see mast testing method

2. Sr No. Description Page No.
1. Types of Tests 03
2. Chemical Test 04-05
3. Mechanical Test 06-10
4. Ultrasonic Test 11-13
5. Retests 14-19
6. Galvanizing Tests 20-28

3. (1) CHEMICAL TEST
(2) MECHANICAL TEST
(a) Tensile Test
(b) Impact Test
(c) Temperature Test
(3) ULTRASONIC TEST
(4) RETESTS
(5)GALVANAZATION TEST

6. (a) Test Temperature:-
* Tensile tests shall be carried out in the temperature
range 10 °C to 35 °C. Impact tests shall be carried out at
the temperatures specified for non-alloy steels and for
fine grain steels.
(b)Tensile Test:-
* The test is carried out at ambient temperature
between 10 °C to 35 °C , unless otherwise specified.
test carried out under controlled condition shall be
made at a temperature of 23 °C ± 5 °C .

7. (c) Impact tests :-
The impact the following requirements shall apply:
(I)The average value of a set of three test pieces shall be equal
to or greater than the specified value. One individual value
may be below the specified value, provided that it is not
less than 70 % of that value.
(II)If the conditions under (a) are not satisfied then an
additional set of three test pieces may be taken, at the
discretion of the manufacturer, from the same sample and
tested. To consider the test unit as conforming after testing
the second set, the following conditions shall all be satisfied
simultaneously:
(II) (a) The average value of the six tests shall be equal to or
greater than the minimum specified value.*

8. (b) Not more than two of the six individual values may
be lower than the minimum specified value;
(c) Not more than one of the six individual values may be
lower than 70% of the minimum specified value.
(III) If these conditions are not satisfied, the sample
product is rejected and retests.

11. The method used is based on the reflection of ultrasonic
waves (generally longitudinally),the
direction of which is approximately perpendicular to the
surface of the product .
Procedure for testing :-
* Ultrasonic testing shall be performed in accordance with
written procedure ,Where specified in this enquiry or
order , the written procedure shall be submitted to the
purchaser for approval prior for testing.
This written procedure shall be in form of :-

12. (a) a product specification or ;
(b) a procedure written specially for the application;
The procedure shall contain minimum requirement;
(a) description of item to be examined;
(b) reference document;
(c) qualification and certification of examination
personnel ;
(d) stage of manufacture at which the examination is
carried out ;
(e) examination zone specified in terms of applicable
quality classes;

13. (f) any special preparation of scanning surface , if
applicable;
(g) couplant;
(h) description of examination equipments;
(i) recording level;
(j) characterization of discontinuities;
(k) calibration ;
(l) recording level;
(m) acceptance criteria;
(n) examination report;

14. General:-
Where one or more tests given unsatisfactory results the
manufacturer may either withdraw the test unit require
re-tests in accordance with following method:-
(a) Non- sequential tests :-
Where the unsatisfactory results comes from tests for
which no average , but only individual values are
specified the following shall be carried out.

15. * The test unit is single piece.
Two new tests of the same type as the one giving
unsatisfactory result shall be carried out . both new tests
shall give satisfactory results . If not , product shall be
rejected .
* The test unit is more then one piece the manufacturer
may at his discretion , retain in the test unit the sample
product from which the unsatisfactory test result has
been obtained.
(b) Sequential test :-
The impact the following requirements shall apply:
(I)The average value of a set of three test pieces shall be
equal to or greater than the specified value. One
individual value may be below the specified value,
provided that it is not less than 70 % of that value.

16. (II)If the conditions under (a) are not satisfied then an
additional set of three test pieces may be taken, at the
discretion of the manufacturer, from the same sample
and tested. To consider the test unit as conforming
after testing the second set, the following conditions
shall all be satisfied simultaneously:
(II) (a)The average value of the six tests shall be
equal to or greater than the minimum specified
value.*
(b) Not more than two of the six individual values may
be lower than the minimum specified value;

17. (c)Not more than one of the six individual values may
be lower than 70% of the minimum specified value.
(III) If these conditions are not satisfied, the sample
product is rejected and retests.

20. (A) TYPE TESTS
(1) Visual Inspection
(2) Adhesion of coating
(3) Uniformity of coating
(4) Mass of zinc coating

21. (B) ACCEPTANCE TESTS
(1) Visual Inspection
(2) Adhesion of coating
(3) Uniformity of coating
(4) Mass of zinc coating
(C) ROUTINE TESTS
(1) Visual Inspection

22. (1). VISUAL INSPECTION : -
The material shall be inspected visually to observe that it
is smooth, reasonably bright, continuous and free from
such imperfections a flux/ash/dross inclusions, bare
patches, black spots, pimples, lumpiness runs, rust stains,
bulky white deposits and blisters. The stains of flux,
usually white in color, shall not be regarded as flux
intrusions.

23. (2).ADHESION OF GALVANISED
COATING :-
Coating shall withstand the knife tests as prescribed in IS :
2629-1966.when cut or pried into, such as with a stout knife
applied with considerable pressure , in a manner tending to
remove a portion of the coating , it shall only be possible to
remove small particles of the coating ; and it shall not be
possible to peel any portion of the coating so as to expose
iron or steel underneath.

24. (3). UNIFORMITY OF GALVANISED
COATING :-
On small articles, which can be conveniently handled the
uniformity of the coating shall be determined by Preece
Test in accordance with IS : 2633-1966 by dipping the
whole article in the copper sulphate solution. For tubes,
100 mm long piece shall be cut from each end of the
product, after discarding 300 mm length from the end. The
article shall withstand 5 dips of one minute each.

25. (4). MASS OF GALVANISED COATING :-
(a)Mass before and after galvanizing :-
The mass of coating may be determined by weighing the
article before and after galvanizing , subtracting the first
mass from the second and dividing the result by the
coated surface area. The first mass shall be determined
after pickling, rinsing and drying; and the second after
cooling to the ambient temperature.

26. (b) Stripping method :-
 Average mass of coating shall be determined by stripping
the entire article in accordance with IS : 6745-1972 . If the
surface area of the entire article cannot be measured easily
or if the article is inconveniently large , a specimen of 100
sq. cm. area may be cut from each of the three samples ( 90
cm long test piece in case of masts) and stripped.
M = (M1-M2 ) X10^6
A
M = mass of zinc coating, in g/m2, of surface.
M1 = original mass, in g, of test piece.
M2 = mass in g, of stripped test piece, and
A = coated area of the test piece, in mm2.

27. (c) Magnetic thickness gauge method :-
 For large products such as poles, towers, structural shapes
and castings the average weight of the coating shall be
determined by a magnetic thickness gauge.
 Before making the measurement the gauge shall be
calibrated by measuring the thickness of zinc coating on a
test panel and comparing the measured value with the
value obtained by stripping method on the same piece.

28.  In case of masts etc. readings shall be taken along the
length at 100 mm interval and in approximate centre of
the flange and then averaged to give a single figure for
thickness of coating.
 For castings etc. at least 5 readings may be taken at
convenient locations nearly in the centre.
 Thickness, in micro-meters, when multiplied by 7.047
would give the average mass of zinc coating (g/m2).
Three articles in each lot of up to 100 shall be tested in
this manner. Thickness shall not be less than the
minimum.
value specified in Clause 4.1. [i.e 1000 g/m2]

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