ISO 2063-1:2019

Overview

ISO 2063-1:2019 - Thermal spraying - Zinc, aluminium and their alloys - Part 1: Design considerations and quality requirements for corrosion protection systems - defines design, planning and quality requirements for protecting iron and steel surfaces by thermal-sprayed metallic coatings of zinc, aluminium or their alloys. It targets designers and engineers who specify corrosion protection systems where thermal spraying is the chosen deposition method. The standard covers coating characteristics (e.g. coating thickness, adhesive strength, surface appearance), test procedures and environmental performance in the temperature range −50 °C to +200 °C. Heat‑resistant aluminium coatings (ISO 17834) and other processes (hot-dip galvanizing, sherardizing, electroplating or solely organic coatings) are outside its scope. Execution and manufacturing requirements are addressed in ISO 2063-2.

Key topics and technical requirements

• Design and planning: Guidance for selecting thermal-sprayed corrosion protection as part of the overall corrosion protection system and for constructive design of components to facilitate durable coatings.
• Corrosion behaviour: Descriptions of how zinc, aluminium and their alloys perform in different corrosivity categories and exposure conditions (see Annex A/B).
• Coating characteristics and tests:
  • Coating thickness requirements and recommended values (see Annex C).
  • Minimum adhesive/tensile strength and test methods (references to ISO 14916, ISO 4624).
  • Visual inspection and appearance criteria.
  • Metallographic investigation and measurement methods (e.g. ISO 1463, ISO 2178).
• Surface preparation and pre-conditions: Requirements for substrate cleanliness and reference areas prior to spraying (linked to ISO 8501-series).
• Manufacturing interfaces: Recommendations for welding with thermal-sprayed coatings, treatment of fastenings, sealing and use of organic topcoats (duplex systems).
• Documentation and certification: Test certificates, manufacturer requirements and checklists (Annexes E–G).

Practical applications and who uses this standard

ISO 2063-1:2019 is used by:

• Structural and corrosion protection designers specifying durable metallic coatings
• Fabricators and contractors planning on-site or workshop thermal spraying
• Inspection and quality assurance personnel conducting coating tests and acceptance
• Asset owners in construction, bridgeworks, water infrastructure, onshore/offshore wind, oil & gas, and heavy industry needing repair/rework or spot protection

Practical benefits:

• Ensures consistent specification of thermal-sprayed zinc/aluminium coatings
• Improves long-term corrosion performance through design-aligned coatings
• Facilitates reliable testing and acceptance criteria for projects

Related standards

• ISO 2063-2 (execution/manufacturing)
• ISO 17834 (heat‑resistant aluminium coatings - out of scope)
• ISO 14917, ISO 14923, ISO 1463, ISO 2178, ISO 4624, ISO 14916, ISO 8501-series, ISO 12671, ISO 14232-1, EN 10163 series

ISO 2063-1:2019 is a practical specification for integrating thermal spraying, zinc coatings, and aluminium coatings into robust corrosion protection systems for steel infrastructure.