qualisteelcoat technical specifications version21 31102013

8/12/2019 Qualisteelcoat Technical Specifications Version21 31102013

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QUALISTEELCOAT Version 2.1

QUALISTEELCOATTechnical Specifications


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QUALISTEELCOAT

Preface: The technical committee of QUALISTEELCOAT is continually improving this Technical Specification.

The main target of version 2.1 was to improve the readability. Changes were mainly made in order to reduce thetext and to avoid mentioning the same issues in different chapters. The result is that chapter 6 and appendixes 5-9 are cancelled. In order to keep the comparability with Version 2.0, the numbering remains unchanged. Onlychapter 7 Approvals of coatings was revised completely.

Chapter 1 General information

Chapter 2 Quality assurance by the coating applicator

2.1 Expected performance2.2 Test panels

2.3 In-house control2.3.1 Procedures2.3.2 Blasting surface preparation quality control2.3.3 Chemical pre-treatment quality control

2.3.4 Finished products quality control2.4 Tests of resistance to environmental impact

Chapter 3 Surface preparation

Chapter 4 Coating systems

Chapter 5 Requirements coating process and storage5.1 Coating process5.2 Storage

Chapter 6 (cancelled)


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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 MasterLicence for the whole country in question.

Testing laboratories: Independent quality testing laboratories duly approved by the generallicensee and/ or QUALISTEELCOAT.

The technical specifications are based on atmospheric Corrosivity Categories in accordancewith 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 alsoapplies 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 applicationfirms 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 Th diff d f l i


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QUALISTEELCOAT Interior Licence (I) C1 and C2:The parts are briefly exposed to temperature changes or humid atmosphere. Suchpre-treated parts are mostly used indoors.

The applicable control level, based on which test samples are taken, is C-2 medium.

QUALISTEELCOAT Exterior Licence(E)C1 C5 (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, thesubstrate 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 applicablecontrol 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 tothose laid down in these specifications must be agreed between the QUALISTEELCOATlicensee and its customers.

QUALISTEELCOAT members production processes must be proven reliable, in accordance

with the stipulated minimum requirements. The members are obliged to comply withQUALISTEELCOATs specifications and any additional specifications provided by the

customer.

If the system has not been approved previously by QUALISTEELCOAT this must be clearlystated 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 theQUALISTEELCOAT inspector.


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Chapter 2 QUALITY ASSURANCE BY THE COATING APPLICATOR

2.1 Expected Performance

The durability of the coating system depends on the surface pre-treatment and thecomposition of the coating system. The purchase order must, therefore, provide relevantinformation as to the Corrosivity Category of the environment where the coated object will be

used. Reference is made to appendix 1.

2.2 Test Panels

The samples must be taken from production. Should this not be possible, test panels mustcomply with EN ISO 1514. A separate list of the standards used in these specifications andthe year(s) of validation is given in appendix 10.

In order to assess the characteristics of coating materials, they are tested on metal testpanels in accordance with EN ISO 1514. Test panels must be made of the same metal asthe 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. Thecoating system applied to the test panel shall show no scratches penetrating as far as thesubstrate.

2.3 In-house control

2.3.1 Procedures

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


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- The references of the coating used;

- RAL colour;

- Lot number;

- Producers name;

- Product name;

- Corrosivity category of the environment in which the product will be used;

- Coating system used;

- The dew point of the air on the object;

- Gloss;

- Thickness of the different layers of the coating system;

- Appearance;

- Colour shade inspection (visual inspection to compare colour with the colourrequired by the customer).

2.3.2 Blasting surface preparation quality control

2.3.2.1 Procedures

The applicator has to monitor his production methods and products in accordance with thefollowing frequency and methods.

Testing method Interior Exterior

Inspection of coatability of parts All parts All parts

Particle size of shot or gritInapplicable

Twice a year by supplier

Surface roughness None Once per shift

Loss of zinc due to blasting Inapplicable Once per shift

Assessment of blasted zinc and None Once per shift


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Laboratory and inspection equipment for Blasting Surface Preparation

Instruments Classification I or E Quantity

Set of sieves to determine grit seizedeviation *1

Exterior (1) From supplier

Roughness measurement equipment Exterior 1

Thickness tester, individual or multi-purpose gauges

Interior + Exterior 2

ThermometerDew Point


Equipment and chemicals for testing the

conversion coating *2

Exterior 1

Conductivity meter *2 Exterior 1

Temperature paths for drying oven Exterior 1

*1 when reusing shot or grit*2 if conversion coating is applied

2.3.2.2 Coatability of parts to be coatedCareful processing is required to avoid split or pockets in which non-removable pre-treatment

residue could cause damage, corrosion or insufficient adhesion.

Before the coating system is applied at first the substrate must be inspected for dirt and anysurface products that may interfere with proper surface preparation. If the surface of the

object is contaminated or otherwise not ready for surface preparation, additional action mustbe taken to prepare the substrate for pre-treatment. This includes checking for welding

spatters, sharp edges and extra-hardened steel on edges. See also EN ISO 8501-3 forwelds, edges etc.


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2.3.2.4 Blast result of hot dip galvanized zincRESULT:

After blasting, using inert sharp non-metallic grit, the zinc layer of hot dip galvanized steel the

substrate must be equally mat. The whole surface has to be equally blasted resulting in slightroughening of the surface to improve adhesion.

2.3.2.5 Inspection of surface cleaning after blasting

The surface of the blasted steel has to be inspected for the removal of all mill scale, rust andimpurities in accordance with EN ISO 8501-1. After visual inspection of the substrate anadditional test can be conducted to assess the surface cleanliness in accordance with ENISO 8502-3.

RESULT:The result may not exceed Class 1, quantity and dust size. The tape may show nodiscoloration and the particles visible under x 10 magnification but not with normal orcorrected vision (usually particles less than 50 !m in diameter.

2.3.3 Chemical pre-treatment quality control

2.3.3.1 Procedures

The chemical pre-treating company has to monitor his production process, methods andproducts.

Test method Interior Exterior

Inspection of coatability ofsubstrates

Every object Every object

Concentration of pre treatment1) Inapplicable Once a day


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The control register must show all measurements and results of the tests shown in the table.If the results of earlier analyses necessitate an increase in the frequency of analyses, thecoating applicator must do so of his own accord.

Laboratory and inspection equipment for chemical pre-treatment

The chemical pre-treating company must have the following devices at its disposal:

Instruments Type of licence Quantity

Thickness tester, individual or multi-purposegauges


Conductivity meter Exterior 1pH meter and thermometer Interior + Exterior 1

Chemicals to determine the bath strengths Exterior 1

Test solutions for Zn and Al content *1 Exterior(Only with mixed bath)

1

Test solutions and equipment for testingchemical conversion coating *1 *2

Exterior1

Temperature paths for drying oven Exterior 1

*1 If combined Zinc and Aluminium baths are used.*2 If recommended by the chemicals supplier

2.3.3.2 Determination of the conductivity of dripping waterThe 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 usedfor the final rinse after chromate treatment, prior to drying.

RESULT:

If t th i ib d b th h i l li th d ti it f d i i t h ll


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Chromate-phosphate treatment (green): 85CChrome-free treatment: maximum as stipulated by the supplier

The maximum drying temperature allowed for continuous treatment is 100C, but thesubstrate must be heated to a minimum of 60C. The specified temperatures apply to the

temperature of the metallic parts and not to the air temperature. The products must be driedthoroughly before the coating is applied, irrespective of the production method (continuous/

discontinuous).

The chemicals supplier in question must provide the application firm with the relevantinformation on the desired test method, equipment and chemicals.

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

2.3.3.5 Inspection of the result of the surface preparationAfter the surface preparation process, the substrates have to be inspected for proper

execution and the removal of all corrosion products.

RESULT:The result must be a clean corrosion-free substrate fit for the application of a coating.

2.3.4 Finished products quality control

2.3.4.1 ProceduresThis table is a concise list of the desired tests.


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Test method

Powdercoating orLiquid

coating

Interior Exterior

Boiling test2)

P Inapplicable Once a week

L Every order Every order

*For liquid coating also wet thickness has to be measured

The test must preferably be conducted on products used in production.

1)

On product if unable to test panel2) On test panels3)On thin test panels 0.6 to 0.8 mm

The control register must show all measurements and results of the tests shown in the table.

Laboratory and inspection equipment for finished products

To conduct the tests the coating applicator must have the following devices at its disposal:

Instruments Type of license Quantity

Cutting devices and accessories for crosscutting

Interior +Exterior

1

Equipment to execute the impact test Exterior 1

Wet thickness gauge* Interior +Exterior

1

Thickness tester, individual or multi-purpose Interior +

E t i 2


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RESULT:

ResultTestmethod

Dft Outdoor

Resistant

coatings

Results

Indoor

resistant

coatings

Results

CorrosivityCategory

!m C1 C2

C3 C5

C1 C2

C3 C5

C1 C2

C3 C5

C1C2

C3 C5

Adh

esio

n

< 60

X

X

0 - 1 -

X na

01 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- 5MPa

- na-

5MP

a

For each colour shade, gloss category and supplier, the adhesion properties must be testedon sample panels once per shift

2.3.4.3 Impact resistance testEN 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 issubjected to deformation caused by a falling weight, using a 20 mm diameter sphericalindenter dropped under standard conditions.

The term "impact resistance" is used in the title of this standard, but one important

h t i ti f th d i d i th t it h ld d id d f ti th th t


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

2.3.4.5 Determination of surface hardness

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. This standard specifies a method of comparing the surface hardness of dried paintsurfaces by using pencils

RESULT:

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

2.3.4.6 Determination of particle size distributionThe objective of the test is to determine the mixture and size of the blast grit or shot particlesused for surface preparation. The particle size distribution test is conducted in accordancewith 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%. Theresult 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 informationabout the size distribution of the blast medium.

If requested, the particle size of the blast shot or grit has to be assessed. The objective is to

d t i h th th bl t i i th i it If it i d ti l


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RESULT:The wet film thickness must be in accordance with the calculated wet thickness in order toobtain the desired dry film thickness.

During the application of the coating, the sprayer must measure the wet film thickness of the

applied coating layer, using a wet thickness gauge. The results must be recorded on theproduction chart.

2.3.4.9 Determination of dry film thicknessThe dry film thickness of the individual coats in the system and the total dry film thicknessmust be measured according EN ISO 2808 Paints and Varnishes Determination of Film

Thickness

The number of measurements to be taken depends on the number of parts in the batch.

Lot size *Number of samples(random selection)

Acceptance limit for rejectedsamples

1 10 All 0

11 200 10 1

201 300 15 1301 500 20 2

501 800 30 3

801 1,300 40 3

1,301 3,200 55 4

3,201 8,000 75 6

8,001 22,000 115 8

22,001 110,000 150 11

* L t i Th b f it f i il h d i


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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 PROTECTIONSTRIPE COAT(S),

INTERMEDIATE COAT 1stcoat

INTERMEDIATE COAT2nd coat

TOPCOAT 1stcoat

Topcoat 2ndcoat

TOTAL NOMINAL DRY FILM THICKNESS

2.3.4.10 GlossFor liquid coating the test only to be conducted if required by the customer.

Gloss has to be measured according to 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 thegloss meter, the gloss should be compared visually with the reference sample (from the

same viewing angle).


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2.3.4.12 Testing the stoving conditions (applicable for forced drying or curing for wetpaint and powders)

For curing the temperature in the curing oven as well as the object temperature in the ovenmust be measured. 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 substrateand one to a reference panel mounted on the traverse.

RESULT:A curve resulting from the results measured (minimum and maximum values). In this curve,times and temperatures provide the requested information on the curing process.

For forced drying 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 attachedto the substrate. When drying at an ambient temperature, the curing temperature of theproducts must be measured using a surface temperature gauge.

RESULT:In the drying oven the thickest part of the steel must reach a temperature of at least 60degrees Celsius. When drying at an ambient temperature the substrate temperature of the

substrate must be in accordance with the curing temperature specified in the product datasheet.

2.3.4.13 Polymerisation testThe objective of this test is to determine the polymerization for powder and liquid coating

systems. This test is useful as compare the test of the panel with a fully cured coating layer.

F h li h l i ti t t t b d t d l l t l t


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2.3.4.14 Appearance test (Visual inspection)Visual inspection should take place by using normal or corrected vision at a distance of 3 mfor indoor application. In case of outdoors application the distance is to be 5 m. When a

coated test panel is examined, no blisters, craters, pinholes or scratches shall be visible froma distance of 1 meter in diffuse light.

RESULT:

At these distances, the coating should not show any wrinkles, runs, sags, craters, blistersand other surface irregularities. Irregularities as a result of the steel substrate or the hot dipgalvanized zinc are not to be taken into account. The inspection must be conducted in diffusedaylight.

When the end user desires other distances or inspection criteria, the client, applicator andgalvanizer should agree these in advance.

The result must be inspected in accordance with the customers requirements.

Lot size (*)Number of samples(random selection)

Acceptance limit forrejected samples

1 - 10 All 0

11 200 10 1201 300 15 1

301 500 20 2

501 800 30 3

801 1,300 40 3

1,301 3,200 55 4

3,201 8,000 75 6

8,001 22,000 115 8


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RESULT:There must be no defects or detachment. Some colour change is acceptable.

2.4 Tests of resistance to environmental impact

2.4.1 Resistance to mortarThis test is used to assess the resistance of the coating system to fresh mortar. This test isonly 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 withsufficient tap water to make a soft paste. Apply four portions of the mortar, approximately 15mm in diameter and 6 mm thick, to the test panel.

Place the test panel horizontally at 38 3C and 95 5% relative humidity for 24 hours.At the end of the period, manually dislodge the mortar from the coating surface and removeany residue with a damp cloth. Allow drying and examining the coating with normal orcorrected vision, to determine the incidence of visible detachment of the coating due to theeffect and removal of the mortar.

RESULT:

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

2.4.2 Neutral salt spray test

Th bj ti f thi t t i t d t i th i i t f th ti t F


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RESULT:

Neutral salt spray

EN ISO 4628-2 Blistering 0 (S0)Assessment immediately

after aging testEN ISO 4628-3 Rusting Ri 0

EN ISO 4628-4 Cracking 0 (S0)

EN ISO 4628-5 Flaking 0 (S0)

Corrosion of thesubstrate fromthe scribe

Test regimeEN ISO 9227

M "2 mm

A. 3 samples in order = 0 sample not in order

B. 2 samples in order = 1 sample not in orderC. 1 sample in order = 2 samples not in order

D. 0 sample in order = 3 samples not in order

Evaluation:

Approval LicenceA In order In order

B In orderIn order with corresponding information to

be submitted to the coating company

C Not in orderRepetition of salt spray test only if result ofsecond test is A or B, the test will beconsidered successful.

Not in order, the whole test must be

t d i


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Approval Licence

A In order In order

B In order In order with corresponding information tobe submitted to the coating company

C Not in orderRepetition of constant atm. of condensationtest only if result of second test is A or B,the test will be considered successful.

D Not in order

Not in order, the whole test must beexecuted again.

Or class to be verified at coating company

2.4.4 Chemical resistance test

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 inaccordance 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 followingchemicals of recognized analytical quality shall be used:

a) NaOH 10 % aqueous solutionb) H2SO4 10 % aqueous solutionc) Mineral spirits containing 18% aromatics

This test is not used for the assessment of corrosion protection properties but to determinethe ability of a system to withstand highly industrial environments. Therefore, the test

d ti i th f M di d Hi h d bilit


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be submitted to the coating company

C Not in orderRepetition of test only if result of secondtest is A or B, the test will be considered

successful.

D Not in order

Not in order, the whole test must beexecuted again.

Or class to be verified at coating company

2.4.5 Resistance to humid atmosphere containing sulphur dioxide test

The objective of this test is to determine the resistance to heavily polluted atmospheres. Thecoated surface is exposed to SO2 in a test cabinet; according EN ISO 12944-6, test EN ISO

3231.

In accordance with EN ISO 3231 using 0.2 litre SO2 and the following test duration:

240 h (10 Cycles) for Medium durability Category 4480 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)Assessment immediatelyafter aging test

EN ISO 4628-3 Rusting Ri 0

EN ISO 4628-4 Cracking 0 (S0)

EN ISO 4628 5 Fl ki 0 (S0)


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This test is only required for coating systems intended for outdoor application. To be grantedapproval 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 20 W/m2 (290 800 nm)

Black-standard temperature 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 attachedtable.


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To assess gloss and colour, three measurements will be made on the cleaned, weatheredsamples and on the unexposed reference panels. These measurements are to be made atdifferent points at least 50 mm apart.

RESULTS:

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 thefollowing table:

Table RAL/Delta E (admissible colour deviation after weathering in Florida)

RAL Delta E

RAL Delta E

RAL Delta E

RAL DeltaE

RAL Delta E

RAL Delta E

RAL Delta E

RAL Delta E

RAL Delta E

1000 3.0 2000 6.0 3000 6.0 4001 4.0 5000 4.0 6000 5.0 7000 4.0 8000 4.0 9001 2.0

1001 3.0 2001 8.0 3002 6.0 4002 4.0 5001 4.0 6001 5.0 7001 3.0 8001 4.0 9002 2.0

1002 3.0 2002 8.0 3003 4.0 4003 8.0 5002 4.0 6002 5.0 7002 4.0 8003 4.0 9003 2.0

1003 2.0 2003 6.0 3004 4.0 4004 5.0 5003 5.0 6003 5.0 7003 4.0 8004 4.0 9005 5.0

1004 6.0 2004 8.0 3005 4.0 4005 4.0 5004 5.0 6004 5.0 7004 4.0 8007 4.0 9006 2.0

1005 6.0 2008 6.0 3007 4.0 4007 5.0 5007 4.0 6005 3.0 7005 4.0 8008 4.0 9007 2.0

1006 6.0 2009 4.0 3009 4.0 4009 4.0 5008 5.0 6006 4.0 7006 4.0 8011 4.0 9010 2.0

1007 6.0 3011 6.0 5009 4.0 6007 4.0 7008 4.0 8012 4.0 9011 5.0

1011 3.0 3012 8.0 5010 4.0 6008 5.0 7009 4.0 8014 4.0 9016 2.0

1012 3.0 3013 6.0 5011 5.0 6009 4.0 7010 4.0 8015 4.0 9018 2.0

1013 2.0 3014 4.0 5012 4.0 6010 5.0 7011 4.0 8016 4.0

1014 3.0 3015 3.0 5013 5.0 6011 4.0 7012 4.0 8017 4.0

1015 2.0 3016 5.0 5014 4.0 6012 4.0 7013 4.0 8019 3.0

1016 6.0 3017 8.0 5015 3.0 6013 3.0 7015 4.0 8022 5.0

1017 3.0 3018 8.0 5017 5.0 6014 4.0 7016 3.0 8024 4.0

1018 6.0 3020 4.0 5018 5.0 6015 4.0 7021 4.0 8025 4.0

1019 3.0 3022 8.0 5019 4.0 6016 5.0 7022 4.0 8028 3.0


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2.4.8Colour differenceThe nuances in colour between charges and coated parts may not differ beyond certainlevels. The objective is to determine the nuances in colour.

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 colour nuances may only bedetermined at diffuse daylight.

RESULT:The acceptable level is 3 / 4 of the EN 20105-AO2 scale

2.4.9 Gloss differenceThe objective is to measure the differences in gloss. Gloss is also used to determine thepolymerization of glossy powder coatings.

RESULT:The gloss level difference in the production of QUALISTEELCOAT products shall be withinthe tolerance limits indicated by the manufacturer. If the manufacturer has indicated no

tolerance limits, 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 thespecified gloss level

>50 10

"50 7


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Chapter 3 SURFACE PREPARATION (see EN ISO 12944-4)

3.1 Information on substrates

To ensure the surface preparation will be performed in accordance with requirement, detailedinformation 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 sufficientdistance from the pre-treatment devices. The parts are to be protected against condensationand dirt.

3.3 Removal of contamination

Before the substrate is fit for surface preparation and the application of a coating system, anysurface 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, toprevent 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.


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Chapter 4 COATING SYSTEMS

4.1 Coating systems in different environmentsDepending on the environment where the coated object is used, different coating systemsare 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 durabilityproperties 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 coatingsystems 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 powdercontaining epoxy powder coatings, and electro deposition coatings. Depending on theenvironment, 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 ismost demanding. In such a case, coating systems from a Corrosivity Category, one full levelhigher than would be chosen under normal circumstances, is recommended.

It is also recommended to carefully clean the coated substrate at intervals asmentioned in the following table:

Frequency of cleaning usinghot Corrosivity Category


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Chapter 5 REQUIREMENTS COATING PROCESS AND STORAGE

5.1 Coating process

5.1.1. General

This Specification describes general requirements for the coating process and storage.

5.1.2 Testing the Coatability of ObjectsObjects 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.

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 process.

5.1.3 5.1.5 is already described in chapter 3.

5.1.6 Oven drying (only in case of chemical pre-treatment)

After chemical pre-treatment and prior to the application of a coating, the parts must be driedthoroughly in an oven. For this purpose, a drying oven must be installed in each chemical

pre-treatment plant.

5.1.7 Coating application, curing and drying liquid coatingsAfter 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 curedor pre-cured depending on the system.


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5.1.8 Coating application and curing powder coatingsAfter surface pre-treatment the coating system must be applied. The substrate must be cleanprior to application. One or more layers must be applied and the different layers must be

cured or pre-cured depending on the system.

Dust and contamination free conditions must prevail between the spray booth and the oven.All workers handling pre-treated parts must wear clean textile gloves to avoid contamination

of the surface.The coating must be applied in a dust-free environment. The parts must be kept at sufficientdistance to ensure proper application of the powder coating. The powder coating must be dryand free of clotted parts or dirt.

The parts must be installed and earthed sufficiently to ensure an even application of thepowder coating.

After application the coating must be cured. The objects must be placed in an oven. Caremust be taken as regards the temperature of the substrate. The coating applicator mustcheck whether the curing temperature suffices.

All powder coatings must be cured immediately after application. The oven must heat up themetallic parts to the required temperature and maintain them at that temperature for the

duration of the stoving process.The temperature of the metallic parts and the stoving time must match the values

recommended in the manufacturer's technical specifications.It is recommended to keep the difference in temperature between the coldest and hottest

sections of the treated parts below 20C.It must be possible to measure the temperature across the entire length of the oven. Theoven must be equipped with an alarm system that immediately warns when the temperatureexceeds the agreed temperature range.


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5.2.4 Storage of coated materialThe coated products must be professionally stored in a dry and clean room to avoid damageto and dirt collection on the coated surfaces. The parts must be packed as per the

costumers specification as soon as possible. Parts not accepted by quality control must beclearly labelled and kept separated from the accepted parts.

Remark: Chapter 6 (cancelled; see index)


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Chapter 7 APPROVAL OF COATINGS

7.1 Terminology of the process steps

In the following figure, the definition of the several preparations and layers is visual:


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7.2 Scope of the approvalIn order to maintain optimal performance of the paint systems applied by theQUALISTEELCOAT licensed coating applicators, the quality of the coating supplied by

coating manufacturers is tested. In this part of the specification, the test methods andacceptable test result limits are given.

A QUALISTEELCOAT COATING SYSTEM is defined by:

The presence and the type of the metallic layer.

Type of surface pre-treatment (chemical/mechanical)

Number and type of organic layers

Finish of the topcoat (gloss level and smooth/textured) cfr. Qualicoat.

7.3 Examples of coating systemsExamples of powder coating systems are given in Appendix 4.Examples of liquid coating systems are given in accordance with ISO EN 12944-5.

7.4 RulesAny change in the formula of the coating, for example bonding agent (resins and/or

hardening agents), as well as additives, means that the product will be regarded as a newproduct, which, consequently requires separate QUALISTEELCOAT approval. Furthermore,

the manufacturer must renew his application for approval should the visual appearance ofthe final coating show changes (textural or wood effect).

For liquid coating: The manufacturer must not use the approval for a smooth surface.The systems finished using a full colour are different from systems using MIO finishes. Thestipulation of textures is subject to QUALISTEELCOAT-drafts.

Any organization may submit a coating system for approval. The applicant has to provide


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Weathering resistant systems granted temporary approval will receive final approval uponreceipt of satisfactory weathering test results. If not, the temporary approval is withdrawn.

7.6 Approval numberWhen approved, the system will obtain a QUALISTEELCOAT identification number with the

addition of PI for interior coating systems, PE for exterior coating system, and theCorrosivity Category for which the system has been tested.

Certain test results from approved laboratories, collected to obtain other quality labels, maybe used as test results for QUALISTEELCOAT. This only applies to artificial weathering andoutdoor exposure tests.

The laboratorys test results related to obtaining approval from other quality assurancesystems for the given coating systems may be used, provided that the tests conductedcomply with these specifications.

A visit by the general licensee or by QUALISTEELCOAT in countries without a nationalassociation may be required. The applicant will pay the costs of such a visit.


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7.7 Approvals of coatings

7.7.1. Approval of powder coating

7.7.1.1. Powder coating systems (Quick Guide)

Choice of the QUALISTEELCOAT Coating System

The powder supplier can only request an approval for a Coating System Type defined in thetable in 7.7.1.1.b. (yellow fields)He has to define precisely the system targeted and to describe the process used to coat thepanels provided (Chemical pre-treatment or mechanical and complete pre-treatment process

including pre-treatment process steps).

Coating Systems


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7.7.1.2. Type of test panelsTest panels Purpose Substrate Application Dimensions

Type A Mechanical

tests

Test panels +

Coating Systems

Applied by laboratory at

lowest curing conditions(lowest temperature,

lowest corresponding timeaccording TDS)

105 x 190 x 0,75 mm

(ref. GB26S/W/OCEtalon)

Bare steel + zincphosphate

Type B Corrosiontest

Substrate +SurfacePreparation +

Coating Systems

Applied by the powdersupplier or by thelaboratory

140 x 70 x 2 mmType 12-03

Type C Florida EN AW5005 +Coating Systems

Applied by laboratory atlowest curing conditions(lowest temperature,lowest corresponding time

according TDS)

300 x 100 x 2 mm

7.7.1.3. Required tests

For the initial approval, the following colour has to be tested: white, RAL 9010.Test Ref.

QSC

Type

panel

Norm Requirements

Gloss 2-a-10 A ISO 2813 see 2.3.4.10

Film Thickness of metallicand organic coatings

2-a-9 A, B, C ISO 2808 +ISO 19840 +ISO 12944-5

According to system description


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Table 7.7.1.3.a. Requirements for the Neutral Salt Spray tests for the approval ofPowder Coatings.

Coating System Type:

ST1, ST2, ST3, EC1, EC2(test with scribe)

Coating System Type:

SZ1, SZ2, HD1, HD2, MS1, MS2(test without scribe)

EXTERIOR C3H No loss of adhesion, no blistering,no rust breakthrough, M "2 mmafter 480 h

No loss of adhesion, no blistering,no rust breakthrough after 480 h

EXTERIOR C4H No loss of adhesion, no blistering,

no rust breakthrough, M "2 mmafter 720 h

No loss of adhesion, no blistering,

no rust breakthrough after 720 h

EXTERIOR C5H No loss of adhesion, no blistering,

no rust breakthrough, M "2 mmafter 1440 h

No loss of adhesion, no blistering,

no rust breakthrough after 1440 h

Table 7.7.1.3.b. Requirements for the Resistance to Continuous Atmosphere

C2 INTERIOR 120 h

C3 EXTERIOR 240 h

C4 EXTERIOR 480 h

C5 EXTERIOR 720 h

No loss of adhesion, no blistering, no rust breakthrough after the mentioned number of hoursin the test cabinet.

7.7.1.4. Number of test panels Type B for the laboratoryThis part describes the number test panels type B that are necessary to execute all tests.


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7.7.1.5. Renewal of Approval of Powder Coatings

Timing

Every (2) years, the supplier of the coating supplies the laboratory the necessarycoating, test panels for the tests.

TestsThe tests to be executed are the same for the renewal as for the initial granting.

A summary of these tests can be found in the required tests in 7.7.1.3..

Choice of colour and finishEach two years, the WG Approval of PC defines the colour that has to be tested. Initial the


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Chapter 8 LICENCE FOR COATING APPLICATORS

8.1 Procedure

Any coating applicator working in the field of QUALISTEELCOAT can apply for a licence. Inorder to obtain a licence the procedure will be followed:

One inspection must be satisfactory before a licence is granted. This inspection will be made atthe 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 coatingapplicator producing a higher level product is necessary to obtain a licence on the desiredlevel.

8.2 Inspection

During the inspection, the inspector will check the following points using the inspection

form approved by QUALISTEELCOAT.

- Inspection of coating materials; the inspector will check that the coating applicator usescoating systems approved by QUALISTEELCOAT (see chapter 7).

- Inspection of laboratory equipment; the inspector has to ensure that the equipment isavailable and functional. He will also verify whether relevant standards or written operating

instructions are available.

- Inspection of process, production, equipment at the laboratory and equipment at the


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8.3 Final assessment for granting the licenceThe inspector submits the inspection report to the general licensee or directly to

QUALISTEELCOAT in countries where there is no general licensee. The inspection reportsare assessed by the general licensee or by QUALISTEELCOAT in countries where there is

no general licensee.

If the result of the inspection meets the requirements, a licence to use the quality label willbe granted.

If the result of the inspection does not meet the requirements, the coating applicator will be

informed that a licence cannot be granted for the time being, stating reasons. The coatingapplicator must wait at least three months before making a new application for a licence.

8.4 Routine inspections of licensees

After a plant has been granted a licence to use the quality label, it shall be inspected twice ayear. Routine inspections shall include the same items as for granting a license.

For the years 2013, 2014 and 2015 only one inspection shall be carried out.

The inspector submits the inspection report to the general licensee. If no general licensee isavailable the report will be sent to QUALISTEELCOAT. The inspection reports areassessed by the general licensee or by QUALISTEELCOAT in countries where there is no

general licensee.

If the result of the inspection meets the requirements, authorisation to use the quality label will


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Appendix 3a 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 gasbubbles appearing as blisters or craters on the coated surface. Parting compoundstoo could impair adhesiveness. Therefore, coating companies should be informed ofthe 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 beinformed about the surface preparation needed after galvanizing. Hot dip galvanizingmust be executed in accordance with ISO 1461. The galvanized steel must becleaned 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


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Substrate remarks before coating application

" Laminated steel cold

Low thicknessClean aspect

Generally oiled" Laminated steel hot

Average with strong thicknessAny type of aspect and cleanliness

Pickled oiledWith adherent calamine (IPS)

With blue or black calamine" STAINLESS

Disadvantages to applying paint

The laser beam releases great energy, and assembles metal at very hightemperature under pulsated oxygen, resulting in brutal oxidation of metal. Iron

oxide Fe3O4, called Magnetite or blue calamine is formed along the lasercutting 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 zonesmost exposed to shocks.

Possible solutions

Underwater or inert gas laser cutting may solve the problem. (Parameters


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- Hydrochloric

- Sulphuric

- Phosphoric

- Citric

- Gluconic

- PhosphonicThey are additives of surfactants and inhibiters in accordance with therequired treatment (simple scouring, scouring-grease-remover, grease-remover-paint remover-phosphatizer). Both soaking and sprinkling arepossible.

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, bymeans 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:


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3.a.6 Information table for the treatment of substrates

Types of parts E coatPowder zincprimer

Zinc spraying50 a 200 !m

Sendzimir15 a 30 !m

Hot dip

galvanized 50a 200 !m

PortalSecure thedimensionsof the baths

Be careful withthe air-gaps(volutes, rings,beaten)

Be careful withthe air-gaps(volutes, rings,beaten)

Closed andtight welds

Sheets andnettings mustbe separate

Keep body

Requireholes ofcirculation

andevacuation

Require arecovery at

the level ofthe welds

Require holesof circulation

and evacuation

Plane sheet

Weakness anti-corrosive onthe level of thenozzles ofcutting

Adapted

Weaknessanti-corrosive onthe level ofthe nozzlesof cutting

Suitable forlargethicknesses

Cut out Sheet

Suitable for

finethicknesses

PerforatedSheet

Expandedmetal

Riskdeformationdue to shot-blasting forsheets < = to

Riskdeformationdue to shot-blasting forsheets < = to

The surfacequality canpresent defects


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Types of parts E coatPowder zincprimer

Zinc spraying50 a 200 !m

Sendzimir15 a 30 !m

Hot dipgalvanized 50

a 200 !m

Without Sheets

Requireholes ofcirculationand

evacuation

If noprecautions aretaken by themetal sprayer

there a risk ofimprisonmentof the shotduring theoperation of

shot-blasting

If noprecautions aretaken by themetal sprayer

there a risk ofimprisonmentof the shotduring theoperation of

shot-blasting

Require arecovery at

the level ofthe weldingandmachining

Require holesof circulation

and evacuation.Is likely to fill therabbets orthroats

Opening Sheet

If the sheetsare not

weldeduninterruptedl

y they mustbe coatedseparately, toavoid the

absence ofprotectionbetween

sheet andtallies

If the sheets

are not weldeduninterruptedly

they must becoatedseparately, toavoid the

absence ofprotectionbetween sheet

and tallies

If the sheets

are not weldeduninterruptedly

they must becoatedseparately, toavoid the

absence ofprotectionbetween sheet

and tallies

Require arecovery atthe level of

the weldingandmachining

One face

In the eventof insulationthe 2 sheetsare coated

In the event ofinsulation the 2sheets arecoated

In the caseof twosheets,


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Appendix 3b REMOVAL OF CONTAMINATION

3.b Surface treatment before pre-treatment

3.b.1 Old coating (coated substrates)

All residues 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 beremoved 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 aftercoating: they cause clearly visible craters and smears and reduce the adhesive powerof the coating material on the surface. Therefore, application of silicone parting

agents has to be avoided during processing on the untreated part. In case suchagents 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.


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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 beremoved

Procedure

Grease and oil

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

freshwater.

Steam cleaning Fresh water. If detergents are added, rinsewith freshwater.

Emulsion cleaning Rinse with freshwater.

Alkaline cleaning Aluminium, zinc and certain other types ofmetal coating may be susceptible tocorrosion if strong alkaline solutions are used

and should, therefore, be rinsed with freshwater.

Organic-solventcleaning

Many organic solvents are hazardous tohealth. If the cleaning is performed using

rags, they will have to be replaced at frequentintervals, otherwise oil and greasecontaminants will not be removed, but will beleft as a smeared film after the solvent hasevaporated.


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Appendix 3c 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 beremoved 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 corrosionresistance 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 aswell 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 heavychemical cleaning. Preliminary tests are recommended.

The quality of the surface preparation and the methods available depend highly on the shapeand 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 ofsurfaces and surface preparation. This standard also refers to EN ISO 8501-1 preparation

of steel substrates before application of paint and related products.


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3.c.2 Part 4 of EN ISO 12944 deals with the following types of surfaces of steelstructures 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 ISO12944.

In appendix 3-b the cleaning and removal of all foreign matter is discussed. In this appendixthe 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.

For chemical methods the composition of the chemicals is the responsibility of the chemicalsmanufacturer. 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 foraluminium is also used for steel or galvanized steel, the chemicals manufacturer must informthe coating applicator of the maximum concentration of zinc and aluminium allowed. The


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3.c.3 Surface Pre-Treatment MethodsProcedures for removal of rust and mill scale

Matter tobe

removed

Procedure

Mill scaleChemical Cleaning The process is generally not performed on site.

Rinse with freshwater.

Dry abrasive blast-cleaning

Shot or grit abrasives. Residue of dust andloose deposits will have to be removed byblowing off with dry oil-free compressed air or

by vacuum cleaning.Wet abrasive blast-

cleaning


Flame cleaning Mechanical cleaning will be required to remove

residue from the combustion process, followedby removal of dust and loose deposits.

Rust

Chemical Cleaning

The process is generally not performed on site.


Power-tool cleaning Mechanical brushing may be used in areaswith loose rust. Grinding may be used for firmlyadhering rust; residue of dust and loose

deposits will have to be removed.

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

Spot blast-cleaning For localized removal of rust.


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3.c.4 Pre-treatment (Category 1)Abrasive - abrasive-blasting Sa 2, or

Chemical - degreasing, orChemical - phosphating or alternative processes.

3.c.5 Pre-treatment (Category 2)

Abrasive - abrasive blasting Sa 2, orChemical - phosphating, or alternative processes.

3.c.6 Pre-treatment (Category 3 + 4 + 5):Abrasive - Abrasive blasting to Sa 2 1/2 orAbrasive/chemical - Abrasive blasting Sa 2 1/2 + passivation or

Chemical - De-oxidation and passivation, phosphating oralternative processes.

The purpose of the pre-treatment process is to remove all corrosion products from thesubstrate and to produce a substrate suitable for the application of a coating system.


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Appendix 4a LIQUID COATING SYSTEMSAll the systems given are examples.4.a.1 Liquid coating systems on steel


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4.a.2 Liquid coating systems on galvanized steel


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4.a.3 Liquid coating systems on metal sprayed steel substrates

QUALISTEELCOAT V i 2 1


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4b POWDER COATING SYSTEMS

All the systems given are examples4.b.1 Powder coating systems interior

* Total film thickness exclusive zinc thickness Sys No = I= insidesystems O= outsidesystems, P= powder coating followed by system number.Substrate = for information of substrates see table 4-b.3. Chem. = for information on surface preparation see table 4-b.4 Primer; Binder: E=epoxy P=polyester S= Metal spray Ef = Electrophoresis coatType: C= colour Z= zinc

Sys No Sub-strate

Surf.Prep.

Primer Intermediate coats Topcoat CoatingSystem

Durability

Cat1

Cat2

Cat3

Cat4

Cat5I

Cat5M

B Type !m resin Type !m resin Type !m Lay-ers

!m M H M H M H M H M H M H

I-P 01 Steel 1 P/E C 60 1 60 X X

I-P.02 ZE 50/50 1 P/E C 60 1 60* X X X X

I-P.03 ZE 50/50 1 P C 60 1 60* X X X X

I-P.04 ZE 100 1 P C 80 1 80* X X X X X

I-P.05 Z100 1 p C 60 1 60* X X X X

I-P.06 Z100 2 P C 60 1 60* X X X X X

I-P.07 Z225 3 P C 80 1 80* X X X X X X X X

I-P-08 Z275 3 P C 80 1 80* X X X X X X X X

I-P-09 HDG 3 p C 60 1 60* X X X X X X X

I-P-10 HDG 3 P C 60 1 60* X X X X X X X

I-P-11 HDG 3 P C 80 1 80* X X X X X X X X

I-P-12 HDG 3 P C 80 1 80* X X X X X X X X

I-P-13 Steel 3 E Z 50 P C 60 2 110 X X X X X X X X X X



I-P-18 Steel Sa 2" E Z 50 P C 80 2 130 X X X X X X X X X X X

I-P-19 Steel Sa2" S Z 50 P C 60 2 110 X X X X X X X X

I-P-20 Steel Sa2" S Z 50 P C 60 2 110 X X X X X X X X

I-P-21 Steel Sa 2" S Z 50 P C 80 2 130 X X X X X X X X X X

I-P-22 Steel 1 E f C 15 P C 60 2 75 X X X X X X X

I-P-23 Steel 1 E f C 15 P C 60 2 75 X X X X X X X

I-P-24 Steel 1 E f C 15 P C 80 2 95 X X X X X X X X



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4.b.2 Powder coating systems exterior

M H M H M H M H M H

0-P 01 Z 225 3 P C 60 1 60 X X X X

O-P 02 Z 275 3 P C 80 1 80* X X X X X

O-P 03 HDG 3 P C 60 1 60* X X X X X

O-P 04 HDG 3 P C 80 1 80* X X X X X X

O-P 05 HDG 3 E C 60 P C 60 2 120* X X X X X X X X


O-P 07 HDG 3 E C 60 E/P C 60 P C 60 3 180* X X X X X X X X X X

O-P 07 Bis HDG 4 80 1 80 X X X X

O-P 08 HDG 4 E C 60 E/P C 60 P C 60 3 180* X X X X X X X X X X

O-P 09 Steel 3 E Z/ZF 50 P C 60 2 110 X X X X X


O-P 11 Steel 3 E Z/ZF 50 E/P C 60 P C 80 3 190 X X X X X X

O-P 12 Steel Sa 2,5 E Z/ZF 50 P C 60 2 110 X X X X X

O-P 13 Steel Sa 2,5 E Z/ZF 70 P C 80 2 150 X X X X X X

O-P 14 Steel Sa 2,5 E Z/ZF 50 E/P C 60 P C 80 3 190 X X X X X X X X

O-P 15 Steel Sa 3 S Z 35 P C 80 1 115 X X X X X

O-P 16 Steel Sa 3 S Z 50 P C 80 1 130 X X X X X X

O-P 17 Steel Sa 3 S Z 35 E C 60 P C 60 2 155 X X X X X X X X

O-P 18 Steel Sa 3 S Z 100 P C 80 1 180 X X X X X X X X

O-P 19 Steel Sa 3 S Z 150 E C 60 P C 80 2 290 X X X X X X X X X X

O-P 20 Steel 1 Ef C 15 P C 60 2 75 X X X X X X

O-P 21 Steel 1 Ef C 15 P C 80 2 95 X X X X X X X X

O-P 22 Steel 1 Ef C 15 E/P C 60 P C 60 2 135 X X X X X X X X X X

Layers !m

Cat 2 Cat 3

Total coating

system Durability

!m Binder Type

Topcoat

!mBinder Type !m

Cat5-MCat 4 Cat5-I

Syst No Su bstrate Surface

Preparation

Pri m er In te rm e di a te c oa ts

Binder Type

X in the previous table

X No X in the previous tableO-P 07

BisThis process cycle doesn't exist in the previous table

Z/ZF Zinc or Zinc free



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M H M H M H M H M H

0-P 01 Z 225 3 P C 60 1 60 X X X X

O-P 07 Bis HDG 4 80 1 80 X X X X

O-P 02 Z 275 3 P C 80 1 80* X X X X X

O-P 03 HDG 3 P C 60 1 60* X X X X X



O-P 12 Steel Sa 2,5 E Z/ZF 50 P C 60 2 110 X X X X X

O-P 15 Steel Sa 3 S Z 35 P C 80 1 115 X X X X X

O-P 04 HDG 3 P C 80 1 80* X X X X X X

O-P 11 Steel 3 E Z/ZF 50 E/P C 60 P C 80 3 190 X X X X X X

O-P 13 Steel Sa 2,5 E Z/ZF 70 P C 80 2 150 X X X X X X

O-P 16 Steel Sa 3 S Z 50 P C 80 1 130 X X X X X X

O-P 20 Steel 1 Ef C 15 P C 60 2 75 X X X X X X



O-P 14 Steel Sa 2,5 E Z/ZF 50 E/P C 60 P C 80 3 190 X X X X X X X X

O-P 17 Steel Sa 3 S Z 35 E C 60 P C 60 2 155 X X X X X X X X

O-P 18 Steel Sa 3 S Z 100 P C 80 1 180 X X X X X X X X

O-P 21 Steel 1 Ef C 15 P C 80 2 95 X X X X X X X X

O-P 07 HDG 3 E C 6 0 E/P C 60 P C 60 3 180* X X X X X X X X X X

O-P 08 HDG 4 E C 6 0 E/P C 60 P C 60 3 180* X X X X X X X X X X

O-P 19 Steel Sa 3 S Z 1 50 E C 60 P C 80 2 290 X X X X X X X X X X

O-P 22 Steel 1 Ef C 15 E/P C 60 P C 60 2 135 X X X X X X X X X X

Cat5-I

Total coatin g

system Durability

Binder Type !m Binder Type Binder Type

Topcoat

!mCat5-M

Layers !mCat 2 Cat 3 Cat 4

Syst No Substrate Surface

Preparation

Pri me r In te rm edi at e co ats

!m

QUALISTEELCOAT Version 2 1 November 2013


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QUALISTEELCOAT Version 2.1 November 2013

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Table 4.b.3Table 4.b.1 and 4.b.2 explanations

Substrate Explanation

ZE 50/50 Sheet electrolytic zinc on steel 5 !m

ZE 100/100 Sheet electrolytic zinc on steel 10 !m

Z100 Sendzimir zinc 100 g/m2 double faced

Z225 Sendzimir zinc 225 g/m2 double facedZ275 Sendzimir zinc 275 g/m2 double faced

HDG Steel thickness < 1.5 mm!250 g/m2/face approx. 35 !m, Hot DipGalvanizing

HDG Steel thickness >1.5 and < 3.0 mm 325 g/m2/face approx. 45 !m, Hot DipGalvanizing

HDG Steel thickness >3mm and < 6.0 mm 395 g/m2/face approx. 55 !m, HotDip Galvanizing

HDG Steel thickness > 6.0 mm 505 g/m2/face approx. 70 !m, Hot DipGalvanizing

Table 4.b.44.b.1 and 4.b.2 explanations

Surfacepreparation

Explanation

1 Only degreasing of substrate

2 De-oxidation

3 Phosphating EN 13438 + passivation or alternative processes

4 Blasting zinc substrate in accordance with EN 15773

Sa 2" Blasting in accordance with EN ISO 8501-1



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Appendix 10 Specification of the standards

N YEAR TITLE SPECIFICATIONS

EN 13438 2005Paints and varnishes - Powder organic coatings for galvanized or sherardized steelproducts for construction purposes

2.b.2; 2.b.3; 2.b.4; 2.b.9;2.b.13; 3.c.b; 4.b.4

EN 15773 2009Industrial application of powder organic coatings to hot dip galvanized or sherardizedsteel articles [duplex systems] - Specifications, recommendations and guidelines

4.b.4

EN ISO 1461 2009Hot dip galvanized coatings on fabricated iron and steel articles - Specifications and testmethods (ISO 1461:2009)

3.a.2

EN ISO 1514 2004 Paints and varnishes - Standard panels for testing (ISO 1514:2004) 2.1

EN ISO 1518 2000 Paints and varnishes - Scratch test (ISO 1518:1992) 2.2.4; 2.a.4

EN ISO 2360 2003Non-conductive coatings on non-magnetic electrically conductive basis materials -Measurement of coating thickness - Amplitude-sensitive eddy current method (ISO2360:2003)

6.c.2.3; 6.d.2.4

EN ISO 2409 2007 Paints and varnishes - Cross-cut test (ISO 2409:2007) 2.2.1; 2.a.1

EN ISO 2808 2007 Paints and varnishes - Determination of film thickness (ISO 2808:2007) 2.a.9



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EN ISO 2810 2004Paints and varnishes - Natural weathering of coatings - Exposure and assessment (ISO2810:2004)

2.b.9

EN ISO 2812-1 2007Paints and varnishes - Determination of resistance to liquids - Part 1: Immersion in liquidsother than water (ISO 2812-1:2007)

2.3.6; 2.b.6

EN ISO 2813 1999Paints and varnishes - Determination of specular gloss of non-metallic paint films at 20,60 and 85 (ISO 2813:1994, including Technical Corrigendum 1:1997)

2.a.10; 2.b.8; 2.b.9;6.c.2.4; 6.d.2.5

EN ISO 3231 1997Paints and varnishes - Determination of resistance to humid atmospheres containingsulphur dioxide (ISO 3231:1993)

2.3.7; 2.b.7

EN ISO 3274 1997Geometrical product specifications (GPS) - Surface texture: Profile method - Nominal

characteristics of contact (stylus) instruments (ISO 3274:1996)

6.b.2.3

EN ISO 4628 -2 2003Paints and varnishes - Evaluation of degradation of coatings - Designation of quantity andsize of defects, and of intensity of uniform changes in appearance - Part 2: Assessmentof degree of blistering (ISO 4628-2:2003)

2.b.4; 2.b.5; 2.b.6; 2.b.7

EN ISO 4628-3 2003Paints and varnishes - Evaluation of degradation of coatings - Designation of quantity andsize of defects, and of intensity of uniform changes in appearance - Part 3: Assessmentof degree of rusting (ISO 4628-3:2003)

2.b.4; 2.b.6; 2.b.7

EN ISO 4628-4 2003

Paints and varnishes - Evaluation of degradation of coatings - Designation of quantity and

size of defects, and of intensity of uniform changes in appearance - Part 4: Assessmentof degree of cracking (ISO 4628-4:2003) 2.b.4; 2.b.5; 2.b.6; 2.b.7



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EN ISO 4628-5 2003Paints and varnishes - Evaluation of degradation of coatings - Designation of quantity andsize of defects, and of intensity of uniform changes in appearance - Part 5: Assessmentof degree of flaking (ISO 4628-5:2003)

2.b.4; 2.b.5; 2.b.6; 2.b.7

EN ISO 5436-1 2000Geometrical Product Specifications (GPS) - Surface texture: Profile method;Measurement standards - Part 1: Material measures (ISO 5436-1:2000)

2.a.7; 6.b.2.3

EN ISO 5436-2 2001Geometrical Product Specifications (GPS) - Surface texture: Profile method;Measurement standards - Part 2: Software measurement standards (ISO 5436-2:2001)

2.a.7; 6.b.2.3

EN ISO 5436-2/AC: 2001/2008Geometrical Product Specifications (GPS) - Surface texture: Profile method;Measurement standards - Part 2: Software measurement standards (ISO 5436-2:2001/Cor 1:2006/Cor 2:2008)

2.a.7; 6.b.2.3

EN ISO 6270-2 2005Paints and varnishes - Determination of resistance to humidity - Part 2: Procedure for

exposing test specimens in condensation-water atmospheres (ISO 6270-2:2005)

2.3.5

EN ISO 6272-1 2004Paints and varnishes - Rapid-deformation (impact resistance) tests - Part 1: Falling-weight test, large-area indenter (ISO 6272-1:2002)

2.2.3; 2.a.3

EN ISO 8501-1 2007

Preparation of steel substrates before application of paints and related products - Visualassessment of surface cleanliness - Part 1: Rust grades and preparation grades ofuncoated steel substrates and of steel substrates after overall removal of previouscoatings (ISO 8501-1:2007)

3.c.1; 4.a.1; 4.b.4; 6.b.2.7

EN ISO 8501-3 2007

Preparation of steel substrates before application of paints and related products - Visual

assessment of surface cleanliness - Part 3: Preparation grades of welds, edges and otherareas with surface imperfections (ISO 8501-3:2006) 3.a.3; 3.b.5; 5.b.1



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EN ISO 8502-3 1999Preparation of steel substrates before application of paint and related products - Tests forthe assessment of surface cleanliness - Part 3: Assessment of dust on steel surfacesprepared for painting (pressure-sensitive tape method) (ISO 8502-3:1992)

6.b.2.7

EN ISO 8502-4 1999Preparation of steel substrates before application of paint and related products - Tests forthe assessment of surface cleanliness - Part 4: Guidance on the estimation of the

probability of condensation prior to paint application (ISO 8502-4:1993)

5.a.2

EN ISO 8503-1 1995

Preparation of steel substrates before application of paints and related products - Surfaceroughness characteristics of blast-cleaned steel substrates - Part 1: Specifications anddefinitions for ISO surface profile comparators for the assessment of abrasive blast-cleaned surfaces (ISO 8503-1:1988)

2.a.7

EN ISO 8503-2 1995

Preparation of steel substrates before application of paints and related products - Surfaceroughness characteristics of blast-cleaned steel substrates - Part 2: Method for thegrading of surface profile of abrasive blast-cleaned steel - Comparator procedure (ISO8503-2:1988)

2.a.7

EN ISO 8503-3 1995

Preparation of steel substrates before application of paints and related products - Surfaceroughness characteristics of blast-cleaned steel substrates - Part 3: Method for the

calibration of ISO surface profile comparators and for the determination of surface profile-Focusing microscope procedure (ISO 8503-3:1988)

2.a.7

EN ISO 8503-4 1995

Preparation of steel substrates before application of paints and related products - Surfaceroughness characteristics of blast-cleaned steel substrates - Part 4: Method for thecalibration of ISO surface profile comparators and for the determination of surface profile- Stylus instrument procedure (ISO 8503-4:1988)

2.a.7

EN ISO 9227 2006 Corrosion tests in artificial atmospheres - Salt spray tests (ISO 9227:2006) 2.b.4

EN ISO 11125-2 1997

Preparation of steel substrates before application of paints and related products - Test

methods for metallic blast-cleaning abrasives - Part 2: Determination of particle sizedistribution (ISO 11125-2:1993) 2.2.6; 2.a.6



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EN ISO 11127-2 1997Preparation of steel substrates before application of paints and related products - Testmethods for non-metallic blast-cleaning abrasives - Part 2: Determination of particle sizedistribution (ISO 11127-2:1993)

2.2.6; 2.a.6

EN ISO 11341 2004Paints and varnishes - Artificial weathering and exposure to artificial radiation - Exposureto filtered xenon-arc radiation (ISO 11341:2004)

2.b.8

EN ISO 12944-1 1998Paints and varnishes - Corrosion protection of steel structures by protective paint systems- Part 1: General introduction (ISO 12944-1:1998)

1; a.1; 4.a.2; 4.a.3

EN ISO 12944-2 1998Paints and varnishes - Corrosion protection of steel structures by protective paint systems- Part 2: Classification of environments (ISO 12944-2:1998)

1; 4.1

EN ISO 12944-3 1998Paints and varnishes - Corrosion protection of steel structures by protective paint systems

- Part 3: Design considerations (ISO 12944-3:1998)

1

EN ISO 12944-4 1998Paints and varnishes - Corrosion protection of steel structures by protective paint systems- Part 4: Types of surface and surface preparation (ISO 12944-4:1998)

3; 3.c.1; 3.c.2; 4.a.2;4.a.3

EN ISO 12944-5 2007Paints and varnishes - Corrosion protection of steel structures by protective paint systems- Part 5: Protective paint systems (ISO 12944-5:2007)

4.1; 7

EN ISO 12944-6 1998

Paints and varnishes - Corrosion protection of steel structures by protective paint systems

- Part 6: Laboratory performance test methods (ISO 12944-6:1998) 2.3.6; 2.3.7; 2.b.6



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EN ISO 12944-7 1998Paints and varnishes - Corrosion protection of steel structures by protective paint systems- Part 7: Execution and supervision of paint work (ISO 12944-7:1998)

5a

EN ISO 12944-8 1998Paints and varnishes - Corrosion protection of steel structures by protective paint systems- Part 8: Development of specifications for new work and maintenance (ISO 12944-

8:1998)

1

EN ISO 16276-2 2007Corrosion protection of steel structures by protective paint systems - Assessment of, andacceptance criteria for, the adhesion/cohesion (fracture strength) of a coating - Part 2:Cross-cut testing and X-cut testing (ISO 16276-2:2007)

2.2.1; 2.a.1; 6.c.2.1;6.d.2.1

EN ISO/IEC 17025 2005General requirements for the competence of testing and calibration laboratories (ISO/IEC17025:2005)

7

EN ISO/IEC

17025:2005/AC

2006

General requirements for the competence of testing and calibration laboratories (ISO/IEC17025:2005/Cor.1:2006)

7

ISO 105-AO2 1993Textiles - Tests for colour fastness - Part A02: Grey scale for assessing change in colour(ISO 105-A02:1993)

2.b.10

ISO 7724-3 1984 Paints and varnishes -- Colorimetry -- Part 3: Calculation of colour differences 2.b.8; 2.b.9

ISO 9223 1992 Corrosion of metals and alloys -- Corrosivity of atmospheres -- Classification a.1



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ISO 15184 1998 Paints and varnishes -- Determination of film hardness by pencil test 2.2.5; 2.a.5

qualisteelcoat technical specifications version21 31102013

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