QSTC2012

QUALISTEELCOAT version 2.0 January 2012

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QUALISTEELCOAT

Technical Specifications

Version 2.0


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QUALISTEELCOAT Technical Specifications The objective is to establish an internationally recognized quality label for liquid and powder coating of steel-based material.

Chapter 1 General information!.................................................................................................!3!Chapter 2 Test methods!..............................................................................................................!5!Chapter 3 Surface preparation (EN ISO 12944-4)!..............................................................!9!Chapter 4 Coating systems!.....................................................................................................!10!Chapter 5 Application of coatings!........................................................................................!11!Chapter 6 Applicators in-house control!.............................................................................!13!Chapter 7 Approval of coating systems!............................................................................!14!Chapter 8 Licence for coating applicators!........................................................................!15! Appendixes Appendix 1-a Corrosivity category!.....................................................................................................!16!Appendix 2-a Mechanical test and results!.......................................................................................!17!Appendix 2-b Chemical test methods and results!........................................................................!22!Appendix 3-a Information on substrates!..........................................................................................!30!Appendix 3-b Removal of contamination!.........................................................................................!35!Appendix 3-c Surface pre-treatment!..................................................................................................!37!Appendix 4-a Liquid coating systems!...............................................................................................!41!Appendix 4-b Powder coating systems!............................................................................................!47!Appendix 5-a Application of liquid coatings!...................................................................................!51!Appendix 5-b Application of powder coatings!...............................................................................!53!Appendix 6-a In-house control for chemical surface preparation!.........................................!55!Appendix 6-b In-house control for blasting surface preparation!...........................................!59!Appendix 6-c In-house control for powder coating applicators!.............................................!63!Appendix 6-d In-house control for liquid coating applicators!.................................................!69!Appendix 7-a Approval of powder coating systems!....................................................................!74!Appendix 7-b Approval of liquid coating systems!.......................................................................!77!Appendix 8-a Issuing a QUALISTEELCOAT licence!....................................................................!80!Appendix 9-a Table RAL/DELTA E (adm. colour deviation after weathering in Fl.)!........!83!Appendix 10-a Specification of the standards!...............................................................................!84!


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Chapter 1 General information QUALISTEELCOATs objective is to establish rules for coating applicators applying protective coating on steel for new works executed in shops. TERMINOLOGY Licence: Permission for a coating applicator to use the

QUALISTEELCOAT quality label. Approval: Confirmation that a specific coating system meets the

requirements of the Specifications. General Licensee (GL): National association holding the QUALISTEELCOAT Master

Licence for the whole country in question. Testing laboratories: Independent quality testing laboratories duly approved by the

general licensee and/ or QUALISTEELCOAT. The technical specifications are based on atmospheric corrosivity categories in accordance with EN ISO 12944-2. In general EN ISO 12944 1 to 8 only apply to conventional solvent-borne coatings. To supplement these standards, the QUALISTEELCOAT specification also applies to powder coating systems. These systems durability data are collected in a table similar to the EN ISO 12944-5 solvent-containing coating systems table.

These standards provide the specifications of the quality level with which coating application firms must comply in order to be granted a QUALISTEELCOAT certificate.

At least twice a year, inspections will be carried out by a QUALISTEELCOAT Inspector to evaluate the licensees sustained compliance with the required quality levels.

The specifications laid down in this document concern:

1. the different processes used for steel protection;

2. in-house control by the coating applicators in connection to 1;

3. the performance of applied coating systems in relation to Corrosivity categories;

4. Inspection of licensees.

The regulations laid down in this document give the minimum requirements which the licensees, their finished coated products, as well as the applied coating materials have to meet. The QUALISTEELCOAT coating licences are divided into two categories:

interior use only (C-1 and 2 interior), called INTERIOR licence interior/exterior use (C-1, 2, 3, 4 and 5), called EXTERIOR QUALISTEELCOAT

licence. The exact definitions of the Corrosivity Categories are given in ISO EN 12944- 2. The atmospheric corrosivity categories applicable to QUALISTEELCOATs standards are given in appendix 1.


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QUALISTEELCOAT Interior Licence C 1/2 (I): The parts are briefly exposed to temperature changes or humid atmosphere. Such pre-treated parts are mostly used indoors. The applicable control level, based on which test samples are taken, is C-2 medium.

QUALISTEELCOAT Exterior Licence C1, C2, 3, 4 and 5 (E): (also including interior)

The parts have undergone extensive chemical pre-treatment, allowing exposure to slightly and severely corrosive and humid atmosphere for a prolonged period. Alternatively, the substrate is grit blasted after galvanizing, or blasted and zinc/aluminium sprayed. The pre-treated surface is coated with organic coating as specified in this document. The applicable control level and test samples are based on compliance with the Corrosivity Category specified in the applicators production documents.

Tests will be carried out in accordance with these specifications. Tests supplementary to those laid down in these specifications must be agreed between the QUALISTEELCOAT licensee and its customers. QUALISTEELCOAT members production processes must be proven reliable, in accordance with the stipulated minimum requirements. The members are obliged to comply with QUALISTEELCOATs specifications and any additional specifications provided by the customer. If the system has not been approved previously by QUALISTEELCOAT this must be clearly stated on the production forms for the benefit of the QUALISTEELCOAT inspector. The system applied must be suitable for the corrosivity category stated on the production sheet. Production samples may be tested for corrosivity category compliance by the QUALISTEELCOAT inspector.


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Chapter 2 Test methods Expected Performance The durability of the coating system depends on the surface pre-treatment and the composition of the coating system. The purchase order must, therefore, provide relevant information as to the corrosivity category of the environment where the coated object will be used. Reference is made to appendix 1. In order to maintain optimal performance of the paint systems applied by the QUALISTEELCOAT licensed coating applicators, the quality of the coating supplied by coating manufacturers is tested. In this part of the specification the test methods and acceptable test result limits are given. Some of the test methods described hereafter are used for in-house control of the finished products by the licensed QUALISTEELCOAT coating applicator, some are used for the approval of the coating systems by QUALISTEELCOAT, and some are optional tests. Appendixes 2-a for mechanical and 2-b for chemical tests contain information about the methods and the acceptable test results for coating systems. The samples must be taken from production. Should this not be possible, test panels must comply with EN ISO 1514. A separate list of the standards used in these specifications and the year(s) of validation is given in appendix 10.

2.1 Test panels In order to assess the characteristics of coating materials, they are tested on metal test panels in accordance with EN ISO 1514. Test panels must be made of the same metal as the substrate used in the system. Testing of coating systems is executed on the test panels mentioned in the test standards. The natural and the accelerated weathering test can be conducted on aluminium AlMg1. The coating system applied to the test panel shall show no scratches penetrating as far as the substrate. When a coated test panel is examined, no blisters, craters, pinholes or scratches shall be visible from a distance of 1 meter in diffuse light.

2.2 Mechanical tests (appendix 2-a)

2.2.1 Adhesion (2-a-1) The following methods are used to determine the adhesion of the coating system to the substrate and the expected results:

EN ISO 16276-2 Cross-cut, X-cut and pull-off test method

EN ISO 2409 Cross-cut test equipment and results

2.2.2 Determination of chip resistance by falling hexagonal nuts (2-a-2) cancelled


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2.2.3 Impact resistance test (2-a-3) EN ISO 6272-1 describes a method for assessing the resistance of a dry film of paint, coating material or related product to cracking or peeling from a substrate when it is subjected to deformation caused by a falling weight, using a 20 mm diameter spherical indenter dropped under standard conditions.

2.2.4 Resistance to scratching (2-a-4) The objective of this test is to determine the resistance of the coating system to scratching (EN ISO 1518).

2.2.5 Determination of surface hardness (2-a-5) The objective of this test is to determine the resistance of the coating system to scratching. The method is described in ISO 15184 - determination of surface hardness by means of pencils.

2.2.6 Determination of particle size distribution (2-a-6) The objective of the test is to determine the mixture and size of the blast grit or shot particles used for surface preparation (EN ISO 11125-2 and EN ISO 11127-2).

2.2.7 Determination of surface roughness (2-a-7) The objective of this measurement is to determine the roughness of the substrate after blasting, prior to application of the first primer.

2.2.8 Determination of wet film thickness (2-a-8) The wet film thickness of the coating has to be monitored during the application. The method of determining the wet film thickness has been specified.

2.2.9 Determination of dry film thickness (2-a-9) The dry film thickness of the individual coats in the system and the total dry film thickness must be measured.


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2.3 Chemical and environment tests (appendix 2-b)

2.3.1 Polymerisation test (2-b-1) The purpose of this test is to determine the polymerization for powder and liquid coating systems. Before testing the liquid coating system must be cured for four hours at a temperature of 60 oC.

2.3.2 Resistance to mortar (2-b-2) This test is used to assess the resistance of the coating system to fresh mortar.

2.3.3 Boiling test (permeability) (2-b-3) This test is used to determine the adhesion properties of the coating system.

2.3.4 Neutral salt spray test (2-b-4) The purpose of this test is to determine the corrosion resistance of the coating system. For the corrosive categories the test results will give an indication of the durability of the coating system. The test is similar for coated hot dip galvanized steel. Test procedures are given for liquid coating material systems and powder coating material systems.

2.3.5 Resistance to continuous condensation (2-b-5) This test is used to determine the adhesion of the coating system during prolonged periods of high humidity (EN ISO 6270).

2.3.6 Chemical resistance test (2-b-6) The objective of his test is to assess the chemical resistance of the coating system. The chemicals used are 10 % NaOH, 10 % H2SO4, and mineral spirits containing 18 % aromatics. (EN ISO 12944-6, test EN ISO 2812-1).

2.3.7 Resistance to humid atmosphere containing sulphur dioxide test (2-b-7) The objective of this test is to determine the resistance to heavily polluted atmospheres. The coated surface is exposed to SO2 in a test cabinet (EN ISO 12944-6, test EN ISO 3231).

2.3.8 Accelerated weathering test (2-b-8) This test is used to determine the resistance to discoloration and loss of gloss during use outdoors. This is a laboratory test and can only be used to give an indication of the durability outside. Aluminium and steel panels may not be tested in the same batch.

2.3.9 Natural weathering (2-b-9)

This test is conducted to determine the outdoor resistance of the coating system to weathering as a result of solar radiation. The test is executed by exposing the coating materials in Florida.


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2.3.10 Colour difference (2-b-10) The nuances in colour between charges and coated parts may not differ beyond certain levels. The objective is to determine the nuances in colour.

2.3.11 Gloss difference (2-b-11) The difference in gloss level of the coated material must remain within the given tolerance levels. Gloss is also used to determine the polymerization of glossy powder coatings.

2.3.12 Determination of etching degree (2-b-12) The objective is to determine the loss of zinc during surface preparation by etching. This is determined by measuring the film thickness before and after etching.

2.3.13 Assessment of the conversion coating (2-b-13) The objective is to determine the quality of the conversion coating by means of visual assessment of the layer. Twice a year the actual thickness must be measured jointly with the chemicals supplier.

2.3.14 Determination of the conductivity of dripping water (2-b-14) The purpose is to determine the result of the final rinse by demineralised water.


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Chapter 3 Surface preparation (EN ISO 12944-4)

3.1 Information on substrates To ensure the surface preparation will be performed in accordance with requirement, detailed information of the material to be treated is necessary. In appendix 3-a information is given about different substrates, the special treatment required and points of particular interest as regards pre-treatment. When ordering a protective coating system it is advisable to read the instructions given in this appendix and to carefully follow the advice.

3.2 Storage of parts to be treated The parts to be treated are stored in a room separated from production, or at sufficient distance from the pre-treatment devices. The parts are to be protected against condensation and dirt.

3.3 Removal of contamination Before the substrate is fit for surface preparation and the application of a coating system, any old coating and surface contamination has to be removed. Any surface contamination must be removed from the surface, paying special attention to non-standard products like protective oils, markings, salt, dirt and burned production residue. This is necessary to improve the effectiveness of chemical and mechanical treatment, to prevent unnecessary pollution of pre-treatment baths and to prevent the sheer of marking through the coating system. This also involves the removal of signs and stickers from the substrate. These activities may result in additional work if not mentioned in the tendering procedure. More information is given in appendix 3-b: Removal of Contamination.

3.4 Pre-treatment for powder and liquid coating systems The parts are handled in the plant - the reliability of the process having been ascertained. The existing facilities for pre-treatment serve as the standard. Any external treatment, like chemical treatment or blasting, is excluded with the exception of hot dip galvanizing and electro galvanizing. The purpose of the pre-treatment is to prepare the substrate for application of the protective system. Different methods are used to serve different purposes. This may vary from removing mill scale or corrosion from the substrate, to roughening the substrate to improve adhesion of the protective system. All contamination must be removed prior to the pre-treatment of the substrate. More information can be found in appendix 3-c.


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Chapter 4 Coating systems

4.1 Coating systems in different environments Depending on the environment where the coated object is used, different coating systems are defined. Solvent-containing coating systems are listed in EN ISO 12944-5. In appendix 4-a the most recent solvent-based coating systems are defined, including their durability properties in different environments. Examples of coating systems are given in appendix 4-a: Liquid Coating Systems. Powder coating systems are not included in EN ISO 12944-5. In appendix 4-b coating systems based on powder coating are listed, including the durability properties in various corrosivity categories. The systems are based on first coats of galvanized zinc, zinc-spayed and zinc powder containing epoxy powder coatings, and electro deposition coatings. Depending on the environment, additional layers of powder coating are applied. Examples of powder coating systems are given in appendix 4-b. In addition to the corrosivity categories defined in EN ISO 12944-2, local environment is very important. An outdoors environment in which no natural rain will clean the surface is most demanding. In such a case, coating systems from a corrosivity category, one full level higher than would be chosen under normal circumstances, is recommended. It is also recommended to carefully clean the coated substrate at intervals as mentioned in the following table:

Frequency of cleaning using hot water (60C*a)) and high pressure*b)

Corrosivity category C2 - C3 C4 - C5

Rain washed surfaces Once a year 1 - 2 times a year Surfaces not rain-washed naturally 1 - 2 times a year Twice a year Frequency of cleaning using cold water and low pressure

Corrosivity category C2 - C3 C4 - C5

Rain washed surfaces Once a year Twice a year Surfaces not rain-washed naturally 2 - 3 times a year 3 - 4 times a year

*a) The temperature of the cleaning water at the moment of impact must be

approx. 60 C. Take care not to use water at a temperature above 80 C. *b) The high pressure of the water used for cleaning the coated areas must be approx.

4 Bar. The spraying of the surface must be carried out carefully. Openings and rubbers in a facade must be avoided.


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Chapter 5 Application of coatings

5.1 Liquid coating

5.1.1 Testing the coatability of objects (5-a-1) Objects containing various metals are to be pre-tested. Pre-treatment requires extra attention, to prevent making premature decisions on the use of pre-treatment products like chemicals and blast grit. Careful processing is required to avoid split or pockets in which non-removable pre-treatment residue could cause damage, corrosion or insufficient adhesion. If there is any doubt about the suitability of the object for a certain coating system, it is necessary to discuss this problem with the coating applicator beforehand.

5.1.2 Coating application and curing (5-a-2) After surface pre-treatment the coating system must be applied. The substrate must be clean and dry before application. One or more coats must be applied and the coats must be cured or pre-cured depending on the system. Additional information is given in appendix 5-a: Application and Curing of Coatings.

5.1.3 Drying procedure (5-a-3) The coating must be left to dry in a clean environment and at a temperature sufficient for drying and hardening. When more coats have to be applied sufficient time must be left between the application of coating layers.

5.1.4 Storage of coating material (5-a-4) The storage of coating materials must comply with the applicable safety requirements. Only the coating used during the application and the additional solvent may be present in the coating application area.

5.1.5 Storage of coated material (5-a-5) The coated material must be professionally stored to avoid damage and dirt collection on the coated surfaces.

5.2 Powder coating

5.2.1 Testing the coatability of objects (5-b-1) Objects containing various metals are to be pre-tested. The pre-treatment requires extra care, to prevent making premature decisions on the use of pre-treatment products like chemicals and blast grit. Careful processing is required to avoid split or pockets in which non-removable pre-treatment residue could cause damage, corrosion or insufficient adhesion. If there is any doubt about the suitability of the object for a certain coating system, it is necessary to discuss this problem with the coating applicator before starting the operation.


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5.2.2.Oven drying (5-b-2) After chemical surface pre-treatment, the substrate must be dried prior to applying the coating system.

5.2.3 Application of powder coating (5-b-3) After surface pre-treatment the coating system must be applied. The substrate must be clean prior to application. One or more layers must be applied and the different layers must be cured or pre-cured depending on the system.

5.2.4 Curing the powder coating (5-b-4) After application the coating must be cured. The objects must be placed in an oven. Care must be taken as regards the temperature of the substrate. The coating applicator must check whether the curing temperature suffices.

5.2.5 Storage of coating material (5-b-5) The storage of coating materials must comply with the applicable safety requirements. Coating materials must be stored in a dry atmosphere and free of contamination.

5.2.6 Storage of coated material (5-b-6) The coated products must be stored in a dry area and packed in accordance with the instructions.


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Chapter 6 Applicators in-house control The applicator is obliged to have a quality control system in place in the production facilities. In order to become a QUALISTEELCOAT licensed company, dedicated quality control is imposed on the applicator to ensure the quality of his product. In-house control is vital for being granted a QUALISTEELCOAT licence.

6.1 In-house control pre-treatment and application The applicator certified for Interior must have a dedicated space for testing the results of the companys coating activities. Applicators certified for Exterior must have a laboratory separated from the production facilities. The laboratory must be equipped for the purpose of assessing the quality of the production method used. For applicators using chemical baths this means that the contents of baths (solutions) as well as the finished products must be tested and verified. In appendix 6-a, the requirements applicable to applicators using chemical pre-treatment are given. In appendix 6-b, the requirements applicable to applicators using abrasive blasting are given. Companies using a combination of blasting and chemical passivation must conduct the combined test. In appendix 6-c, the requirements for in-house control related to companies using powder application are given. In appendix 6-d, the requirements for in-house control related to companies applying liquid coatings are given.


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Chapter 7 Approval of coating systems A system is defined by:

type of surface pre-treatment;

number of layers;

minimal dry film thickness per layer;

coating products for primer, midcoat and topcoat;

application method.

In appendix 4-b, examples of powder coating systems are given. In appendix 4-a, examples of liquid coating systems are given in accordance with ISO EN 12944-5. The coating systems used by QUALISTEELCOAT approved licensees must be approved by 1st January 2012. To have a coating system approved, an EN ISO 17025 accredited laboratory recognised by QUALISTEELCOAT must be requested to test the system. The test panels will be prepared by the laboratory. Technical data sheets and safety data sheets must be provided for all the coatings in the system. The systems are accepted in accordance with the corrosivity category stipulated by the applicant. If the application for approval of a coating system applies to corrosivity category 1 then the approval will only apply to category 1. If the application is for example for corrositivity category 3 - high durability - then the approval is given for corrosivity categories 1, 2 and 3 - high durability, as well as 4 - medium durability. In appendix 2-a, and 2-b, the test methods and required results are given. In appendix 7-a, and 7-b, further information is given as regards the approval of coating systems. Certain test results from approved laboratories, collected to obtain other quality labels, may be used as test results for QUALISTEELCOAT. This only applies to artificial weathering and outdoor exposure tests. A visit by the general licensee - or by QUALISTEELCOAT in countries without a national association - may be required. The costs of such a visit will be paid by the applicant.


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Chapter 8 Licence for coating applicators Any coating applicator working in the field of QUALISTEELCOAT can apply for a licence. In order to obtain a licence the procedure will be followed: One inspection must be satisfactory before a licence is granted. This inspection will be made at the coating applicators request. The inspection will be conducted by appointment. The coating applicator must, before the initial inspection, identify the corrosion category of the licence. After obtaining a licence the inspection can be executed on a production up to the level of the licence. If a higher licence is required by the coating applicator an inspection of the coating applicator producing a higher level product is necessary to obtain a licence on the desired level.


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Appendix 1-a Corrosivity category According to: EN ISO 12944 part 2 Table 1 - Atmospheric-corrosivity categories and examples of typical environments:

Corrosivity category

Mass loss per unit surface/thickness loss (after first year of exposure)

Examples of typical environments in a temperate climate (informative only)

Low-carbon steel Zinc

Exterior Interior Mass loss

g/m2

Thickness loss

m

Mass loss

g/m2

Thickness loss

m

C1 very low 10 1,3 0,7 0,1 _

Heated buildings with clean atmospheres, e.g. offices, shops,

schools, hotels.

C2 low

> 10 to 200 > 1,3 to 25 > 0,7 to 5 > 0,1 to 0,7

Atmospheres with low level of

pollution. Mostly rural areas.

Unheated buildings where condensation

may occur, e.g. depots, sports halls.

C3 medium

> 200 to 400 > 25 to 50 > 5 to 15 > 0,7 to 2,1

Urban and industrial

atmospheres, moderate sulfur dioxide pollution.

Coastal areas with low salinity

Production rooms with high humidity and

some air pollution, e.g. food-processing plants, laundries,

breweries, dairies.

C4 high

> 400 to 650 > 50 to 80

> 15 to 30 > 2,1 to 4,2

Industrial areas and coastal areas with moderate salinity.

Chemical plants, swimming pools, coastal ship- and

boatyards.

C5-I very high (industrial)

> 650 to 1500 > 80 to 200

> 30 to 60 > 4,2 to 8,4

Industrial areas with high humidity

and aggressive atmosphere.

Buildings or areas with almost permanent

condensation and with high pollution.

C5-M very high (marine)

> 650 to 1500 > 80 to 200

> 30 to 60 > 4,2 to 8,4

Coastal and offshore areas with

high salinity.

Buildings or areas with almost permanent

condensation and with high pollution.

NOTES: 1.

2.

The loss values used for the corrosivity categories are identical to those given in ISO 9223. In coastal areas in hot, humid zones, the mass or thickness losses can exceed the limits of category C5-M. Special precautions must therefore be taken when selecting protective paint systems for strucures in such areas.


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Appendix 2-a Mechanical test and results 2-a-1 Adhesion test EN ISO 16276-2 Cross-cut, X-cut test and pull-off method EN ISO 2409 Cross-cut test equipment and results This method describes the adhesiveness of the coating films to the substrate. The cut distance for coating thickness up to 60 m is 1 mm, for thickness up to 120 m 2 mm and 3 mm for greater thickness up to 250 m. If the dry film thickness exceeds 250 m, the pull-off test is recommended. Acceptable Results:

Result Test method Dft

Outdoor resistant coatings

Results Indoor resistant coatings Results

Corrosivity Category m C1 - C2 C3 - C5 C1 - C2 C3 - C5 C1 - C2 C3 - C5 C1 - C2 C3 - C5

Adhesion < 60 X X 0 - 1 - X na 0 - 1 0 - 1 < 120 X X 0 - 1 0 - 1 X na 0-1 0 - 1 < 250 - X - 0 - 1 - na - 0 - 1 NA > 250 - X - 5 MPa - na - 5 MPa 2-a-2 Determination of chip resistance by falling hexagonal nuts NEN 5335 cancelled 2-a-3 Impact resistance test EN ISO 6272-1 describes a method for assessing the resistance of a dry film of paint, coating material or related product to cracking or peeling from a substrate when it is subjected to deformation caused by a falling weight, using a 20 mm diameter spherical indenter, dropped under standard conditions. The term "impact resistance" is used in the title of this standard, but one important characteristic of the device used is that it should produce rapid deformation rather than true impact. The method described can be applied:

either as a pass/fail test, the test being carried out from one drop height and with a specified mass, so as to test compliance with a particular specification;

or as a classification test, to determine the minimum mass and/or drop height at which the coating cracks or peels from its substrate by gradually increasing the drop height and/or the mass.

QUALISTEELCOAT uses the test only for pass/fail testing. The minimum reverse impact resistance value for liquid coatings in relation to the required coating thickness must be given by the coating system supplier. For powder coatings the energy of 2.5 Nm reverse impact must be used.


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RESULT:

Coating systems must show no detachment of the system and no crack formation up to the substrate.

2-a-4 Resistance to scratching EN ISO 1518 The resistance of the coating system to scratching is determined in accordance with EN ISO 1518 using a load of 2000 g on a tungsten-carbide ball with a diameter of 1 mm.

RESULT:

With this load, no more than 50 % of the scratch mark should penetrate as far as the substrate.

2-a-5 Determination of the surface hardness ISO 15184 The resistance of the coating system to scratching is determined in accordance with ISO 15184 - the determination of surface hardness by means of pencils. This standard specifies a method of comparing the surface hardness of dried paint surfaces by using pencils.

RESULT:

The result of the test must be in accordance with the information provided by the coating manufacturer.

2-a-6 Determination of particle size distribution The objective of the test is to determine the size and the mixture of the blast grit or shot particles used for surface preparation. The particle size distribution test is conducted in accordance with EN ISO 11125-2 for metallic blast-cleaning abrasives and EN ISO 11127-2 for non - metallic blast-cleaning abrasives. Determine the mean mass value of two tests and report the result to the nearest 1 %. The result must be within the limits of the desired blast clean operation.

RESULT:

Information about the amount of blast medium left in the various sieves gives information about the size distribution of the blast medium.

2-a-7 Determination of surface roughness The purpose of this measurement is to determine the roughness of the substrate after blasting and prior to application of the first primer coat. The assessment of the roughness is conducted in accordance with EN ISO 8503-2 for grading of the surface profile, EN ISO 8503-1 for ISO surface profile comparators, EN ISO 8503-3 for profile focusing by microscope, and 8503-4 for profile, stylus instruments.

RESULT:

The result of the test must comply with the desired results of the primer coating or metal layer to be applied.


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2-a-8 Determination of wet film thickness The wet film thickness of the coating has to be monitored during the application. For this purpose the thickness of the applied film is determined by a wet thickness comb immediately after application of a liquid coating layer.

RESULT:

The wet film thickness must be in accordance with the calculated wet thickness in order to obtain the desired dry film thickness.

2-a-9 Determination of dry film thickness The dry film thickness of the individual coats in the system and the total dry film thickness must be measured as shown in EN ISO 2808. The number of measurements to be taken depends on the number of parts in the batch. Number of parts in the batch

Number of samples Permissible number of non-complying samples

1 - 10 Every 0 11 - 200 10 1 201 - 300 15 1 301 - 500 20 2 501 - 800 30 3 > 800 40 3 Alternative: Surface in m2 or m Number of measurements *1) 1 4 1 - 3 10 3 - 10 15 10 - 30 20 30 - 100 30 >100 *2) For every 100 add 10 measurements *1) The measurements must be representative of the inspected area. *2) It is recommended to divide areas in excess of 1000 m2 into smaller inspection parts


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The minimum acceptable dry film thickness is 80 % of the requested dry film thickness. Dry film thickness between 80 and 100 % of the requested dry film thickness is acceptable if the average dry film thickness is equal to or higher than the requested dry film thickness. The maximum dry film thickness may be three times the requested average dry film thickness. The results are given in the following table:

Coating layers Name Average dry film thickness Remarks

Spec m Found m Primer coat(s) 1st coat

Primer coat(s) 2nd coat

Edge protection stripe coat(s) Intermediate coat 1st coat Intermediate coat 2nd coat

Topcoat 1st coat

Topcoat 2nd coat

Total nominal dry film thickness

2-a-10 Gloss meter Gloss EN ISO 2813 - using incident light at an angle of 60 . Note: if the significant surface is too small or unsuitable for gloss to be measured with the gloss meter, the gloss should be compared visually with the reference sample (from the same viewing angle).

RESULT:

Category 1: 0 - 30 +/- 5 units Category 2: 31 - 70 +/- 7 units Category 3: 71 - 100 +/- 10 units (Permissible variation from the nominal value specified by the coating supplier)

2-a-11 Determination of dew point The dew point is determined by the following steps:

1. measuring the relative humidity of the air;

2. measuring the substrate temperature;

3. calculating the dew point or taking this from a table or graph.


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RESULT:

The dew point must be at least three degrees Celsius above the substrate temperature of the metal.

2-a-12 Testing the stoving conditions The equipment to be used must be a 4-temperature measuring point device. Three detectors must be attached to the top, middle and lower parts of the substrate and one to a reference panel mounted on the traverse. The results of these tests should be recorded and retained and the stoving curves should be recorded in a register readily accessible to the inspector.

RESULT:

A curve resulting from the results measured. In this curve, times and temperatures provide the requested information on the curing process.

2-a-13 Testing the drying temperature The temperature of the substrate in the drying oven must be measured. This may be done by means of a 4-point measuring device, using indication tablets attached to the substrate.

RESULT:

In the drying oven the thickest part of the steel must reach a temperature of at least 60 C.

2-a-14 Appearance test (visual inspection) Visual inspection should take place using normal or corrected vision at a distance of 3 m for indoors application. In case of outdoors application the distance is to be 5 m.

RESULT:

At these distances, the coating should not show any wrinkles, runs, sags, craters, blisters and other surface irregularities. Irregularities as a result of the steel substrate or the hot dip galvanized zinc are not to be taken into account. The inspection must be conducted in diffuse daylight. When the end user desires other distances or inspection criteria, these should be agreed in advance by the client, applicator and galvanizer.


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Appendix 2-b Chemical test methods and results 2-b-1 Polymerization test This test serves to determine the degree of polymerization for powder and liquid coatings. This test is useful as compare the test of the panel with a fully cured coating layer. Procedure: Before testing, the liquid coating system must be cured for four hours at 60 C. The mixture used must be tested first on a properly cured version of the coating system. A range of solvent mixtures must be used to determine the proper mixture for the final coating in the system. The solvents given below are an indication of solvents to be used. Required solvent for liquid coatings: MEK (methyl ethyl keton) or as specified by the paint or lacquer manufacturer and approved by the Technical Committee. Required solvent for powder coatings: As specified by the powder coatings manufacturer and approved by the Technical Committee. Saturate a swab of cotton wool with solvent. Within 30 seconds, rub it lightly back and forth, 30 times in each direction, over the part to be tested. Wait 30 minutes before making the assessment. The Polymerization quality is assessed in accordance with the following ratings:

1. the coating is very dull and quite soft;

2. the coating is very dull and can be scratched with a finger-nail;

3. slight loss of gloss (less than 5 units);

4. no perceptible change - the surface cannot be scratched with a finger-nail.

RESULT:

Ratings 3 and 4 are satisfactory. Ratings 1 and 2 are not satisfactory.

2-b-2 Resistance to mortar This test is only used for powder coatings. The test must be performed in accordance with EN 13438 part A.4.7. The required composition of the mortar is sand, lime and water. The testing time is 24 hours. The mortar must be prepared by mixing 15 g of hydrated lime, 41 g of cement and 224 g of sand with sufficient tap water to make a soft paste. Apply four portions of the mortar, approximately 15 mm in diameter and 6 mm thick, to the test panel. Place the test panel horizontally at 38 3 C and 95 5 % relative humidity for 24 hours.


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At the end of the period, manually dislodge the mortar from the coating surface and remove any residue with a damp cloth. Allow to dry and examine the coating with normal or corrected vision, to determine the incidence of visible detachment of the coating due to the effect and removal of the mortar.

RESULT:

It must be easy to remove the mortar without leaving any residue. Any mechanical damage to the coating caused by grains of sand should be disregarded. There must be no change in appearance/colour after the mortar test.

2-b-3 Permeability EN 13438, A.4.11 Fill a pressure cooker with de-ionized water with a maximum conductivity of 30 S/cm at 20 C to a depth of 25 mm 3 mm. Partially immerse the coated test panel in the water so that a minimum length of 25 mm is immersed and secure the lid of the pressure cooker.

Apply heat to the pressure cooker until steam is emitted from the valve. Insert a weighted needle valve to give a pressure of 100 kPa and continue heating for two hours from the time the steam was first emitted.

Cool the apparatus with care.

Remove the sample and allow it to cool down to room temperature. Examine the test piece for signs of blistering. Apply an 18 mm wide strip of Scotch 610, Permacel 99 or equivalent adhesive tape to the surface, ensuring that no air is trapped. After one minute, remove the tape at an angle of 45 with a sharp even pull. Exposure time for exterior use is 2 hours The test is not applicable for interior coating

RESULT:

There must be no defects or detachment. Some colour change is acceptable. 2-b-4 Neutral salt spray test EN ISO 9227 and EN 13438, 5.3.12 In the middle of the test panel, scribe a cross to expose, but not penetrate, the substrate. The cross shall be a rectangular cross in which each of the diagonals has a length of 50 mm, the intersection is centred in the middle of the panel and the scribe lines intersect at 90 . Place the coated test piece in a spray cabinet complying with EN ISO 9227 - continuous salt spray. After testing, remove the sample carefully from the test cabinet, wash the test panels in de-ionized water at a temperature of less than 35 C, and dry immediately. Attempt to lift the coating from the scribed line with a sharp tool. Examine the area around the scribed cross. M = (C-W)/2 C = average of nine measurements of corrosion including the worst points of corrosion W = width of the scratch


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There should be no difference between steel substrate and hot dip galvanized substrate.

Category medium high 1 Exposure time Na Na 2 Exposure time Na 240 h 3 Exposure time 240 h 480 h 4 Exposure time 480 h 720 h 5I Exposure time 720 h 1440 h 5M Exposure time 720 h 1440 h

RESULT:

Neutral salt spray EN ISO 4628-2 Blistering 0 (S0)

Assessment immediately after aging test

EN ISO 4628-3 Rusting Ri 0 EN ISO 4628-4 Cracking 0 (S0) EN ISO 4628-5 Flaking 0 (S0) Corrosion of the substrate from the scribe

Test regime EN ISO 9227

M 2 mm

A. 3 samples in order = 0 sample not in order B. 2 samples in order = 1 sample not in order C. 1 sample in order = 2 samples not in order D. 0 sample in order = 3 samples not in order

Evaluation:

Approval Licence A in order in order

B in order in order with corresponding information to be submitted to the coating company

C not in order Repetition of salt spray test - only if result of second test is A or B, will the test be considered successful.

D not in order

Not in order, the whole test must be executed again. Or class to be verified at coating company

2-b-5 Constant atmosphere of water condensation EN ISO 6270-1 Testing period:

Category Interior Exposure time Na Category Exterior Exposure time 1000 h

RESULT:

Blister must not be visible to the naked eye.


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Constant atmosphere of water condensation EN ISO 4628-2 Blistering 0 (S0)

Assessment immediately after aging test EN ISO 4628-4 Cracking 0 (S0)

EN ISO 4628-5 Flaking 0 (S0)


Approval Licence

A in order in order


C not in order Repetition of constant atm. of condensation test - only if result of second test is A or B, will the test be considered successful.

D not in order Not in order, the whole test must be executed again. Or class to be verified at coating company

2-b-6 Determination of resistance to liquids other than water The objective of this test is to assess the chemical resistance of the coating system. See also EN ISO 12944-6. For atmospheric Corrosivity Categories C2, C3, C4 and C5 tests are carried out in accordance with EN ISO 2812-1. For the purpose of determining the chemical resistance, an additional test for C5I in accordance with EN ISO 2812-1 is carried out. The following chemicals of recognized analytical quality shall be used:

NaOH 10 % aqueous solution

H2SO4 10 % aqueous solution

Mineral spirits containing 18 % aromatics

This test is not used for the assessment of corrosion protection properties but to determine the ability of a system to withstand highly industrial environments. Therefore, the test duration remains the same for Medium and High durability. The samples are placed in a container holding the described test liquid for 168 hours. There is no difference between steel substrate and hot dip galvanized substrate except no scribe is made for hot dip galvanized substrate (reference is made to annex A of ISO 12944-6).

RESULT:

Chemical test EN ISO 4628-2 Blistering 0 (S0)


EN ISO 4628-3 Rusting Ri 0 EN ISO 4628-4 Cracking 0 (S0) EN ISO 4628-5 Flaking 0 (S0)


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Infiltration of a maximum of 16 mm2 is allowed across a scratch length of 10 cm but the length of any single infiltration area must not exceed 4 mm.


Evaluation:

Approval Licence A in order in order


C not in order Repetition of test - only if result of second test is A or B, will the test be considered successful.

D not in order Not in order, the whole test must be executed again. Or class to be verified at coating company

2-b-7 Resistance to sulphur dioxide In accordance with EN ISO 3231 using 0.2 litre SO2 and the following test duration:

240 h (10 cycles) for medium durability category 4

480 h (20 cycles) for medium durability category 5

720 h (30 cycles) for high durability category 5

RESULT:

colour resistance test (Kesternich) EN ISO 4628-2 Blistering 0 (S0)


EN ISO 4628-3 Rusting Ri 0 EN ISO 4628-4 Cracking 0 (S0) EN ISO 4628-5 Flaking 0 (S0) EN ISO 4628-5 Surface

changes No Surface defects or discoloration



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Evaluation: Approval Licence

A in order in order


C not in order Repetition of test - only if result of second test is A or B, will the test be considered successful.

D not in order Not in order, the whole test must be executed again. 2-b-8 Accelerated weathering test This test is only required for coating systems intended for outdoor application. To be granted approval for the coating system in question, Aluminium panels may be used. The test serves to determine behaviour under EN ISO 11341 - weathering. Loss of gloss and changes in colour are determined.

Intensity of light 550 20 W/m2 (290 - 800 nm)

Black-standard temperature 65 5 C

De-ionized water max. 10 S/cm

special-UV filter (290 nm) Cycles of 18 min. in humid and 102 min. in dry medium. After 1000 h exposure, the test specimen is washed in entirely demineralised water. The following criteria are verified - Loss of gloss EN ISO 2813

Angle of incidence 60 - Total deviation in shade: E resulting from CIELAB formula in

accordance with ISO 7724-3, included gloss RESULT:

Loss of gloss Should not exceed 50 % of the initial value.

Total deviation in shade In accordance with E-values of the attached table.

2-b-9 Natural weathering EN 13438, A.4.8.2 This test only applies to coating systems intended for outdoor application.

Weathering Test in Florida in Accordance with EN ISO 2810 The test must start in April.

The samples must be exposed to the elements facing 5 south for one year. For approval, four test panels are required (three for weathering purposes and one reference panel).


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Dimensions of the samples: approx. 100 x 305 x 0.8 - 1 mm After exposure, the exposed samples are to be cleaned using the following method: Wash the test panels prior to inspection with water containing 1 % neutral detergent, using a sponge and avoiding polishing. Afterwards rinse the panels with water with a maximum electrical conductivity of 10 S/cm, or using any other method approved by the Technical Committee. This process must not scratch the surface. Gloss is to be measured in accordance with EN ISO 2813, at an angle of 60 . The colorimetric measurements are averaged. The conditions for measurement and colorimetric assessment are:

Colour variation: E CIELAB formula in accordance with ISO 7724-3, with gloss.

The colorimetric assessment must be conducted for the standard illuminate D65 and the ten-degree normal observer.

To assess gloss and colour, three measurements will be made on the cleaned, weathered samples and on the unexposed reference panels. These measurements are to be made at different points at least 50 mm apart. RESULT:

Gloss The remaining gloss must be at least 50 % of the original gloss.

Colour change

The E values must not exceed the maximum values laid down in the attached table (reference is made to appendix 8-a).

2-b-10 Colour difference The difference in colour between charges of coated parts may not exceed certain levels. The purpose is to determine the acceptable nuances in colour. The colour nuances may only be determined at diffuse daylight. The nuances in colour can be measured in the field by the standard grey scale. In this scale, colour nuances are expressed in grey tones. The acceptable level is 3/4 of the EN 20105-AO2 scale. 2-b-11 Gloss difference The gloss level difference in the production of QUALISTEELCOAT products shall be within the tolerance limits indicated by the manufacturer. If no tolerance limits have been indicated by the manufacturer the gloss level of the coating shall be in accordance with the table below. This method is also used to determine sufficient curing of a powder coating. Gloss requirements: Specific gloss level Acceptable variation from the

specified gloss level >50 10 50 7


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2-b-12 Determination of etching degree An initial zinc etching or blasting stage must be carried out as pre-treatment for any powder and liquid coating. The etching degree is determined by measuring the difference in the zinc film thickness before and after etching. RESULT:

Etching carried out in an acid medium or an alkaline plus acid medium must result in a zinc etching degree between 5 and 10 % of the original zinc layer thickness of hot dip galvanized steel. The etching degree for rolled products or casting is not specified. Etching is advised by the chemicals supplier for such products.

2-b-13 Assessment of conversion coating If so desired by the application firm, the chromate or chromate-phosphate pre-treatment has to be carried out in accordance with EN 13438. The conversion coating must comply with the requirements of conversion coating for steel or hot dip galvanized steel as given by the chemicals supplier. The drying temperature of the chrome conversion layer must be approx. 60 C.

The chemicals supplier in question must provide the application firm with the relevant information on the desired test method, equipment, chemicals and conductivity of dripping water. RESULT:

A sufficient layer of conversion coating must be applied to the substrate, resulting in a uniformly coloured surface, showing no powdering.

2-b-14 Determination of conductivity of dripping water The conductivity of the final rinse preceding chromate pre-treatment must comply with the suppliers instructions and be checked by the inspector. Demineralised water must be used for the final rinse after chromate treatment, prior to drying. RESULT:

If not otherwise prescribed by the chemicals supplier, the conductivity of dripping water shall not exceed 30 S/cm at 20 C. Conductivity should only be measured for open sections and not for hollow sections. Certain chrome pre-treatment processes require varying and lower coating weight to be deposited on the clean galvanized surfaces and should be rinsed in water with relatively high conductivity, e.g. 2500 S/cm. This must be clearly stated by the chemicals supplier and agreed with the coating material supplier.


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Appendix 3-a Information on substrates To ensure the pre-treatment will be performed to requirement, detailed information of the material to be treated is necessary. Types of substrates 3-a-1 Cast parts Depending on the kind and quality of cast, the curing of coating powder in particular, or - to some extent - the forced drying of liquid coating material could lead to gas bubbles appearing as blisters or craters on the coated surface. Parting compounds too could impair adhesiveness. Therefore, coating companies should be informed of the presence of such parting compounds, enabling them to verify the coating properties of the material in advance and thus avoiding ensuing faults. 3-a-2 Hot dip galvanized and electro zinc coated steel parts Prior to applying a coating system to galvanized steel, the galvanizer must be informed about the surface preparation needed after galvanizing. Hot dip galvanizing must be executed in accordance with ISO 1461. The galvanized steel must be cleaned and any smut, zinc runs and dirt must be removed. Depending on the quality of the steel, thickness of the zinc coating and possible hollows, galvanized steel parts are susceptible to gas bubbles during curing and forced drying of powder and liquid coating material. Blisters and craters become visible on the surface. Deadening agents might cause insufficient coating film adherence on Sendzimir- and electro zinc coated steel surfaces. This is the reason why only protective layers that can be removed gently during chemical pre-treatment are suitable. The zinc layer must be treated with care. The coating company has to be informed accordingly. Prolonged storage and exposure to humidity may lead to visible white rust which has to be removed before coating - in some cases slight sweeping has proved efficient. If agreed upon by the client, the parts have to undergo this preparatory treatment. 3-a-3 Laser (oxygen) cut steel One of the advanced methods to cut steel in desired shapes and lengths is the cutting of steel using laser beams. The result of the cutting method is a very sharp cutting edge. Another problem may occur at the cutting side. The steel substrate is extra hard after cutting. This causes the need for extra attention during surface preparation. Before any surface preparation takes place the sharp edges must be rounded and the heat changed surface must be ground or blasted to create a treatable substrate by the customer. (EN ISO 8501-3) The techniques of laser cutting allow for burr-free cutting of a large variety of metal substrates with extreme precision at high speed without any limit to shape. In addition, laser cutting is even suitable for thicknesses of 18 mm and above.


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Substrate remarks before coating application:

Laminated steel cold

- Low thickness

- Clean aspect

- Generally oiled

Laminated steel hot

- Average with strong thickness

- Any type of aspect and cleanliness

- Pickled oiled

- With adherent calamine (IPS)

- With blue or black calamine

Stainless

Disadvantages to applying paint The laser beam releases great energy, and assembles metal at very high temperature under pulsated oxygen, resulting in brutal oxidation of metal. Iron oxide Fe3O4, called Magnetite or blue calamine is formed along the laser cutting edges. Calamine adheres very poorly to metal. Applying paint to calamine involves a huge risk as regards adhesiveness and may well result in chipping at the cutting areas, which, generally, are also the zones most exposed to shocks. Possible solutions Underwater or inert gas laser cutting may solve the problem. (Parameters unfortunately not controlled by the applicators painting). Other solutions are:

Mechanical treatment

Chemical treatment

Mechanical treatment Principle: mechanical treatment eliminates calamine by various techniques:

shot-blasting

sanding

brushing

Advantages: Clean solution: no use of water and chemicals, allowing an entirely clean setting for the purpose of applying paint.


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Disadvantages: On tack welded units, some areas may be hard to reach. Chemical treatment Principles: By passage in an acid medium, non-adherent laser calamine is detached from the substrate by the hydrogen release created when the metal is attacked. The products to be used can be made up of mineral acids and/or organic:

Hydrochloric

Sulphuric

Phosphoric

Citric

Gluconic

Phosphonic

They are additives of surfactants and inhibiters in accordance with the required treatment (simple scouring, scouring-grease-remover, grease-remover-paint remover-phosphatizer). Both soaking and sprinkling are possible. Advantages:

The treatment reaches laser calamine even in the inaccessible places of the parts.

Several successive baths can be used.

Possibly enables the increase of anti-corrosive properties of coatings, by means of conversion post-treatment.

Disadvantages:

Implements chemicals and implies a treatment of the rejects.

Eliminated calamine is found in the bath and creates mud.

Total decarbonising of the mild steel is not achieved.

The phenomenon of clothing powder can settle on certain steels.

Conclusions: To avoid adhesion problems in laser cutting areas, the surface must be properly prepared. The method to be used must be decided upon on a case-by-case basis, depending on the restrictions of the workshop in question.


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3-a-4 Special steel, stainless (chromium-plate) The known types of pre-treatment do not result in suitable adhesion properties. Only appropriately roughened surfaces ensure the adhesive strength of coating films. Without such a manual roughening, the parts have to be coated with a suitable primer and protective coating. 3-a-5 Various material combinations Such types of substrates are critical in chemical pre-treatment. Because of different metals and behaviour under chemical pre-treatment, corrosion may be stimulated. Preliminary tests are, therefore, recommended. 3-a-6 Information table for the treatment of substrates

Types of parts E coat Powder zinc primer Zinc spraying 50 a 200 m

Sendzimir 15 a 30 m

Hot dip galvanized 50 a 200 m

Portal Secure the dimensions of the baths

Be careful with the air-gaps (volutes, rings, beaten)

Be careful with the air-gaps (volutes, rings, beaten)

Closed and tight welds

Sheets and nettings must be separate

Keep body

Require holes of circulation and evacuation

Require a recovery at the level of the welds


Plane sheet

Weakness anti-corrosive on the level of the nozzles of cutting

Adapted

Weakness anti-corrosive on the level of the nozzles of cutting

Suitable for large thicknesses

Cut out Sheet Suitable for fine thicknesses

Perforated Sheet

Expanded metal

Risk deformation due to shot-blasting for sheets < = to 1.5 mm

Risk deformation due to shot-blasting for sheets < = to 1.5 mm

The surface quality can present defects

Profile for windows

Secure the dimensions of the baths


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Types of parts E coat Powder zinc primer Zinc spraying 50 a 200 m

Sendzimir 15 a 30 m

Hot dip galvanized 50 a 200 m

Without Sheets


If no precautions are taken by the metal sprayer there a risk of imprisonment of the shot during the operation of shot-blasting

If no precautions are taken by the metal sprayer there a risk of imprisonment of the shot during the operation of shot-blasting

Require a recovery at the level of the welding and machining

Require holes of circulation and evacuation. Is likely to fill the rabbets or throats

Opening Sheet

If the sheets are not welded uninterruptedly they must be coated separately, to avoid the absence of protection between sheet and tallies



Require a recovery at the level of the welding and machining

One face two faces

In the event of insulation the 2 sheets are coated separately - the insulator being burnt after heating

In the event of insulation the 2 sheets are coated separately - the insulator being burnt after heating

In the case of two sheets, second is treated separately

Profile hot roll Possible after shot-blasting

Shot blasting DS 2,5 a DS 3 requirement

Recommended NA Recommended

UPN-IPN-IPE-HEA-HEB

Secure the dimensions of the baths

Possible after shot-blasting

Shot blasting Sa 2,5 a Sa 3 requirement

Recommended NA Recommended

Unit mecano welds in profile

Secure the dimensions of the baths Little practised

Do not stop the air-gaps and non-closed weldings

Can protect weak interstices and air-gaps

can clog weak interstices and air-gaps, risk of sweating


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Appendix 3-b Removal of contamination Surface treatment before pre-treatment 3-b-1 Old coating (coated substrates) All residue of prior coatings should be completely removed prior to renewed pre-treatment. Different methods, such as blasting, pyrolysis or chemical stripping can be used. Remaining phosphate or chromate layers on the stripped substrates must be removed by mechanical or chemical pre-treatment as well. 3-b-2 Adherent residue, silicone and labels Adherent residue and silicone have a negative effect on the visual appearance after coating, they cause clearly visible craters and smears and reduce the adhesive power of the coating material on the surface. Therefore, application of silicone parting agents has to be avoided during processing on the untreated part. In case such agents have been applied, the coating company is to be informed unsolicited. If possible, adherent residue is to be removed by suitable solvents before the pre-treatment. 3-b-3 Weld seam Oxide films in the area of weld seams should be removed by suitable methods e.g. abrasive blasting, mechanical pre-treatment or chemical acidic etching. 3-b-4 Water-soluble residue This type of residue, such as salts, should be removed by using water (e.g. application of steam jet) or hot water-based cleaning systems. 3-b-5 Sharp edges and cuts All sharp edges and laser cuts have to be rounded. This is absolutely necessary to enable the application of sufficient film thickness on these parts of the substrate. This can be carried out by grinding or sweep brushing the edges of the objects. (EN ISO 8501-3)


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3-b-6 Information on procedures of removal of foreign matter

Procedures for removal of extraneous layers and foreign matter

Matter to be removed Procedure

Grease and oil

Water cleaning Fresh water with addition of detergents. Pressure (< 70 MPa) may be used. Rinse with freshwater.

Steam cleaning Fresh water. If detergents are added, rinse with freshwater. Emulsion cleaning Rinse with freshwater.

Alkaline cleaning

Aluminium, zinc and certain other types of metal coating may be susceptible to corrosion if strong alkaline solutions are used and should, therefore, be rinsed with fresh water.

Organic-solvent cleaning

Many organic solvents are hazardous to health. If the cleaning is performed using rags, they will have to be replaced at frequent intervals, otherwise oil and grease contaminants will not be removed, but will be left as a smeared film after the solvent has evaporated.

Water-soluble contaminants, e.g. salt

Water cleaning Freshwater Pressure (< 70 MPa) may be used.

Steam cleaning Rinse with freshwater.

Alkaline cleaning Aluminium, zinc and certain other types of metal coating may be susceptible to corrosion if strong alkaline solutions are used. Rinse with freshwater.

Coatings

Stripping: Dry abrasive cleaning Wet abrasive cleaning Water blast-cleaning Sweep blast-cleaning Spot blast-cleaning

Solvent-borne pastes for coatings sensitive to organic solvents. Residue to be removed by rinsing with solvents. Alkaline pastes for specifiable coatings. Rinse thoroughly with fresh water. Stripping is restricted to small areas. Shot or grit abrasives. Residue of dust and loose deposits will have to be removed by blowing off with dry oil-free compressed air or by vacuum cleaning. Rinse with fresh water. For removal of poorly adhering paint coatings. Ultra-high-pressure cleaning may be used for firmly adhering coatings. For roughening coatings or removal of the outermost coating layer. For localized removal of coatings.


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Appendix 3-c Surface pre-treatment 3-c-1 Surface pre-treatment Mill scale has a negative effect on the durability of the coating system. Therefore, it has to be removed using a suitable mechanical pre-treatment method (abrasive-blasting, grinding, brushing) or chemical cleaning. These methods are also applied to burrs caused by cutting or other punching devices. Sharp edges result in a considerably lower film thickness, thus severely diminishing the corrosion resistance in this area. Corrosion products have the same unwanted properties as the problems mentioned above. Complete removal is absolutely necessary. Slight formation of red rust on steel substrates as well as slight formation of white rust on zinc-coated steel substrates can often be removed by special acidic etching. Considerable rust formation necessitates mechanical removal (e.g. sweeping) or heavy chemical cleaning. Preliminary tests are recommended. The quality of the surface preparation and the methods available depend highly on the shape and thickness of the steel used. In most cases abrasive blasting is not recommended if the steel sheet is less than 1.5 mm thick. The required quality of blast cleaning methods is given in EN ISO 12944-4 - types of surfaces and surface preparation. This standard also refers to EN ISO 8501-1 - preparation of steel substrates before application of paint and related products. 3-c-2 Part 4 of EN ISO 12944 deals with the following types of surface of steel structures

consisting of carbon or low-alloy steel, and their preparation:

uncoated surfaces;

surfaces thermally sprayed with zinc, aluminium or their alloys;

hot-dip galvanized surfaces;

zinc-electroplated surfaces;

sherardized surfaces;

surfaces painted with prefabrication primer;

other painted surfaces.

This part of EN ISO 12944 defines a number of surface preparation grades but does not specify any requirements for the condition of the substrate prior to surface preparation. Highly polished surfaces and work-hardened surfaces are not covered by this part of ISO 12944. In appendix 3-b the cleaning and removal of all foreign matter is discussed. In this appendix the surface preparation prior to application is given. The different methods are presented in the table referring to the expected lifetime of a system using this type of pre-treatment.


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For chemical methods the composition of the chemicals is the responsibility of the chemicals manufacturer. The composition of the baths is only defined in general terms. A chemical bath may be used for one type of substrate only. If a chemical bath composed for aluminium is also used for steel or galvanized steel, the chemicals manufacturer must inform the coating applicator of the maximum concentration of zinc and aluminium allowed. The baths must be tested on a regular basis, these test results must include the concentration of these components. 3-c-3 Surface pre-treatment methods Procedures for removal of rust and mill scale: Matter to be removed Procedure

Mill scale

Chemical Cleaning The process is generally not performed on site. Rinse with freshwater.

Dry abrasive blast-cleaning

Shot or grit abrasives. Residue of dust and loose deposits will have to be removed by blowing off with dry oil-free compressed air or by vacuum cleaning.

Wet abrasive blast-cleaning Rinse with freshwater.

Flame cleaning Mechanical cleaning will be required to remove residue from the combustion process, followed by removal of dust and loose deposits.

Rust

Chemical Cleaning The process is generally not performed on site. Rinse with freshwater.

Power-tool cleaning

Mechanical brushing may be used in areas with loose rust. Grinding may be used for firmly adhering rust; residue of dust and loose deposits will have to be removed.

Water blast-cleaning For removal of loose rust. The surface profile of the steel is not affected.

Spot blast-cleaning For localized removal of rust.

Zinc Hot dip Galvanized

Light surface blast to improve adhesion

The objective is to clean the surface and to cause a slight roughening of the surface.

- Sharp inert non-metallic grit; - Stainless steel grit; - Grain size up to 0.5 mm; - Pressure up to 0.3 MPa; - Blasting distance at least 60 cm; - Blasting angle 50 to 70 .

Zinc corrosion products

Sweep blast-cleaning

Sweep blast-cleaning on zinc may be performed with aluminium oxide (corundum), silicates or olivine sand: an ammonia solution in combination with a synthetic-fabric pad with embedded abrasives may be used for localized spots of zinc corrosion. When removing all the zinc corrosion products (white rust) the amount of zinc removed by the procedure may not exceed 10 % of the zinc layer thickness.


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Matter to be removed Procedure

Chemical cleaning

Chemical cleaners may be used for larger surfaces. All zinc corrosion products must be removed. The process has to be executed carefully, not to dissolve the zinc. No more than 10 % of the zinc thickness may be lost due to the process.

When rinsing and drying, structures with slots or rivets shall be treated with particular care. 3-c-4 Pre-treatment (category 1) Abrasive - abrasive-blasting Sa 2, or Chemical - degreasing, or Chemical - phosphating or alternative processes. 3-c-5 Pre-treatment (category 2) Abrasive - abrasive blasting Sa 2, or Chemical - phosphating, or alternative processes. 3-c-6 Pre-treatment (category 3 + 4 + 5) Abrasive - abrasive blasting to Sa 2 1/2 or Abrasive/chemical - abrasive blasting Sa 2 1/2 + passivation or Chemical - de-oxidation and passivation, phosphating or

alternative processes. The purpose of the pre-treatment process is to remove all corrosion products from the substrate and to produce a substrate suitable for the application of a coating system. 3-c-7 Rinsing Rinsing water quality has to comply with the instructions of the pre-treatment agents manufacturer. The chemicals suppliers process working instruction must be available on demand. 3-c-8 Drying of pre-treated parts If required, forced drying has to be effected. Drying has to be executed in accordance with the instructions of the pre-treatment agents manufacturer. 3-c-9 Conversion coating of pre-treated parts If desired by the application firm, conversion by chrome free, chromate or chromate-phosphate pre-treatment must be carried out in accordance with EN 13438 appendix B.3.1 The weight of the conversion coating and the conversion method chosen have to be in accordance with the chemicals suppliers requirements related to conversion coating of steel or hot dip galvanized steel. This chemicals supplier must also provide the application firm with the relevant information about the desired test method, equipment and chemicals.


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The conductivity of the final rinse preceding chromate pre-treatment must comply with the suppliers instructions and be checked by the inspector. Demineralised water must be used for the final rinse after chromate treatment, prior to drying. If not advised otherwise by the chemicals supplier, the conductivity of the dripping water must not exceed a maximum of 30 S at 20 C. The conductivity should only be measured for open sections and not for hollow sections. The weight of the chromate conversion layer must be accordance with the information provided by the chemicals supplier. Pre-treated parts must not be stored for more than 16 hours. As a rule, they should be coated immediately after pre-treatment. The risk of insufficient adhesion increases as the parts are stored longer. Pre-treated parts must never be stored in an atmosphere that is dusty and potentially detrimental. Good atmospheric conditions must always be maintained in the storage area. All workers handling pre-treated parts must wear clean textile gloves to avoid contamination of the surface.

The parts must be dried at the following temperatures:

Chromate treatment (yellow): maximum 65 C

Chromate-phosphate treatment (green): maximum 85 C

Chrome-free treatment: maximum as stipulated by the supplier The maximum drying temperature allowed for continuous treatment is 100 C, but the substrate must be heated to a minimum of 60 C. The specified temperatures apply to the temperature of the metallic parts and not to the air temperature. The products must be dried thoroughly before the coating is applied, irrespective of the production method (continuous/ discontinuous). 3-c-10 Temperature of conversion and rinsing baths

The temperature of the conversion bath and - in case of a hot water rinse - the final rinse, must be measured during production using a dip thermometer. When using a spray tunnel, the temperature at the level of the treated product has to be measured. An even temperature in the entire pre-treatment bath and sufficient rotation of the chemicals are important.


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Appendix 4-a Liquid coating systems All the systems given are examples 4-a-1 Liquid coating systems on steel The paint sytems given in tables A.1 - A.8 are only examples. Other paint systems having the same performance are possible. If these examples are used, it shall be ensured that the paint systems chosen comply with the indicated durbility when execution of the paint work takes place as specified. See also 5.5 Shading of every second line in the text part of the table is added for increased readability Table A.1 - Paint systems summary table for corrosivity categories C2, C3, C4, C5-I and C5-M:

Substrate: low alloy carbon steel. Surface preparation: For Sa 2 1/2 rust grade A, B or C (ISO 8504-1).

Syst. No.

Priming coat(s) Subsequent coat(s) Paint system Expected durability

(see 5.5 and ISO 12944-1) Corresponding systems in table Cat 2 Cat 3 Cat 4 Cat 5-I Cat 5-M

Binder Type of primer *1) No. of coats

NDFT m *2) Binder

No. of coats

NDFT m *2) L M H L M H L M H L M H L M H A. 2 A. 3 A. 4 A. 5-I A. 5-M

A 1.01 AK, AY Misc. 1-2 100 --- 1-2 100 A 2.08

A 1.02 EP, PUR, ESI Zn (R) *6) 1 60 --- 1 60 A 2.18 A 3.20

A 1.03 AK Misc. 1-2 80 AK 2-3 120 A 3.02 A 1.04 AK Misc. 1-2 80 AK 2-4 160 A 2.06 A 3.04

A 1.05 AK Misc. 1-2 80 AK 3-5 200 A 3.06 A 4.01

A 1.06 EP Misc. 1 160 AY 2 200 A 4.10

A 1.07 AK, AY, CR, PVC Misc. 1-2 80 AY, CR,

PVC 2-4 160 A 2.06, A 2.14 A 3.12

A 1.08 EP, PUR, ESI Zn (R) *6) 1 60 AY, CR, PVC 2-3 160 A 3.23

A 4.16 A 4.25

A 1.09 AK, AY, CR *3), PVC

Misc. 1-2 80 AY, CR, PVC 3-5 200 A 3.07 A 3.13

A 4.04 A 4.08


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Syst. No.




NDFT m *2) Binder

No. of coats


A 1.10 EP, PUR Misc. 1 80 AY, CR, PVC 3-4 200 A 3.18 A 4.12


A 1.12 AK, AY, CR *3), PVC

Misc. 1-2 80 AY, CR, PVC 3-5 240 A 4.05 A 4.09


A 1.14 EP Misc. 1 160 AY, CR, PVC 2-3 280 A 5I.02

A 1.15 EP, PUR, ESI Zn (R) *6) 1 60 AY, CR, PVC 4-5 320 A 5I.11

A 1.16 EP Misc. 1-2 80 EP, PUR 2-3 120 A 2.15 A 3.16

A 1.17 EP Misc. 1-2 80 EP, PUR 2-4 160 A 2.16 A 3.17

A 1.18 EP, PUR, ESI Zn (R) *6) 1 60 EP, PUR 2-3 160 A 3.21 A 4.19 A 4.28

A 1.19 EP Misc. 1-2 80 EP, PUR 3-5 200 A 3.18 A 4.12

A 1.20 EP, PUR, ESI Zn (R) *6) 1 60 EP, PUR 3-4 200 A 4.20 A 4.29

A 1.21 EP, PUR, ESI Zn (R) *6) 1 60 EP, PUR 3-4 240 A 4.21 A 4.30 A 5I.06

A 5M.07 A 5M.12

A 1.22 EP Misc. 1-2 80 EP, PUR 3-5 280 A 4.14 A 5I.03 A 5M.04


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Syst. No.




NDFT m *2) Binder

No. of coats


A 1.23 EP Misc. 1 150 EP, PUR 2 300 A 5I.04 A 5M.01

A 1.24 EP, PUR, ESI Zn (R) *6) 1 60 EP, PUR 3-4 320 A 4.23 A 5I.08 A 5M.09 A 5M.14

A 1.25 EP, PUR Misc. 1 80 EP, PUR 3-4 280 A 5I.04 A 5M.04 A 1.26 EP, PUR Misc. 1 250 EP, PUR 2 500 A 5M.06

A 1.27 EP, PUR Misc. 1 400 --- 1 400 A 5M.05

A 1.28 EPC Misc. 1 100 EPC 3 300 A 5M.16

A 1.29 EP, PUR Zn (R) *6) 1 60 EPC 3-4 400 A 5M.11


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Binder for priming coat(s)

Paints (liquid)

Binders for top coat(s)

Paints (liquid) No. of

components Water- borne

possible

No. of components

Water- borne

possible 1-Pack 2-Pack 1-Pack 2-Pack AK = Alkyd X X AK = Alkyd X X

CR = Chlorinated rubber X CR = Chlorinated rubber X

AY = Acrylic X X AY = Acrylic X X

PVC = Polyvinyl chloride X PVC = Polyvinyl chloride X

EP = Epoxy X X EP = Epoxy X X

ESI = Ethyl silicate X X PUR = Polyurethane aliphatic X X

PUR = Polyurethane aromaticor aliphatic

X X EPC = Epoxy combination X

*1) Zn (R) = Zinc rich primer, see 5.2. Misc = Primers with miscellaneous types of anticorrosive pigments.

*2) NDFT = Nominal Dry Film Thickness, see 5.4 for further details.

*3) It is recommended that compatibility is checked with the paint manufacturer.

*6) It is also possible to work with a NDFT of 40 m provided that the EP or PUR zinc rich primer chosen is suitable for such a NDFT. In this case, the NDFT of the complete paint system can be adjusted by subsequent coats.


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4-a-2 Liquid coating systems on galvanized steel Table A.7 - Paint systems for hot-dip-galvanized steel for corrosivity categories C2 to C5-I and C5-M: Substrate: Hot-dip-galvanized steel. ISO 12944-4 gives some examples of surface preparation. The type of surface preparation depends on the type of paint system, and should be stated by the paint manufacturer.

Syst. No.

Priming coat(s) Subsequent coat(s) Paint system Expected durability *5)

(see 5.5 and ISO 12944-1) Cat 2 Cat 3 Cat 4 Cat 5-I Cat 5-M

Binder No. of coats NDFT m *2) Binder No. of coats NDFT m *2) L M H L M H L M H L M H L M H

A 7.01 --- --- --- PVC 1 80 A 7.02 PVC 1 40 PVC 2 120 A 7.03 PVC 1 80 PVC 2 160 A 7.04 PVC 1 80 PVC 3 240 A 7.05 --- --- --- AY 1 80 A 7.06 AY 1 40 AY 2 120 A 7.07 AY 1 80 AY 2 160 A 7.08 AY 1 80 AY 3 240 A 7.09 --- --- --- EP, PUR 1 80 A 7.10 EP, PUR 1 60 EP, PUR 2 120 A 7.11 EP, PUR 1 80 EP, PUR 2 160 A 7.12 EP, PUR 1 80 EP, PUR 3 240 A 7.13 EP, PUR 1 80 EP, PUR 3 320

Binder for priming

coat(s) No. of components

Waterborne possible Binders for priming coat(s)

No. of components

Waterborne possible

AY = Acrylic 1 Pack X AY = Acrylic 1 Pack X

PVC = Polyvinyl chloride 1 Pack PVC = Polyvinyl chloride 1 Pack

EP = Epoxy 2 Pack X EP = Epoxy 2 Pack X

PUR = Polyurethane aromatic or aliphatic

1 or 2 Pack PUR = Polyurethane aliphatic 1 or 2 Pack


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*2) NDFT = Nominal Dry Film Thickness, see 5.4 for further details.

*5) The durability is in this case related to the adhesion of the paint system to the hot-dip galvanized substrate 4-a-3 Liquid coating systems on metal sprayed steel substrates Substrate: Thermally sprayed metal (zinc, zinc/aluminium alloys and aluminium) surfaces. Surface preparation: See ISO 12944-4:1998, clause 13. It is recommended that sealing or application of the first coat of the paint system is carried out within 4 hours. If used, sealers should be compatible with the subsequent paint system.

Syst. No. Sealer coat Subsequent coat(s) Paint system

Expected durability *5) (see 5.5 and ISO 12944-1)

Cat 4 Cat 5-I Cat 5-M Im 1-3

Binder No. of coats NDFT m

*2) Binder No. of coats

NDFT m *2) L M H L M H L M H L M H

A 8.01 EP, PUR *3) 1 NA *7) EP, PUR 2 160 A 8.02 EP, PUR *3) 1 NA *7) EP, PUR 3 240 A 8.03 EP *3) 1 NA *7) EP, EPC 3 450 A 8.04 EP, PUR 1 NA *7) 3 320

Binder for sealing coat

and priming coat(s) No. of components

Waterborne possible *8) Binders for top coat(s)

No. of components

Waterborne possible

EP = Epoxy 2 Pack X EP = Epoxy 2 Pack X

EPC = EP combination 2 Pack EPC = EP combination 2 Pack

PUR = Polyurethane aromatic 1 or 2 Pack PUR = Polyurethane aliphatic 1 or 2 Pack *2) NDFT = Nominal Dry Film Thickness, see 5.4 for further details.

*3) It is recommended that compatibility is checked with the paint manufacturer.

*5) The durability is in this case related to the adhesion of the paint system to thermally sprayed substrate.

*7) The dry film thickness of the sealer coat will not significantly contribute to the total dry film thickness of the system.

*8) Water-borne products are in general not suited for immersion.


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Appendix 4-b Powder coating systems All the systems given are examples 4-b-1 Powder coating systems interior

Syst. No. Substrate Surface preparation

Primer Intermediate coats Topcoat Coating system Durability

Binder Type m resin Type m resin Type m Layers m Cat 1 Cat 2 Cat 3 Cat 4 Cat 5-I Cat 5-M M H M H M H M H M H M H I-P 01

QSTC2012

Documents

powder coating applicators

b powder coating systems

liquid coating systems

liquid coating applicators

approval of coating

powder coating of steel

qualisteelcoat version

application of liquid