181_de0521 paint standard rev81 (1)

Document No. DE0521 Rev 8

Automotive Service Solutions QMS

Print Date: 01/13/14 Automotive Service Solutions Confidential 1 of 5 QMS electronic document is the controlled copy

Paint Standard

1. Purpose: This standard details the physical, coverage, and cosmetic requirements of paint finishes. Physical requirements are listed for the three types of paint used: Air Dry or Oven Bake Liquid Paints and Powder Paint Finishes. Cosmetic requirements are stated based upon customer quality requirements and fitness for use concepts. The intent of this standard is to communicate the cosmetic and coverage requirements so that the painted product is of uniform visual appearance quality at the most economical cost.

2. Scope: This standard shall be utilized by Automotive Service Solutions internally, as well as suppliers and partners externally when manufacturing product to an Automotive Service Solutions design, or when third-party partner product are sourced and compliance with this paint standard is explicitly required on the design documentation. This standard applies to all Service Solutions locations and supplier network where paint is required on the drawing.

3. Definitions:

3.1. Air Dry Paint – Paint which is applied automatically or with hand equipment which does not require an oven bake to cure. Paint may be baked at up to 71° C. (160° F.) part temperature to aid in drying and increase durability. Air dry paints require 72 hours to fully cure after paint application.

3.2. Hardness – The ability of a dry paint film to withstand indentation. This is often measured in production situations with a pencil point.

3.3. Hook Marks – Marks left on the Part where it was attached to the holding fixture in the painting process.

3.4. Orange Peel – An irregularity in the surface of the paint film resulting from the inability of the coating to “level out” during cure cycle. Orange peel occurs as a characteristically uneven or grainy surface to the eye, but usually feels smooth to the touch.

3.5. Oven Bake Paint – Liquid or Powder paint applied either automatically or with hand equipment. Bake temperature range from 71° C. (160° F.) to 232 V C. (450° F.). (Note: Assemblies with rubber products in them cannot be baked above 71° C. (160° F.) part temperature. Temperatures above this will result in damage to the product.

3.6. Runs and Sags – The downward flow of a paint film as a result of its being applied as too heavy or too fluid a wet coat.

3.7. Viewing Conditions – For paint inspection, part should be viewed from approximately 914 mm (36”) under normal shop florescent lighting (of approximately 100 candle power) for no longer than 5 seconds per surface. This applies to Class B, C & E surfaces only.




4. Deviation4.1. Existing design documentation will not be updated for the sole purpose of updating the paint

color specification. When design documentation is updated for other technical reasons, all reasonable efforts shall be made to update the paint color to comply with Table 1 at that time.

4.2. In the event that a product or part must be manufactured and the drawing has not been updated with the new paint color, Table 1 shall be used to cross-reference previous color requirements with the color standards required by this design standard. This shall be considered a standing deviation with the end result being a painted finish which complies with this standard fully. No other deviations are permitted under this deviation, such as (but not limited to) changing paint color to a color other than what has already been approved in Table 1, changing coverage requirements, etc.

4.3. All other deviations related to paint, color, gloss, or any other area covered by this standard shall follow Service Solutions Waiver Process, SU0161.

5. Paint Standard5.1. Documentation Requirements

5.1.1. The requirement for paint shall be indicated in the design documentation. 5.1.2. The design documentation shall specify the paint color, according to the RAL color scale

shown in Table 1.5.1.3. When an Engineering document specifies only a paint color and no additional paint

requirements, the following specifications shall apply:5.1.3.1. Oven bake enamel, powder paint, or other approved coating is acceptable.5.1.3.2. Class “B” finish is the required cosmetic coverage code for all external surfaces.5.1.3.3. Class “C” finish coverage code is required for all internal accessible surfaces.5.1.3.4. Class “D” finish coverage code applies to all internal inaccessible areas.5.1.3.5. Gloss – Defined in section 5.4.2.

5.1.4. When an Engineering document specifies “masking” or “no paint” for specific areas of the part, Class “E” is the required cosmetic and coverage code in the indicated area.

5.2. Coverage 5.2.1. Unless otherwise specified, all dimensions, features, and tolerances required on the design

documentation shall apply after painting.5.2.2. Masking - The design documentation may explicitly require features, or specified areas to

be completely free from paint by calling-out “Mask” or “No Paint”, and then defining the affected area on the drawing. The affected area which is to be free from paint shall be fully defined.

5.2.3. Threaded Areas – Regardless of paint classification, threads must remain functional after paint. Fully functional is defined by the following inspection method(s): Go/ No-go gauge

5.3. Environmental5.3.1. All paint and application methods shall be compliant to the following standards:

RoHs REACH




5.4. Cosmetic Requirements5.4.1. Color – Colors shall be defined using the RAL color system. No noticeable difference in

color shall be apparent when production parts are compared to the RAL standard using the defined viewing conditions (Sec 3.7).

5.4.2. Gloss – Unless otherwise specified on the design documentation, the default gloss shall be 70% minimum at an angle of 20 degrees, as verified either through testing per ASTM D523, or by supplier’s submission of certification of compliance. Gloss shall be consistent across entire coverage area under the defined viewing conditions (Sec 3.7).

5.4.3. Orange Peel – Using the Powder Coat Institute (PCI) smoothness reference standard, for Class “A” of “B” finishes, the #5 panel is the maximum acceptable orange peel.

Note: Color and Gloss, or Orange Peel Standards, Do Not apply to the following: Mechanically cleaned or abraded surfaces External machining ribbed surfaces (i.e. milled surfaces, saw cuts) Castings with rough surfaces Pre-painted surfaces or parts with scale Forgings

5.4.4. Finish Classes5.4.4.1. Class “A” Finish – are required on products where appearance is critical to the

customer, in areas normally visible in the assembled product. Class “A” areas are to be noted on the part print. Viewing conditions for a Class A Finish are different than the defined viewing conditions of this specification. View from approximately 12” under normal shop florescent lighting (of approximately 100 candle power) for 5 seconds per surface. Requirements include: Conformance to the chemical and physical requirements of the coating product. Conformance to the RAL color scale. Complete coverage. No bare areas, hook marks, light paint or transparency is

allowed. Smooth finish similar to base metal finish Orange Peel must meet a #5 to #10 panel of the (PCI) reference standards, with #5

as minimum acceptable, #10 as a “perfect” smoothness condition. Overspray and dry appearances not permitted. Runs, sags, chips, dirt particles and scratches not permitted. Well-adhered dust particles are permitted, at the discretion of Service Solutions,

provided they are covered by paint and blend well with the surface finish of the paint.

5.4.4.2. Class “B” Finish – is the standard finish on Service Solutions products in areas of a product that are visible to the consumer. Coverage shall have a uniform appearance when viewed using the defined viewing conditions (Sec 3.7). If there are no visible defects at this point, the product is visually acceptable. If there are any visible defects, use the AUTOMOTIVE SERVICE SOLUTIONS Defect Size rules (Sec. 5.6) to determine if the condition is acceptable (bubbles, scattered dirt, dust, bumps, etc.) Class “B” finishes must conform to all chemical and physical requirements of the coating product.

5.4.4.3. Class “C” Finish – is required where corrosion protection is desired but cosmetics are of minor importance. Blemishes are permitted proved corrosion protection is not compromised. Class “C” finishes must conform to all chemical and physical requirements of the coating product using defined viewing conditions (Sec 3.7).




5.4.4.4. Class “D” Finish areas – are areas noted on the part print that does not require painting, but where incidental overspray is allowed. There is no coverage or cosmetic requirements for “D” areas. Class “D” finishes must conform to all chemical and physical requirements of the product.

5.4.4.5. Class “E” Finish areas – are areas noted on the part print that requires masking. Using defined viewing conditions (Sec 3.7), any overspray present after masking must be removed.

5.4.4.6. Minor Rework areas – Small rework areas may be touched up using air dry paint on class “B” or “C” (does not apply to Class “A”) finishes if the resulting touched up area blends in well with the existing paint finish when viewed using defined viewing conditions (Sec 3.7).

5.5. Packaging Requirements5.5.1. It is the supplier’s responsibility to package product being shipped to AUTOMOTIVE

SERVICE SOLUTIONS in a manner which will prevent damage to the product during shipment. It is also the supplier’s responsibility to take precautionary measures to ensure that product shipped to AUTOMOTIVE SERVICE SOLUTIONS is free from rust. To prevent rust on unpainted surfaces the supplier may use: VCI paper, VCI bags, light oil, or other rust preventatives. Parts shall be fully cured prior to packing for shipping.

5.6. AUTOMOTIVE SERVICE SOLUTIONS Defect Size rules for use:5.6.1. Inspect the part under the defined viewing conditions (Sec 3.7). If no problems are

identified at this point, the product is visually acceptable.5.6.2. If a problem is detected, use these criteria to determine if the condition is acceptable.

Bubbles, scattered dirt, dust, bumps from whatever source or other contamination are acceptable if they: Are covered by paint Are well adhered Fit within the 1.5 mm (.060”) circle Have a density of 3 or less 152 x 152 mm (6” x 6”) area

5.6.3. Except for Class A finishes, runs, sags, and hook marks are acceptable if they fit within the 13 mm (.500”) circle and do not end in a breakable bubble. Minor lightness or transparency is allowable in inaccessible or hard to paint areas, at the discretion of Service Solutions.

5.7. Physical Requirements (after cure/dry)5.7.1. It is Service Solutions’ responsibility to furnish the supplier with: rust free, and heat treat

scale free parts. In general, Service Solutions does not accept rusted parts. It is the supplier’s responsibility to inspect unpainted parts for rust, heat treat scale, and other defects prior to painting. Supplier shall notify Service Solutions of defects on parts affecting their ability to comply with this standard prior to application of paint.

5.7.2. Application Methods – Acceptable application methods include powder coat, or liquid paint. Other methods may be acceptable with prior approval from Service Solutions.

5.7.3. Thickness – Paint film thickness shall be uniform as required to meet the physical, coverage, and cosmetic requirements.

5.7.4. Adhesion – All paint finishes shall be properly adhered to the base material as defined by ASTM-D-3359, Method B (Cross-hatch adhesion test) with a minimum of a 4B rating.

5.7.5. Pencil Hardness – The minimum hardness of paint finished shall be “H” rating per ASTM-D-3363.




Table 1 – Color Specification and Cross-Reference

RAL Color Standard with Cross-ReferenceOld Code New RAL Number RAL Description

-YE3 RAL 1021 Rape Yellow-OR9 RAL2002 Vermillion-RE3 RAL 3001 Signal Red-RE2 RAL 3002 Carmine Red-BL2 RAL 5005 Signal Blue

Kent-Moore Blue RAL 5005 Signal Blue-GR9 RAL 6002 Leaf Green-GR14 RAL 6021 Pale Green-GR5 RAL 6025 Fern Green-TA2 RAL 7002 Olive Grey

Caterpillar Buckskin RAL 7002 Olive Grey-WH2 RAL 7004 Signal Grey-GY3 RAL 7004 Signal Grey-GY4 RAL 7004 Signal Grey-GY9 RAL 7004 Signal Grey-BR13 RAL 8003 Clay Brown-BR4 RAL 8008 Olive Brown

- RAL 9003 Signal White-BK2 RAL 9004 Signal Black-GY8 RAL 9006 White Aluminum

Note: RAL 9004 can be substituted for RAL 9005 (black)

181_de0521 paint standard rev81 (1)

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