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भारतीय मानक IS 13238 : 2021

Indian Standard

एपोक्सी आधारित जस्ता फास्फे ट प्राईमार

( दो पैक ) — विशिष्टि
( पहला पनु रीक्षण )

Epoxy Based Zinc Phosphate Primer

( Two Pack ) — Specification
( First Revision )

ICS 87.040

© BIS 2021

भारतीय मानक ब्रयू ो

B U R E A U O F I N D I A N S TA N D A R D S
मानक भवन, 9 बहादरु शाह ज़फर मार्ग, नई िदल्ली – 110002
MANAK BHAVAN, 9 BAHADUR SHAH ZAFAR MARG
NEW DELHI-110002
         www.bis.gov.in  
www.standardsbis.in

September 2021  Price Group 4

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Paints, Varnishes and Related Products Sectional Committee, CHD 20

FOREWORD
This Indian Standard (First Revision) was adopted by the Bureau of Indian Standards, after the draft finalized by
the Paints, Varnishes and Related Products Sectional Committee had been approved by the Chemical Division
Council.
This standard was first published in 1991. The paint obtained by the in two packs is used as a highly protective
anticorrosive primer on steel surfaces for providing a much higher degree of protection than conventional single
pack primer.
This revision has been taken up with a view to incorporate the maximum permissible limit of lead as lead restriction
(see 4.2). The Committee responsible for formulation of this standard observed that in general some paints like
this paint are used for household/decorative as well as for industrial applications. Taking cognizance of the fact
that lead exposure of human being, particularly children, has adverse effect on human health and also adverse
impact on environment and safety, the Committee felt the need to introduce different levels of lead restriction in
all paint standards likely to be used for household and decorative applications. It was also decided to introduce
lead restriction in some of the industrial paints, as far as possible, keeping in view, the relevance of lead restriction
with respect to application condition and service life of the paint and wherever the product corresponding to a
particular specification is of such composition that it would be easy to incorporate lead restriction without creating
any negative impact.
Though this product is intended to be used for railway coaches, diesel and electric locomotive, it is found to be
extensively used also in heavy automobiles like bus body etc. due to its good adhesion and corrosion resistance
properties. For synthetic polymer based products naturally occurred extenders/fillers are not used as a part of
the constituents. So it is technologically feasible to formulate this product with very low maximum permissible
limit of lead. Therefore, in this revision, lead restriction up to a maximum permissible limit of 90 ppm, has
been prescribed to avoid hazardous impact of lead exposure and consequent adverse impact on environment and
human health. This limit also has been prescribed keeping in view of the scope for exposure to children to the
paint once dried. Further, majority of consumers are not aware of the consequences of lead toxicity and its long
term implications to human health. Therefore, In this revision, along with lead restriction, a suitable cautionary
notice has been included in the marking clause. Reference has been given to various IS 101 (All parts) for the
requirements given in the standard.
The composition of the committee responsible for the formulation of this standard is given in Annex C.
For the purpose of deciding whether a particular requirement of this standard is complied with the final value,
observed or calculated, expressing the result of a test or analysis shall be rounded off in accordance with
IS 2 : 1960 ‘Rules for rounding off numerical values ( revised )’. The number of significant places retained in the
rounded off value should be the same as that of the specified value in this standard.
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IS 13238 : 2021

Indian Standard
EPOXY BASED ZINC PHOSPHATE PRIMER
( TWO PACK ) — SPECIFICATION
( First Revision )

1 SCOPE IS No. Title

1.1 This standard prescribes requirements and methods
of sampling and test for two pack epoxy based zinc (Part 4) Optical tests on paint films
phosphate primer, intended to be used for the protection Sec 2 : 1989 Colour (third revision)
of exterior of railway coaches, wagons and bridges.
(Part 5) Mechanical tests on paint films
1.1.1 The material is intended to be used as an Sec 2 : 1988 Flexibility and adhesion
anti-corrosive primer in epoxy/polyurethane paint (third revision)
System over adequately prepared exterior steel surfaces
(Part 6) Durability tests on paint films
of railway coaches, etc.
Sec 1 : 1988 Resistance to humidity under
2 REFERENCES conditions of condensation
(third revision)
The Indian Standards given below contain provisions
which through reference in this text, constitute Sec 2 : 1989 Keeping properties (third revision)
provision of this standard. At the time of publication, (Part 8) Tests for pigments and other solids
the editions indicated were valid. All standards are
Sec 2 : 1990 Pigments and non-volatile matter
subject to revision, and parties to agreements based
(third revision)
on this standard are encouraged to investigate the
possibility of applying the most recent editions of the Sec 5 : 1993 Lead restriction test (third revision)
standards. Sec 6 : 1993 Volume solids (third revision)
IS No. Title 170 : 1986 Acetone (third revision)
1070 : 1992 Reagent grade water (third revision)
101 Methods of sampling and test for 1303 : 1983 Glossary of terms relating to paints
paints, varnish and related products: (second revision)
(Part l) Test on liquid paints (general and 1407 : 1980 Round paint tins (second revision)
physical)
2552 : 1989 Steel drums (galvanized and
Sec 1 : 1986 Sampling (third revision) ungalvanized) (third revision)
Sec 2 : 1987 Preliminary examination and 9162 : 1979 Methods of tests for epoxy
preparation of samples for testing resins, hardners and epoxy resin
(third revision) composition for floor topping
Sec 5 : 1989 Consistency 9850 : 1981 Methyl iso butylketone
Sec 3 : 1986 Preparation of panels 10897 : 1984 Specification for Zinc Phosphate
(third revision) Pigment for Paints
Sec 6 : 1987 Flash point (third revision)
Sec 7 : 1987 Mass per 10 litre (third revision) 3 TERMINOLOGY
(Part 3) Tests on paint film formation For the purpose of this standard, the definitions given in
Sec 1 : 1986 Drying time (third revision) IS 1303 and the following shall apply.
Sec 2 : 1989 Film thickness (third revision) 3.1 Component — Each of the two parts of the paint
Sec 4 : 1987 Finish (third revision) which when mixed together, forms an epoxy based zinc
phosphate priming paint.

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IS 13238 : 2021

3.2 Paint — The mixture of the two components in the 5 PACKING AND MARKING
proportion recommended by the manufacturer.
5.1 Packing
4 REQUIREMENTS Unless otherwise agreed to between the purchaser
and the supplier, the material shall be packed in metal
4.1 Composition
containers conforming to IS 1407 and IS 2552. The
The paint shall consist essentially of two components, packing is subject to the provisions of the law in force
base and hardener to be mixed in such simple proportion in the country at that time.
preferably by volume to satisfy all the requirements of
this standard. 5.1.1 Each component as delivered shall be free of gel,
coarse particles, skins, foreign matter and sediments.
4.1.1 Bases hall consist of: Any sediment formed in the container shall be mixed
a) epoxy resin, and thoroughly preferably with power driven stirrer to form
b) a pigment. homogeneous paint.

4.1.1.1 Epoxy resin, used in the formulation of the 5.2 Marking

paint, shall have the weight per epoxy equivalent of 5.2.1 Each container shall be marked with the following:
400-600 on non-volatile vehicle content, when tested
according to 4 of IS 9162. a) Name of the material;
b) Indication of the source of manufacture;
4.1.1.2 The base shall contain a minimum of 40 percent
by mass of pigment on the mass of paint. The pigment c) Lead content (Maximum);
shall contain a minimum of 16 percent by mass of d) Volume of the material;
zinc phosphate (see IS 10897) in the total pigment e) Batch number or lot number in code or otherwise;
content apart from other pigments such as extenders, f) Month and year of manufacture; and
rust inhibitors, etc, when tested according to
IS 101 (Part 8/Sec 2) using the following extraction g) Mixing proportion recommended for use;
mixture: h) Other instructions for safe handling and use of the
material;
a) Methyl iso-butyl ketone 25 parts
(see IS 9850), or methly methyl j) Safe storage period; and
ketone, < or k) A cautionary note as below:
a mixture of both in the ratio 1 : 1, 1) Keep out of reach of children.
by volume; 2) Dried film of this paint may be harmful, if
b) Xylene 50 parts eaten or chewed.
c) Acetone (see IS 170) 25 parts 3) This product may be harmful, if swallowed or
inhaled.
4.1.2 Hardener shall be liquid type, such as an aliphatic 5.2.2 BIS Certification Marking
amine, an aliphatic or aromatic amine adduct, a
The product(s) conforming to the requirements of
polymide or amidopolyamine. It shall react with epoxy
this standard may be certified as per the conformity
resin at normal ambient temperature.
assessment schemes under the provisions of the
4.1.3 The mixture of base and hardener shall be allowed Bureau of Indian Standards Act, 2016 and the Rules
to mature for 20 min at 27 ± 2 °C. The mixture must be and Regulations framed thereunder, and the products
consumed within 4 h after mixing. may be marked with the Standard Mark.

4.2 Lead Restriction 6 SAMPLING

The material shall not contain lead or compounds of
6.1 Representative samples of the material shall be
lead or mixtures of both, as metallic lead more than
drawn as per to 6 of IS 101 (Part 1/Sec 1).
90 ppm, when tested for restriction from lead in
accordance with IS 101 (Part 8/Sec 5). 6.2 Preparation of Test Samples
4.3 The material shall also comply with the requirements 6.2.1 Apparatus
given in Table 1.

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IS 13238 : 2021

Table 1 Requirements for Epoxy Based Zinc Phosphate Primer (Two Pack)
( Clause 4.3 and 7.1 )
Sl No. Characteristic Requirement Method of Test Ref to

IS 101 Annex
(1) (2) (3) (4) (5)
i) Consistency Smooth, uniform and suitable for — A
spray application
ii) Drying time, Max, h: (Part 3/Sec 1) —
a) Surface dry 4
b) Hard dry 16
c) Hard dry, 70 °C 30 min, with 15 min flash off time
d) Curing time, Max 7 days
iii) Finish Smooth, matt and egg shell flat (Part 3/Sec 4) —
iv) Colour Off white/grey (Part 4/Sec 2) —
v) Dry film thickness per coat: Clause 6.2.2.1 —
of (Part 3/Sec 2)
a) By brushing, Min 30 microns
b) By spray 35-40 microns
vi) Volume solids, percent, Min 40 (Part 8/Sec 6) —
vii) Flexibility and adhesion:
a) Bend test (with 6.25 mm dia mandrel and type No visible damage or Clause 2 of —
1 apparatus) detachment after (Part 5/Sec 2)
b) Scratch hardness (1 500 g) No such scratch as to show Clause 3 of —
the bare metal (Part 5/Sec 2)
viii) Flash point (for each component) Not below 25 °C (Part l/Sec 6) —
ix) Resistance to humidity under condition of (Part 6/Sec 1) —
condensation and salt spray (expose for 500 h):
a) Resistance to humidity To pass the test Clause 2
b) Resistance to salt spray To pass the test Clause 3
x) Pot life, h, 27 ± 2 °C, Min 4 — B
xi) Mass, in kg/10 Iitre, Min 13.0 (Part l/Sec 7) —
xii) Keeping properties Not less than one year from (Part 6/Sec 2) —
date of manufacturing

6.2.2.1 Suitable high speed stirrer 6.2.3 Preparation of Panels for Drying Time and Dry
Film Thickness
6.2.2.2 Spray gun
Prepare mild steel panel of sizes 150 mm × 100 mm
A spray gun with adjustable nozzle aperture and air × 1.25 mm as prescribed in 2 of IS 101 (Part 1/Sec 3).
pressure suitable for spraying paints. The spray gun Apply the paint as prepared in 6.2.2 uniformly on each
shall be thoroughly cleaned before use. Correct size of
side of the panel by air spraying/by brushing to give a
nozzle and air-cap shall be fitted to it. The air pressure
dry film mass commensurate with the mass per 10 litre
shall be adjusted in accordance with the viscosity of the
material to be sprayed. as specified in Table 1 of IS 101 (Part 3/Sec 4). Prepared
test panel then subjected to the test as specified in
6.2.2 Preparation of Paints IS 101 (Part 3/Sec 1) as soon as possible.
The two component epoxy zinc phosphate primer shall 6.2.4 For Flexibility and Adhesion Test
be mixed in the ratio recommended by the manufacturer
of the paint before conducting the test or tests. During For both bend test and scratch hardness test prepare
mixing of two components in large quantities, the separate burnished tin plate panels, rectangular, of
mixing may be done using a high speed stirrer and the sizes 100 mm × 50 mm × 0.3 mm as prescribed in 3 of
rise in temperature shall not be more than 5 °C. IS 101 (Part 1/Sec 3). Apply paint as prepared in 6.2.2

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IS 13238 : 2021

uniformly by air spraying/by brushing on the panels which shall have melting point above 50 °C. Prepared
as to give a dry film mass commensurate with the test panel then subjected to the tests as prescribed in
mass per 10 litre as specified in Table 1 of IS 101 2 and 3 of IS 101 (Part 6/Sec 1).
(Part 3/Sec 4). Allow some time for the coat to dry and
measure the paint thickness by the method prescribed 6.3 Criteria for Conformity
in 6.2.2.1 of IS 101 (Part 3/Sec 2). Ensure that the 6.3.1 Drying time and film thickness shall be tested on
coating is even and uniform and thickness of coating at least two samples taken from different containers
of the paint shall be between 35 and 45 microns. The selected according to 7.1. For lot size above 1 000 kg, this
coated test panels shall be dried for 72 h and then shall be minimum 3. For the rest of the characteristics,
shall be conditioned at a temperature of 27 ± 2 °C tests shall be conducted on one composite sample
and relative humidity of 65 ± 5 percent for a period of prepared from individual samples taken from different
16 h. Prepared test panels then subjected to the test as containers in the sample.
prescribed in 2 and 3 of IS 101 (Part 5/Sec 2) for bend
test and scratch hardness test respectively. 6.3.2 There shall be no failure in respect of any
test, if the lot is to be considered conforming to the
6.2.5 Resistance to Humidity under Condition of requirements of this specification.
Condensation
Prepare mild steel panel of sizes 125 mm × 50 mm 7 TEST METHODS
× 1.25 mm as prescribed in 3 and 2 of IS 101
(Part 1/Sec 3). Apply single coat of the paint on both 7.1 Tests shall be conducted as prescribed in 4.1 to 4.2
sides of the panel uniformly by air spraying/brushing to and the test methods referred in col 4 and 5 of Table 1.
give a dry film thickness on each side 40 ± 5 microns.
7.2 Unless otherwise specified the preparation of metal
Allow to dry for 24 h at room temperature. Determine
panels shall be according to IS 101 (Part 1/Sec 3).
the thickness in micrometre, of the dry coating, by
any appropriate method but using any one of the 7.3 Quality of Reagents
non-destructive procedures as specified in IS 101
Unless specified otherwise, pure chemicals and distilled
(Part 3/Sec 2). Then protect the edges to a depth of
water (see IS 1070) shall be employed.
5 mm with a suitable protective composition [preferably
consisting of 3 parts by weight of paraffin wax (melting NOTE — ‘Pure chemicals’ shall mean chemicals that do not
contain impurities which affect the results of analysis.
point 60 °C) and 1 part by weight of carnauba wax]

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IS 13238 : 2021

ANNEX A
[ Table 1, Sl No. (i) ]
CONSISTENCY

A-1 APPARATUS the nature of settling. Mix the two components in the
proportion recommended by the manufacturer in a
A-1.1 Palette Knife or Metal Rod separate container.
A-1.2 Metal Panels A-2.2 Observations
Unless specified otherwise, steel panels of size The material shall not cake hard inside the container
150 mm × 150 mm × 1.25 mm shall be prepared as and shall be in such a condition that stirring easily
prescribed in 2 of IS 101 (Part 1/Sec 3). produces a smooth uniform paint suitable for spraying.
After mixing of the two components as in A-2.1, it
A-2 PROCEDURE shall produce a smooth uniform paint suitable for
spraying/brushing on steel panels.
A-2.1 Insert a clean metal rod or palette knife into the
original container of each component and examine

ANNEX B
[ Table 1, Sl No. (xi) ]
DETERMINATION OF POT LIFE

B-1 GENERAL NOTE — The interval may be shortened, if desired.

The time taken to reach to end of working life from the B-2.3 Near the end of the coating’s working life, the
original viscosity shall be considered as the pot life of viscosity builds up rapidly. When it appears that the
the material. coating may be too viscous to spray, remove a small
portion and add the appropriate thinner. If the paint can
B-2 PROCEDURE still be thinned, the end of the working life has not been
reached.
B-2.1 Condition the components of the coating for one
h at 27 °C and mix immediately in the proper ratio to B-2.4 The end of the working life is reached when the
fill the can to be approximately 1 cm of the top. The lid paint gels, becomes stringy or cannot be thinned for
should be loosely placed on the can. application.

B-2.2 Measure the viscosity initially and every hour B-3 REPORTING
thereafter, as prescribed in IS 101 (Part 1/Sec 5).
Report the working life as pot life of the period.

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IS 13238 : 2021

ANNEX C
( Foreword )

COMMITTEE COMPOSITION
Paints, Varnishes and Related Products Sectional Committee, CHD 20

Organization Representative(s)

HBTU, Kanpur Dr P. K. Kamani (Chairman)

Central Public Works Dept, New Delhi Shri Amar Singh
Shri M. L. Prasad (Alternate)
Directorate of Naval Architecture Nomination awaited
Ministry of Defence (DGQA) Dr R. K. Upadhyay
Shri S. P. Marthi (Alternate)
Ministry of Industry, New Delhi Shri Nand Lal
Ministry of Defence, Department of Standardization, Lt Col Praveen Deo
New Delhi Shri V. K. Chhabra (Alternate)
Office of the Micro Small & Medium Enterprises Shri Sunil Kumar Newar
(MSME), New Delhi Shri Santosh Kumar (Alternate)
Research Designs & Standards Organization, Shri P. K. Bala
Lucknow Shri K. P. Singh (Alternate)
Central Building Research Institute, Roorkee Dr Sukhdeo R. Karade
Dr P. C. Thapliyal (Alternate)
Harcourt Butler Technical University, Kanpur Dr P. K. Kamani
Dr Arun Maithani (Alternate)
Institute of Chem Technology, Mumbai Dr Prakash Anna Mahanwar
Dr V. V. Shertukade (Alternate)
Indian Institute of Technology, Mumbai Prof Smrutiranjan Parida
National Test House (ER), Kolkata Shrimati P. Natarajan
Dr A. B. Mondal (Alternate)
Naval Materials Research Laboratory (NMRL), Dr T. K. Mahato
Thane Dr G. Gunasekaran (Alternate)
Shriram Institute for Indl Research, Delhi Shri A. K. Majumdar
The Shipping Corporation of India Ltd, Mumbai Shri R. Sood
Shri N. K. Tripathi (Alternate)
SSPC India Chapter, Kolkata Dr Buddhadeb Duari
Shri Anil Singh (Alternate)
Akzo Nobel Coatings India Pvt Ltd Mr Sanatan Hajra
Asian Paints Ltd, Mumbai Mr Rajeev Kumar Goel
Dr Subrahmanya Shreepathi (Alternate)
Berger Paints India Ltd, Howrah Shri Tapan Kumar Dhar
Shri Swagata Chakroborty (Alternate)
J K White Cement Shri Rana Pratap Singh
Dr Priti Pillay (Alternate)
Kansai Nerolac Paints Ltd, Mumbai Fresh Nomination Awaited
Meta-Chem Paints & Adhesives Pvt Ltd Shri Biswanath Panja
Shri Hemant Kulkarni (Alternate)

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IS 13238 : 2021

Organization Representative(s)

Pidilite Indusries Ltd, Mumbai Shri Tapas Kumar Ray

Dr Pradeep T. Gadekar (Alternate)
Indian Paints Association, Kolkata Shri Subroto Banerjee
Dr M. B. Guha (Alternate)
Indian Small Scale Paint Association Shri Mukund Hulvalkar
Shri Ashok-Shreyas Pathare (Alternate I)
Shri Nirav Raveshia (Alternate II)
Paint and Coating Technologists Association, Kanpur Mr Ushendra Singh
Mr Vivek Kumar Saxena (Alternate)
Bharat Heavy Electricals Ltd, Tiruchirapalli Shri K. Srinivasan
Shri V. Rajeshkharan (Alternate)
Engineers India Limited, New Delhi Shri S. Ghoshal
Shri A. Satya Sridhar (Alternate)
Premium Coatings & Chemicals Shri V. N. Dubey
Shalimar Paints Ltd, Kolkata Shri Konkar Muthu
Society of Indian Automobile Manufacturers (SIAM) Nominated Awaited
VOICE Shri M. A. U. Khan
In Personal Capacity Dr Sunil Kumar Saha
In Personal Capacity Dr B. P. Mallik
BIS Director General A. K. Lal Scientist ‘E’ and Head (CHD)
[ Representing Director General ( Ex-officio ) ]

Member Secretary
Pushpendra Kumar
Scientist ‘B’ (CHD), BIS

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BIS is a statutory institution established under the Bureau of Indian Standards Act, 2016 to promote harmonious
development of the activities of standardization, marking and quality certification of goods and attending to
connected matters in the country.

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the prior permission in writing of BIS. This does not preclude the free use, in the course of implementing the
standard, of necessary details, such as symbols and sizes, type or grade designations. Enquiries relating to
copyright be addressed to the Director (Publications), BIS.

Review of Indian Standards

Amendments are issued to standards as the need arises on the basis of comments. Standards are also reviewed
periodically; a standard along with amendments is reaffirmed when such review indicates that no changes are
needed; if the review indicates that changes are needed, it is taken up for revision. Users of Indian Standards
should ascertain that they are in possession of the latest amendments or edition by referring to the latest issue of
‘BIS Catalogue’ and ‘Standards: Monthly Additions’.
This Indian Standard has been developed from Doc No.: CHD 20 (16070).

Amendments Issued Since Publication

Amend No. Date of Issue Text Affected

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