Safeguarding Against
Embrittlement of Hot Dip Galvanized Structural Products and Procedure for
Detecting Embrittlement.

4.3 ASTM A 90 (latest revision) - Test Method for Weight of Coating on Zinc-
Coated (Galvanized) iron or Steel Articles. (latest revision)

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4.4 ASTM A 385 (latest revision) - Practice for Providing High Quality Zinc
Coatings (Hot-Dip).

4.5 ASTM B 6 (latest revision) - Specification for Zinc (slab Zinc).

4.6 ASTM E 376 (latest revision) - Practice for Measuring Coating Thickness by
Magnetic-Field or Eddy-Current (Electromagnetic) Test Methods. (latest
revision)

4.7 EDS-190 – Galvanized Hardware (Internal) (latest revision)

4.8 ASTM A 123 (latest revision) – Specification for Zinc (Hot-Dip Galvanized)
Coating on Iron and Steel Products.

4.9 ASTM A 780 (latest revision) – Standard Practice for Repair of Damaged and
Uncoated Areas of Hot-Dip Galvanized Coatings

4.10 IEEE STD C135.1 (latest revision) – Standard for Zinc-Coated Steel Bolts and
Nuts for Overhead Line Construction.

5.0 Requirements

The drawing or purchase order will specify the application of Type I, Type II or Type III
hot dip galvanizing as outlined in sections 5.1, 5.2 or 5.3, respectively.

5.1 Type I – ASTM A153:

ASTM A153 will apply in its entirety, except where the drawing or purchase order
contradicts, then the drawing or purchase order takes precedence.

5.2 Type II – ASTM A123:

ASTM A123 will apply in its entirety, except where the drawing or purchase order
contradicts, then the drawing or purchase order takes precedence.

5.3 Type III – ANSI C29:

5.3.1 Manufacture and Finish
The zinc used for the coating shall conform with the standard specification for
slab zinc, ASTM designation B-6 and shall be at least equivalent to "Prime
Western" grade. The zinc content of the bath during the actual galvanizing
operation shall be at least 98.5% and the aluminum content shall not exceed

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0.01%.

The parts shall be protected from processes that might permit or encourage the
development of hydrogen embrittlement. Refer to Section 5.4 of this specification
and to ASTM A143.

The zinc coating shall be free from blisters, flux, black spots, dross and
projections or other defects not consistent with good galvanizing practice, and
which will interfere with the proper use of the article. Lumps, projections,
globules, spikes and heavy deposits of zinc are also not permitted.

The cumulative area of bare spots or uncoated areas shall not be greater than
0.5% of the total surface area to be coated for the part. The largest single bare
spot or uncoated area shall have a maximum dimension less than 1 inch and an
area less than 0.25 in2. All bare spots and uncoated areas must be repaired using a
zinc-rich paint consisting of 65 to 69% zinc by weight, or greater than 92% zinc
by weight in dry film. The color shall match that of the surrounding galvanized
areas and the paint thickness shall not exceed 4 mils (0.004”).

All holes shall be clean and free from excess zinc. Marks in the zinc coating
caused by tongs or other galvanizing operations are acceptable unless such marks
have exposed the base metal. If the base metal has been exposed, then it must be
repaired using a zinc-rich paint. The color shall match that of the surrounding
galvanized areas and the paint thickness shall not exceed 4 mils (0.004”).

All hot dip galvanized pieces shall be handled so that they do not freeze together
on cooling after galvanizing.

The specification, grade or designation of the iron or steel in the articles to be

galvanized shall be supplied to the galvanizer prior to galvanizing. All relevant
information such as chemistry, heat treatment and other processing details that
affect the galvanizing process shall also be provided.

Hubbell Power Systems routinely purchases completely finished hardware from

foundries, forge shops and fabricators. In that case, it shall be the responsibility
of that vendor to provide the necessary material information to the galvanizer.

5.3.2 Weight and Uniformity of Coating

5.3.2.1 Parts Other than Threaded Fasteners and Thin Washers

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Unless otherwise noted on the individual part drawing(s), the weight of
zinc coating per square foot of surface area, as determined in accordance
with ASTM A 90 or E 376 shall have a minimum average thickness of 3.4
mils.

5.3.2.2 Threaded Fasteners

Unless otherwise noted on the individual part drawing, the weight of zinc
coating per square foot of surface area, as determined in accordance with
ASTM A 90 or E 376, shall not be less than 1.25 ounces per square foot
average of the specimens measured (equivalent to 2.12 mils thickness);
not less than 1.00 ounces per square foot (1.7 mils thickness) for any
individual specimen.

Bolts covered by this specification will usually be thread class UNC-2A

before galvanizing. After galvanizing, the maximum pitch diameter of the
bolt shall not exceed the minimum pitch diameter for the mating internal
thread as shown in table 2:

Nominal Number Internal Threads Nominal

Bolt Size of Pitch Diameter Minor Diameter Major Tap Size
threads diameter OD
per inch Min. Max. Min. Max. Min.
3/8 16 0.351 0.357 0.324 0.338 0.392 0.392-16
½ 13 0.468 0.475 0.435 0.452 0.518 0.518-13
5/8 11 0.586 0.593 0.547 0.566 0.645 0.645-11
¾ 10 0.705 0.713 0.622 0.683 0.770 0.770-10
7/8 9 0.825 0.833 0.777 0.800 0.897 0.897-9
1 8 0.943 0.952 0.889 0.914 1.024 1.024-8
1-1/4 7 1.181 1.191 1.119 1.147 1.274 1.274-7
Table 2
Note: Thread sizing after galvanizing is not permitted.

5.3.2.3 Washers Under 3/16" Thick

Unless otherwise noted on the individual part drawing, the weight of zinc
coating per square foot of surface area, as determined in accordance with
ASTM A 90 or E 376, shall not be less than 1.00 ounces per square foot,
average of the specimens measured (equivalent to 1.7 mils thickness); not
less than 0.85 ounces per square foot (1.4 mils thickness) for any
individual specimen.

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5.3.3 Adherence of Coating

The zinc coating shall adhere tenaciously to the surface of the base metal. When
the coating is cut or bruised, or when the base metal is deformed, there shall be
only superficial distortion and it shall not be possible to peel any portion of the
coating so as to expose the base metal. The adhesion is determined by cutting or
prying with the point of a stout knife, applied with considerable pressure in a
manner tending to remove a portion of the coating. The adhesion shall be
considered inadequate if the coating flakes off in the form of a layer of the
coating so as to expose the base metal in advance of the knifepoint. This
adhesion test is not carried out at edges or corners of the part and removal of
small particles of the coating by paring or whittling does not constitute failure.

The pivoted hammer test as defined in ASTM A123 may be used as an alternative
to determine the adhesion of the zinc coating on products fabricated from angles
or plates at least 5/16 inch thick. This test is applicable to flat surfaces only and
shall not be used on round or curved surfaces.

5.3.4 Cleaning/Protection from Embrittlement

5.3.4.1 Non-Heat Treated Fittings (Steel)

These parts may be either forged or machined. These parts are identified
as having a maximum Brinell hardness of 170. For initial cleaning or
salvage purposes, these parts may be pickled or shot blasted and
galvanized with no special treatment required.

5.3.4.2 Steel Fittings, Hardened

Forged steel fittings receive hardening operations and may have all or
some of the part with a hardness approaching 30 Rc. These parts may be
pickled in preparation for galvanizing provided that starting within two
(2) hours after the pickling operation the parts receive a hydrogen release
thermal treatment of 375F to 400F for four (4) hours. Following this
treatment, the parts may be galvanized.

If such parts are blast cleaned prior to galvanizing, the hydrogen release
thermal treatment is not required. The treatment is required, however, in

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the event that such parts are salvaged and pickled prior to re-galvanizing.

A flash pickle (3 minute maximum) is permissible to remove residue from

shot blasting, and shall not require the hydrogen bake-out procedure.

The hydrogen release treatment is required if pickling is used prior to

galvanizing of bolts rated SAE Grade 5 or Grade 8.

5.3.4.3 Malleable/Ductile Castings

These parts may be pickled or shot blasted to clean prior to galvanizing

without a hydrogen release treatment. Castings normally require shot
blasting to remove sand and other adherent surface contaminants prior to
pickling.

5.4 Rework of Galvanized Product

If parts fail to meet any requirements of this standard and they are to be
reworked, they must be completely stripped.

5.5 Packaging and Shipment

Wet or damp parts should not be tightly sealed nor shipped in unseasoned wood
containers.

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6.0 Authorization

This Specification must be approved by the following personnel:

_________________________
R. A. Bernstorf
Principal Engineer - Insulators

_________________________
W. D. Kirk
Principal Engineer – Construction Products

_________________________
C. A. Andrews
Senior Sourcing Engineering

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