qualisteelcoat version 3 0

Version 3.0 January 2015

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Qualisteelcoat

Technical Specifications V3.0


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Table of Contents

I. GENERAL INFORMATION ................................................................................... 4

1. SCOPE ................................................................................................................. 4 2. DEFINITIONS ......................................................................................................... 4 3. LIABILITY DISCLAIMER .............................................................................................. 4

II. LICENSE FOR COATING APPLICATORS .............................................................. 5

1. APPLICATION FOR A QUALISTEELCOAT LICENSE ................................................................. 5 2. FIRST INSPECTION .................................................................................................. 5 3. FINAL ASSESSMENT FOR GRANTING THE LICENSE................................................................ 6 4. INSPECTIONS OF LICENSEES ....................................................................................... 6 5. CHANGE OF CHEMISTRY ............................................................................................. 6 6. USE OF THE LOGO BY COATING APPLICATORS .................................................................... 6 7. COMPANY STATUS CHANGE ......................................................................................... 7

III. QUALITY ASSURANCE BY THE COATING APPLICATOR ....................................... 7

1. IN-HOUSE CONTROL PROCEDURES .............................................................................. 7 2. COMPANY LABORATORY ............................................................................................. 7 3. THE REGISTER........................................................................................................ 7 4. STORAGE ............................................................................................................. 8

IV. SURFACE PREPARATION .................................................................................... 9

1. SOME INFORMATION ON SUBSTRATES ............................................................................ 9 2. REMOVAL OF CONTAMINATION ..................................................................................... 9 3. PRETREATMENT FOR POWDER AND LIQUID COATING SYSTEMS ................................................ 9

A. QUALITY CONTROL FOR SURFACE PREPARATION BY BLASTING ........................................ 9

1. In-house control ................................................................................................................................................ 9 2. Laboratory and inspection equipment for Blasting Surface Preparation ................................... 10

B. QUALITY CONTROL FOR CHEMICAL PRETREATMENT ..................................................... 10

1. Procedures......................................................................................................................................................... 10 2. Laboratory and inspection equipment for chemical pretreatment ............................................... 11

V. FINISHED PRODUCTS QUALITY CONTROL ....................................................... 11

1. TEST PANELS ....................................................................................................... 11 2. PROCEDURES ....................................................................................................... 11 3. LABORATORY AND INSPECTION EQUIPMENT FOR FINISHED PRODUCTS ...................................... 12

VI. APPROVAL OF COATINGS ................................................................................ 13

1. SCOPE OF THE APPROVAL ......................................................................................... 13 2. EXAMPLES OF COATING SYSTEMS ................................................................................ 13 3. PROCEDURE ........................................................................................................ 13

A. APPROVAL OF POWDER COATING SYSTEMS ................................................................ 15

1. Powder coating systems (Quick Guide) ................................................................................................................. 15 2. Test panels ............................................................................................................................................................ 16 3. Required tests ........................................................................................................................................................ 17

B. APPROVAL OF LIQUID COATING SYSTEMS .................................................................. 17

1. Liquid coating systems .......................................................................................................................................... 17 2. Test panels ............................................................................................................................................................ 18 3. Required tests for the Initial approval ................................................................................................................... 18


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VII. ADDITIONAL DETAILS ON TESTING PROCEDURES .......................................... 19

1. COATABILITY OF PARTS ........................................................................................... 19 2. DETERMINATION OF PARTICLE SIZE DISTRIBUTION ............................................................ 19 3. DETERMINATION OF SURFACE ROUGHNESS .................................................................... 19 4. ASSESSMENT OF THE ZINC COATING AFTER SWEEP BLASTING ............................................... 19 5. INSPECTION OF SURFACE CLEANLINESS AFTER BLASTING ................................................... 20 6. DETERMINATION OF THE CONDUCTIVITY OF DRIPPING WATER .............................................. 20 7. EFFECTIVENESS OF THE PICKLING BATH ........................................................................ 20 8. ASSESSMENT OF THE CONVERSION COATING .................................................................. 20 9. THE DRYING TEMPERATURE FOR LIQUID COATINGS ............................................................ 20 10. ADHESION .......................................................................................................... 20 11. DIRECT IMPACT RESISTANCE TEST .............................................................................. 21 12. DETERMINATION OF DRY FILM THICKNESS ..................................................................... 21 13. GLOSS .............................................................................................................. 21 14. DETERMINATION OF DEW POINT ................................................................................ 22 15. STOVING CONDITIONS ............................................................................................ 22 16. APPEARANCE TEST ................................................................................................. 22 17. BOILING TEST ...................................................................................................... 22

VIII. ENVIRONMENTAL TESTS ON FINISHED PRODUCTS ......................................... 23

1. RESISTANCE TO MORTAR ......................................................................................... 23 2. NEUTRAL SALT SPRAY TEST ...................................................................................... 23 3. RESISTANCE TO HUMIDITY ....................................................................................... 24 4. CHEMICAL RESISTANCE TEST .................................................................................... 25 5. RESISTANCE TO HUMID ATMOSPHERE CONTAINING SULFUR DIOXIDE ..................................... 26 6. ACCELERATED WEATHERING TEST .............................................................................. 27 7. NATURAL WEATHERING ........................................................................................... 27

List of Annexes

Annex 1 Admissible E* for RAL numbers after Florida exposure

Annex 2 List of abbreviations used in the Tables

Annex 3 Powder Coatings Interior Systems

Annex 4 Powder Coatings Exterior Systems

Annex 5 Powder Coatings Thermoplastic Systems

Annex 6 List of applicable standards


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I. General Information

1. Scope

a. Qualisteelcoat is an international quality label for coated steel, specifically developed to sustain the quality of coating applications on new steel

constructions or equipment, erected or used in more or less corrosive conditions as detailed in ISO 12944-2. Both powder coatings and liquid coatings are feasible protective coating

systems. Powder coatings may be thermoset or thermoplastic in nature. Liquid coatings may be one component, but generally will be two component

systems.

b. Qualisteelcoat considers as substrates carbon steel, low-alloy and non-alloy, but also hot dip galvanized steel, continuous hot dip galvanized steel, electro-

galvanized steel, sherardized steel or steel covered with a thermal spray coating, and finally steel covered with a primer coat or electrocoating.

These substrates, electrocoating excluded, are either chemically pretreated or blasted.

c. The Qualisteelcoat specifications establish the quality level with which

pretreatments as well as coating systems must comply to obtain a Qualisteelcoat label. They also determine the procedures imposed to the

coater committed to the Qualisteelcoat label.

d. The license attributed to a coater or an approval for a coating system is related to the corrosivity of the environment as detailed in ISO 12944-2. Only

protective coatings presenting high durability properties will be considered. To every corrosivity category corresponds a testing level, for example a number

of hours of corrosion tests. Both a coating system and a coater can obtain a label for a certain corrosivity category. A label is also valid and may be used for lower corrosivity categories. The inspected system is indicated on the

certificate. The label is however not valid for higher corrosion categories.

2. Definitions

a. License: Quality Label Qualisteelcoat granted to a coating applicator fulfilling the requirements of the present specifications.

b. Approval: Quality Label Qualisteelcoat granted to a coating system fulfilling the requirements of the present specifications.

c. General Licensee: A National Association authorized to administrate the label in its country. No General Licensee can be simultaneously a Testing

Laboratory, since an obvious conflict of interests will arise.

d. Testing Laboratory: An independent laboratory capable of and approved by both the national General Licensee and Qualisteelcoat to carry out all the

assessments necessary for the Qualisteelcoat quality label, both for coating systems and for coaters. The Laboratory has to be accredited according ISO/IEC 17025 General requirements for the competence of testing and calibration laboratories

3. Liability disclaimer

Qualisteelcoat stands for a quality label, and attributes its label based on a annual report issued by a qualified laboratory. This report states on the quality level of either a coating applicator or a coating product at the moment of testing.


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Qualisteelcoat cannot be liable for any consequences or damages whatsoever, directly or indirectly imposed to persons or materials, companies, products or

organizations, nor can it be held responsible for any material or other damages caused by a holder of the label in the execution of his coating activities, or by any

product detaining a Qualisteelcoat label.

II. License for Coating Applicators

1. Application for a Qualisteelcoat license

Any coater of steel constructions or steel equipment can apply for a Qualisteelcoat license. A letter of intent expressing the companys engagement to obtain a Qualisteelcoat license must be addressed at the General Licensee responsible in the

country where the company is situated. If there is no General Licensee in the country the coater is located in, the letter can be sent to Qualisteelcoat - c/o AC-Fiduciaire

SA, P.O. Box 1507, CH-8027 Zrich, Switzerland. This letter of intent must also define the corrosion category the coater wishes to apply for, and mention in detail the coating system the license will be applying to.

2. First Inspection

a. After reception of this letter of intent, the General Licensee will start up the

procedure and notify the Testing Laboratory, which will contact the coater for an appointment. During the first inspection the coater must be coating objects that are

intended for the corrosion category he is requesting the license for.

b. The inspector from the Testing Laboratory will check the following points.

(1) Coatings The inspector will check that the coating applicator uses coatings approved by Qualisteelcoat on the parts that will be tested.

(2) Laboratory equipment The required testing equipment must be available and functional,

together with the relevant documents.

(3) The coating process Both the pretreatment and the actual coating process will be monitored.

All the equipment used at the production lines should be properly functioning and will be checked.

(4) Inspection of pretreated and coated products

Only parts and test panels that have been released by the quality control

of the coating applicator will be tested.

The tests are listed in Chapters IV A & B (surface preparation) and Chapter V (Finished Products Quality Assurance).

(5) In-house control and registers

The inspector will check that in-house control has been carried out and

that the coating plant maintains the required registers. The results recorded in the register must be coherent with the results obtained on the test panels. Test panels must be kept and held at the inspectors disposal for one year, and the register must be conserved for five years.


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(6) Training

Personnel involved in pretreatment or coating operations shall be

qualified on the basis of proper education, training or experience. Appropriate records of training shall be established and maintained.

Furthermore, training needs shall be identified and provided for, and shall also be documented.

3. Final assessment for granting the license

The inspector submits the inspection report to the general licensee and a copy must be send to Qualisteelcoat in Zrich where it will be stored.

If the result of the inspection meets the requirements, a license to use the Qualisteelcoat label will be granted.

If the result of the inspection does not meet the requirements due to an

administrative matter, like a missing document, this must be resolved or the document transmitted within 60 days, or the procedure is suspended.

If the result of the inspection does not meet the requirements but meets those for a lower corrosivity class, then a license for this lower corrosivity class can be attributed. Alternatively, the coater can ask for another inspection that must then

be made within 60 calendar days. If this second inspection does not lift the unsatisfactory requirement, the coating applicator will be informed in a letter

explaining the grounds for the momentary refusal, and the license for the lower corrosivity class is granted. He must wait at least three months before making a new license application for the higher corrosivity class.

4. Inspections of licensees

After a plant has been granted a license to use the Qualisteelcoat label, it will be

inspected every year; on appointment to evaluate the level of the license, and the same tests as for granting the license will be performed;.

The inspector submits the inspection report to the general licensee. If no general

licensee is available the report will be sent to Qualisteelcoat in Zrich.

If the result of the inspection meets the requirements, authorization to use the

quality label will continue.

If the result of the inspection does not meet the requirements, but meets those for a lower corrosivity class, then a license for this lower corrosivity class can be

attributed. Alternatively, the coater can ask for another inspection that must then be made within 60 calendar days. If this second inspection does not lift the

unsatisfactory requirement, the coating applicator will be informed in a letter explaining the grounds for the momentary refusal, and the license for the lower

corrosivity class is granted. The coating plant must wait at least three months before making a new license application for the higher corrosivity class.

5. Change of chemistry

When the coater modifies in an important way his pretreatment chemistry or introduces a new pretreatment chemistry, he must notify the General Licensee,

and apply for a new Qualisteelcoat license.

6. Use of the logo by coating applicators

The use of the logo must comply with the Regulations for the use of the

QUALISTEELCOAT quality label (see www.qualisteelcoat.org ).


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7. Company status change

The Qualisteelcoat label is not transferable and not attachable. However, if a

company holding a Qualisteelcoat license is subject of a fusion or taken over by another company, then the license is transferred to the new owner. If for

whatever reason the company stops its activities as a coating applicator, the Qualisteelcoat label granted to this company will cease to be valid.

III. Quality Assurance by the coating applicator

The inspector from the Testing Laboratory will evaluate the quality assurance system set up by the coater by assessing the following points.

1. In-house control Procedures

The coating applicator shall have a quality control system set up, including a test plan in accordance with the present Specifications. Both the production methods

and the coated products must be monitored and tested.

A test plan consists of the parameter or property that will be tested, the test frequency, and where in the process it will be tested. A test plan also needs an

estimation of the duration of the test, and a statement on any required resources.

The suppliers instructions must be followed, both for pretreatment products and for the coatings, and proof thereof must be recorded.

The in-house tests that must be executed are listed below, for a mechanical or blasting surface preparation in Chapter IV.A and for chemical surface preparation

in Chapter IV.B. Assessment of finished products is described in Chapter V.

2. Company Laboratory

The applicator must dispose of a laboratory facility that is separated from the production facilities. The laboratory must be equipped to assess the quality of both the pretreatment and the coated parts.

Technical information and the instruction manuals of every testing device, showing the identification number and proof of calibration, must be available.

The Technical Data Sheets (TDS) and the Material Safety Data Sheets (MSDS) of all the products must be available to the laboratory responsible, as well as the applicable standards or clear working instructions describing the test procedures.

3. The register

The results of the in-house control must be recorded and readily accessible to the

inspector. This control register with numbered pages or a computer record must be maintained by the laboratory supervisor and must comprehend all the

measurement results and laboratory tests. The control register must show the nominal values, maximum values not to be exceeded and the measured values. Any corrective measures, when required or implemented, must be noted in the

register. The register must be kept for a period of five years.

The register must contain the following information:

The customer's name and the order or lot identification Corrosivity category of the environment in which the product will be used


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Gloss, Color or RAL number and visual reference of the color (color card or model piece)

References on the blasting media with dates of their exchange or addition The references of the used coating: product name and manufacturer; batch

numbers; for liquid coatings both of the base and the curing agent and eventually the thinner

The temperature difference between the part and the dew point in the coating

booth prior to coating application The application date of the different coating layers

Thickness of the different layers of the coating system Results of all the performed tests

4. Storage

a. Storage of Coating Materials

The storage of coating materials must comply with the applicable safety requirements. Only the coating used during the application, and in case of liquid coating the additional thinner, may be present in the coating application

area.

All coating materials must be stored in a dry room, protected against freezing

or too hot conditions (see Technical Data Sheet for temperature range), isolated from the production facilities and protected from any contamination.

b. Every lot of parts must be labeled.

c. Storage of pretreated parts

Pretreated parts should preferably be coated immediately after pretreatment.

They must not be stored for more time than mentioned in the table below, and never in a dusty or otherwise detrimental atmosphere. The storage conditions must not allow condensation onto the parts. All workers handling pretreated

parts must wear clean textile gloves to avoid contamination of the surface.

C4-C5 8 hours

C1-C3 24 hours

Blasted hot dip galvanized steel 4 hours

d. Storage of Coated Materials

The coated products must be stored in a suitable area. The parts must be packed for transport as soon as possible.

Parts not accepted by quality control must be clearly labeled and kept

separated from the accepted parts.


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IV. Surface Preparation

1. Some information on Substrates

For surface preparation, a coater is equipped with either a blasting booth or a chemical pretreatment or both. Detailed information on types of surfaces and

surface preparation can be found in ISO 12944-4. Some substrates will however require a supplementary treatment.

a. Laser cut steel

Unless nitrogen gas or alike is used during the cutting, the cutting edge will be oxidized. This oxide must be removed, either mechanically by brushing or

sanding or any other suitable method, or by pickling with an acid.

b. Various metal combinations Preliminary testing of such combinations is mandatory.

2. Removal of Contamination

A surface can be contaminated with oil and grease, marks with chalk or paint or

other, dirt or oxidation. Stickers may be present.

Prior to the surface preparation and the application of a coating system, any such surface contamination must be removed by suitable means.

3. Pretreatment for Powder and Liquid coating systems

The purpose of the pretreatment is to prepare the substrate for the application of

the protective coating system, and consists in sandblasting or in a chemical treatment, or both.

Every surface treatment must be done in the plant. Only hot dip galvanizing,

continuous hot dip galvanizing or electro-galvanizing, and also the application of an electrophoretic coating can be subcontracted.

A. Quality Control for Surface Preparation by Blasting

1. In-house control

The coating applicator must check his production methods and products according to the following methods and frequency.

Evaluated Property C1 C2 C3 C4

C5(M) C5(I)

Coatability of parts Every lot

Particle distribution of

abrasives N/A

Twice per year by supplier

Blast cleanliness and dust removal

Random testing twice per day

Surface roughness

N/A

Once per day

Assessment of the zinc coating after blasting

Once per shift

Difference between dew point and surface temperature

Twice per day morning & late afternoon Every lot of parts suspected of too low temperature


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If the blasting is followed by a conversion treatment, the following is also checked when it applies.


C5(M) C5(I)

Assessment of the conversion

coating

N/A

Visual inspection Chemical assessment 4 times a year by supplier

The temperature of conversion

and rinsing baths

Once per day

Conductivity of rinsing water 1) Once per shift

Drying temperature after

conversion

Once per week if applicable

1) One measurement in the bath before conversion and one in the drippings after final rinse

The results of the tests in the table must be entered in the register.

2. Laboratory and inspection equipment for Blasting Surface Preparation

Instruments

Roughness measurement device Thermometer & Dew Point device Equipment and chemicals for testing the conversion coating (if applicable)

Conductivity meter for the conversion bath and the rinsing Temperature pads for the drying oven (if applicable)

Thickness measurement gauge

3. Additional explanations of the test procedures and test results can be found in Chapter VII (normative) and Chapter VIII (normative).

B. Quality Control for Chemical pretreatment

1. Procedures

The coating applicator must check his production methods and products according to the following frequency.


C5(M) C5(I)

Coatability of Parts Every lot

Concentration of pretreatment baths 1) N/A Once per day

Assessment of pH value of baths 1) Once per

day

Once per shift

Conductivity of rinsing water 1) 3) N/A Once per shift

Temperature of baths 1) Once per day

Zn and Al content 1) 2) N/A

Once per shift

Drying temperature Once per day


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C5(M) C5(I)

Assessment of the loss of zinc by pickling

Once per shift

Assessment of conversion coating 1) N/A Visual once per shift, and

chrome free once per month

Weight of the conversion layer 1) N/A

Once per month

Surface preparation Visual

1) According to the chemicals suppliers instructions. 2) If using a combined zinc and aluminum bath. 3) One measure in the bath before conversion and one measure in the drippings after final rinse


2. Laboratory and inspection equipment for chemical pretreatment

For Corrosivity Category C1 & C2, only the pH meter and the thermometer are needed.

Laboratory Instruments for C3-C5 (if applicable)

Thickness measurement gauge Conductivity meter

pH meter and thermometer Chemicals to determine the bath concentrations

Test solutions for Zn and Al content, when such bath is used Test solutions and equipment to test the chemical conversion coating

according to the chemicals suppliers instructions Temperature pads for drying oven

3. Additional explanations of the test procedures and test results can be found in

Chapter VII (normative) and Chapter VIII (normative).

V. Finished Products Quality Control

1. Test panels

Whenever possible, tests should be conducted on Parts from the production. This

may eventually require a supplementary number of parts from the client. When test panels are used, these shall match the production parts and be covered with

a corresponding metallic layer or primer, and the coating system (See Approval of Coatings Panels for Powder Coatings Liquid Coatings).

2. Procedures

The coating applicator must check his production methods and coated products according to the following methods and frequency.


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Tested Property Coating

(*) C1 C2

C3 C4 C5(M) C5(I)

Film Thickness All Every order according to

the sampling plan Every order according to the sampling plan

Cross-cut Adhesion 1)

or Pull-off test

TSP Once per shift on test panel

Once per shift on test panel

TPP N/A X-cut on parts or test panel

LC Thickness < 250 m: cross-cut

Thickness > 250 m: pull-off test

Direct Impact test 2)

TSP N/A Once per day

TPP N/A By supplier

LC N/A N/A

Gloss measurement

TSP Twice per shift and per

color

Twice per shift and per

color

TPP N/A N/A

LC N/A N/A

Difference between dew point and surface temperature

TSP N/A If applicable, before starting the application

TPP N/A Not for fluidized bed

LC Twice per day: morning & late afternoon Every lot of parts suspected of too low temperature

Measurement of curing (P & TPP) or

forced drying (L) temperature

TSP & TPP

Actual oven temperature once per day. Once per month a 4

point measurement

Actual oven temperature twice per day. Once per week a 4 point

measurement

LC Surface temperature

twice per day

Surface temperature twice

per day

Appearance

assessment

All Every order Every order

Pressure cooker test 1)

3)

TSP N/A Every order

LC N/A N/A

TPP N/A N/A

(*) TSP = Thermosetting Powder

Coatings

1) On test panels

TPP = Thermoplastic Powder Coatings 2) On thin test panels 0.6 to 0.8 mm

LC = Liquid Coatings 3) Not on a thermal sprayed coating nor on hot dip galvanized steel


3. Laboratory and inspection equipment for finished products

Laboratory Instruments (if applicable) Cross-cut tester or Pull-off tester for adhesion Impact tester

Film Thickness gauge Gloss meter 60

Thermometer & dew point device and a device for substrate temperature Recording instrument for object temperature and curing time with 4

measuring points


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Equipment to conduct the boiling test

4. Additional explanations of the test procedures and test results can be found in


VI. APPROVAL OF COATINGS

1. Scope of the approval

A coating applicator can only use approved coating systems for those applications

where the Qualisteelcoat label is involved. Therefore an approval procedure for such coating systems is necessary. A list of approved coating systems can be found on the website www.qualisteelcoat.net .

However, since for the moment there are no approved liquid coating systems available, the coating supplier shall perform a salt spray test on steel test panels

prepared by the coater, to demonstrate the coating systems ability to withstand the imposed hours of salt spray. For a metallic zinc coating, the coating supplier shall perform a condensation test. Both tests must be performed by a Qualisteelcoat

approved laboratory. These obligations for liquid coating suppliers end on January 1st, 2016, and from that moment on, only approved coatings systems shall be used.

A request for a Qualisteelcoat approval of a coating system includes:

The Corrosivity Category it is intended for;

The eventual presence and type of metallic layer; The type of surface pretreatment: mechanical or chemical or both the applied

chemical product must be mentioned; The number and type of organic coating layers; For powder coatings also the nature of the finish (gloss, satin, matt or texture).

2. Examples of coating systems

Examples of thermoset powder coating systems are given in Annex 3 & 4. Examples of thermoplastic powder coating systems are given in Annex 5. Examples of liquid coating systems can be found in ISO 12944-5.

3. Procedure

a. Any company may submit a coating system for approval. In general however, a Qualisteelcoat approval for a coating system will be attributed to a coating

manufacturer, or to any company that defines, partially or completely, the composition of the coating, but relies for the manufacturing on a third party.

b. The company addresses a letter of intent expressing its engagement to obtain a

Qualisteelcoat approval to the General Licensee responsible for the country the company is located in. If there is no General Licensee in the country the applicant

is located in, the letter can be sent to Qualisteelcoat - c/o AC-Fiduciaire SA, P.O. Box 1507, CH-8027 Zrich, Switzerland. This letter of intent must describe in detail the coating system the license will be

applying to, and also define the corrosion category the coating system is intended for.

c. After reception of this letter of intent, the General Licensee will start up the procedure and notify the Testing Laboratory. The coating manufacturer from a


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country without a General Licensee may submit his products to be tested to one of the approved Qualisteelcoat Testing Laboratories. The Laboratory will contact the

manufacturer and the necessary quantities of coating products and/or test panels will be handed over to the Laboratory. If possible, the laboratory will prepare the

test panels, but for an eventual zinc layer or chemical pretreatment, relying on a subcontractor may be necessary and is therefore allowed. Hot Dip Galvanized panels may also be purchased.

d. The submitting company provides all the necessary information on his coating system to the Laboratory, including details on the successive coating layers to

apply and the film thickness of every layer. All the concerned product data sheets must also be transmitted.

e. All the tests will be executed on a complete system as defined above, unless

otherwise specified. The Testing Laboratory will allow the coating system to cure properly according to the manufacturers instructions before starting the tests.

f. Final assessment for granting the initial approval

The Testing Laboratory submits the inspection report to the General Licensee or directly to Qualisteelcoat in countries where there is no General Licensee.

If the test results meet the requirements, a Qualisteelcoat approval for the coating system will be granted.

If the test results do not meet the requirements, the applicant will be informed with a letter explaining the grounds for the momentary refusal. The applicant must wait at least three months before making a new application for an approval.

g. The Qualisteelcoat approval for a coating system is of course valid for the licensed company, but indeed also for all its production sites where the approved coating is

manufactured. For every production site however, an individual document must be established by the coating manufacturer, stating that the composition of the produced coating is identical to the approved coating.

h. Procedure of renewal

(1) The Qualisteelcoat approval for a coating system remains valid for 2 years.

The coating manufacturer supplies the laboratory with the necessary coating products and test panels for the renewal application. The tests requested for the renewal application are the same as for the initial application.

(2) Every two years, the Technical Committee defines the color that shall be submitted to the testing for the next two years. A rotation between RAL 9005

RAL 7016 RAL 6005 will be effective. Applicants which have Qualicoat approvals for their final coats, identified by a

Qualicoat P-number, shall make a rotation of the different P-numbers.

(3) The test report must be submitted through the General Licensee to the Technical Committee. The Committee decides on renewal or withdrawal of

the approval. If the test results meet the requirements, the approval is renewed. In case of noncompliance, the tests that failed are repeated on

samples taken from another batch. If this second series of tests does not lead to satisfactory results, but corresponds to a lower corrosivity category, the approval is decreased to this lower category. The supplier of the tested

product can submit a new application for approval for the higher level.


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i. Any change in the formula of the coating product implies however that it must be considered a new product, which consequently requires a new Qualisteelcoat

approval.

j. For powder coating systems, the Qualicoat approval of a final coat remains valid,

and it must not be retested as part of a Qualisteelcoat coating system. Also test results for artificial weathering and outdoor exposure tests from approved laboratories, collected to obtain other quality labels, may be used as

test results for the Qualisteelcoat approval, provided that the conducted tests comply with these specifications and the test report is approved by the Technical

Committee.

A. Approval of powder coating systems

1. Powder coating systems (Quick Guide)

The powder coating supplier can only request an approval for a Coating System Type of High Durability, defined in the table below (yellow fields).

Substrate System Number

Coating Layers

Pretreatment

Corrosivity Category

C2 C3 C4 C5

Steel

ST1 1 Mechanical

Chemical

ST2 2 Mechanical

Chemical

ST3 3 Mechanical

Chemical

Continuous hot dip

galvanizing

SZ1 1 Mechanical

Chemical

SZ2 2 Mechanical

Chemical

SZ3 3 Mechanical

Chemical

Hot Dip Galvanized

HD1 1 Mechanical

Chemical

HD2 2 Mechanical

Chemical

HD3 3 Mechanical

Chemical

Thermal Spray MS1 1

MS2 2

Electrophoretic primer

EC1 1

EC2 2

The applicant shall define his coating system, he shall transmit for each approval

his unique system name, which includes the Coating System Number (examples: ST2, HD1, MS2,), the manufacturer, for multi-layer systems the primer, and describe in detail the process to be used to coat the test panels.


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2. Test panels

a. Different Types

Type Purpose Substrate Application Dimensions

A Mechanical

tests

Test panels +

Coating Systems

Applied by the laboratory (*) 105 x 190 x 0,75 mm

(ref. GB26S/W/OC

Etalon)

Bare steel + zinc

phosphate

B Corrosion

tests

Substrate +

Surface Preparation

+ Coating Systems

Applied by the powder

supplier or by the laboratory

140 x 70 mm

Type 12-03

1-2 mm thick

C Florida EN AW5005 +

Coating Systems

Applied by the laboratory (*) 300 x 100 mm

1 mm thick

(*) at lowest curing conditions (lowest temperature, shortest corresponding time according to the TDS)

b. Number of test panels Type B for the laboratory

Adhesion 3

Direct impact 1 (substrate thickness < 0.5 mm)

Resistance to boiling water (Pressure Cooker Test)

3 (not for thermal sprayed or hot dip galvanized panels)

Resistance to mortar 3 (not for Qualicoat approved topcoat)

Neutral Salt Spray test 6 for C5H, 5 for C4H, 4 for C3H

Resistance to continuous

condensation

3 (for all categories)

Resistance to humid atmosphere

containing sulfur dioxide

3 (only for C5I)

Resistance to liquids 9 (only for C5I)

Thickness of metallic layer 1 (with metallic layer only)

c. Total number of necessary test panels

System

Number

Substrate +

Metallic coating

Coating

Layers


C2 C3 C4 C5M C5I

ST1 Steel

1 Layer 16

ST2 & ST3 Multi-layer 16 17 18

SZ1 Continuous hot dip galvanizing

1 Layer 16 17

SZ2 & SZ3 Multi-layer 16 17 18

HD1

HDG

1 Layer 16 17 18

HD2 & HD3

Multi-layer 16 17 18 19 31

MS1 Thermal spray

1 Layer 11 14 15

MS2 Multi-layer 11 14 15 16 28

EC1 Electrophoretic

1 Layer 16 17 18

EC2 Multi-layer 16 17 18 19 31


17

3. Required tests

a. Initial approval

For the initial approval the following color will be tested: RAL 9010 white. Additional explanations of the test procedures and test results can be found in


Test Panel Standard

Adhesion B ISO 16276-2 ISO 2409

0 1

Direct Impact Test A, B ISO 6272-1 2.5 Nm Film Thickness A, B, C ISO 2808

ISO 19840 ISO 12944-5

According to system description

Gloss A ISO 2813

Resistance to boiling water (Pressure Cooker Test)

B EN 13438

Resistance to mortar (*) B EN 12206-1

Neutral Salt Spray Test 1) B ISO 9227

Resistance to Continuous Condensation 2)

B ISO 6270

Resistance to Liquids B ISO 2812-1 Only for C5 I

Kesternich B ISO 3231 Only for C5 I 30 cycles Accelerated Weathering (*) A ISO 16474-2

Natural Weathering (*) C ISO 2810

1) Only for steel substrates without a metallic zinc coating a scribe is made 2) For substrates both with and without metallic zinc coating no scribe is made *) See VI A 3 b Additional extensions (3)

b. Additional extensions

(1) For systems with one organic layer, the Qualisteelcoat approval is only

valid for the gloss category and the textured or smooth finish that was tested.

(2) For multiple organic layers, the Qualisteelcoat approval can be valid for

different topcoats of the same supplier, but these topcoats must all be Qualicoat approved.

(3) (*) These tests must not be executed for topcoats with Qualicoat approval or for interior approval. For the topcoats without Qualicoat-approval, the tests with (*) shall be executed on RAL 9010, RAL 7016

and RAL 6005 for the initial approval. The powder supplier provide the necessary coating material and data..

B. Approval of liquid coating systems

1. Liquid coating systems

Any liquid coating system can be submitted for an approval for the corrosion class and substrate it corresponds to in ISO 12944-5. A deviation from the proposed

coating systems in ISO 12944-5 for a particular Corrosivity Category, either in number of coats or in layer thicknesses, must be based on strong field evidence.


18

Such a system will only be allowed with an authorization from the Technical Committee.

2. Test panels

The Testing Laboratory will prepare test panels with the dimensions the laboratory is used to work with, or alternatively use panels of approximately 150x70 mm, with a thickness between 0.5 and 2 mm. For every coating system entered for

qualification, fifteen panels shall be handed over to the Testing Laboratory. Steel panels of cold rolled steel are prepared to a degree of cleanliness

Sa 2 or Sa 3, according to ISO 8501-1. The roughness Rz must be between 50 m and 100 m. Blasted panels are dedusted prior to the application of the primer coat.

Hot dip galvanized or continuous hot dip galvanized panels of the same dimensions may be bought or prepared by a subcontractor. The former

panels are sweep blasted prior to the application of the primer coat; the latter panels may be sweep blasted prior to the application of the primer coat, according to the instructions of the coating manufacturer. The panels

can eventually also be chemically pretreated. Thermal sprayed or electrogalvanized panels of the same dimensions may

be prepared by a subcontractor. Only the latter are eventually sweep blasted prior to the application of the primer coat, according to the instructions of the coating manufacturer.

3. Required tests for the Initial approval

The following tests will be conducted by the Testing Laboratory:

Test Standard Requirement

Film Thickness ISO 2808

ISO 19840 ISO 12944-5

In agreement with the

system description

Adhesion Cross-cut or X-cut test

Pull-off test

ISO 16276-2 ISO 2409

0 1

ISO 16276-1 ISO 4624

> 3 MPa

Neutral Salt Spray Test 1) ISO 9227

Resistance to Continuous

Condensation 2)

ISO 6270

Resistance to Liquids ISO 2812-1 Only for C5 I

Kesternich ISO 3231 Only for C5 I 30 cycles Accelerated Weathering ISO 16474-2

Natural Weathering ISO 2810

1) Only for steel substrates without a metallic zinc coating a scribe is made 2) For substrates both with and without metallic zinc coating no scribe is made


19

VII. Additional details on testing procedures

1. Coatability of parts

The following questions should be considered to evaluate the suitability of an object for the application of a coating system:

(1) Is the pretreatment adapted to the piece ? (2) Can the coating system be applied to this substrate ? (3) Is the paint system suitable for the corrosivity category ?

Doubts about the suitability of the object for the application of the considered coating system must be discussed with the client. A written agreement must then be

available.

Sharp edges must be rounded see EN 1090 p180 F.6.1 and ISO 12944-3 Annex D/Fig D5. Structures with an expected life of the corrosion protection above 5 years with a C3H and higher corrosivity category shall have rounded or chamfered edges in

accordance with EN ISO 12944-3. For a liquid coating system, the edges shall be protected by a stripe coat extending across approximately 25 mm on both sides of the edge and applied to a nominal

thickness appropriate to the coating system.

2. Determination of particle size distribution

The particle size distribution test is conducted according to ISO 11125-2 for metallic blast-cleaning abrasives and ISO 11127-2 for nonmetallic blast-cleaning abrasives.

Determine the mean mass value of two tests and report the result to the nearest 1%. The particle size distribution must correspond to the distribution necessary to achieve

the required surface roughness.

3. Determination of Surface Roughness

The roughness of the substrate after blasting must be assessed. As a parameter, the maximum height is considered, which is the distance between the highest and lowest

points in the evaluation length/area. The coater has the choice of the method. The assessment of the roughness is conducted in accordance with ISO 8503-2 for ISO surface profile comparators, 8503-4 for the use of a stylus instrument, and 8503-5

for replica tape.

The surface roughness must be equal or higher than the value stated by the coating

manufacturer in the Technical Data Sheet.

4. Assessment of the zinc coating after sweep blasting

A zinc coating must be made ready to be coated, and dross particles, droplets and sharp points, zinc ashes, zinc flakes, flux residues, and the like must be removed.

Additional sweeping may be necessary. This must be done with a fine grade non-metallic abrasive at low pressure at an angle 30-35 to the surface. The remaining

film thickness of the zinc coating after sweep blasting must comply with ISO 1461 Table 3, and is function of the steel thickness. Thickness measurements must be done for each project involving hot dip galvanized surfaces.


20

5. Inspection of Surface Cleanliness after Blasting

The surface must be very thoroughly blast cleaned (Sa 2 ) according to

ISO 8501-1. Prior to an eventual chemical pretreatment and prior to the primer application, the surface must be dedusted. The remaining dust quantity and size

must be evaluated according to ISO 8502-3. Both dust quantity and dust size must not exceed Class 1.

6. Determination of the conductivity of Dripping Water

The final rinse preceding the conversion bath must be done with deionized water. The

conductivity must comply with the suppliers instructions. If not otherwise prescribed by the chemicals supplier, the conductivity of dripping water shall not exceed 30 S/cm at 20C.

7. Effectiveness of the pickling bath

Pickling of a zinc coating is done in an acid or alkaline bath, or eventually both of them in different steps. The film thickness of the zinc coating after the pickling bath must comply with ISO 1461 Table 3, and is function of the steel thickness. Thickness measurements must be done for each project involving metallic zinc coatings.

8. Assessment of the Conversion Coating

The quality of the conversion coating can be visually assessed for traditional

conversion coatings. However, for chrome free conversion coatings, visual assessment proves to be difficult or impossible. The chemical supplier's

recommendations about the test method must be applied. The weight of the conversion layer must be determined according to the instructions of the chemicals supplier, and may even be executed by the chemicals supplier.

9. The drying temperature for liquid coatings

The substrate must be heated to the maximum temperature allowed by the coating manufacturer. If such a value is not available, it shall be heated to (605)C.

10. Adhesion

The adhesion of the coating system onto the substrate is measured according to

ISO 16276-2 (Cross-cut testing and X-cut testing). Alternatively and certainly for film thicknesses exceeding 250 m, ISO 16276-1 (Pull-off testing) will be used.

The expected results shall be:

DFT (m) Results

C1 C2 C3 C5 < 60 0 - 1 -

< 120 0 - 1 0 1 < 250 - 0 1 > 250 - > 3 MPa

For each color shade, gloss category and supplier, the adhesion properties must be tested on sample panels.


21

11. Direct Impact Resistance Test

The direct impact resistance is determined according to ISO 6272-1 using a 20 mm diameter spherical indenter dropped under standard conditions. For powder

coatings, the test panels must have the thickness of the parts they are linked to. For powder coatings with a thickness d60 m, a mass of one kilo that falls from a height of 25 cm must be used.

Coating systems should not show any cracking or any detachment of the coating from the substrate.

12. Determination of Dry Film Thickness

The dry film thickness of the individual layers in the system and the total dry film

thickness shall be measured according to ISO 19840 with a method specified in ISO 2808. The measurements must be representative of the inspected area.

According to ISO 19840, the total coated surface can be used to determine the number of necessary measurements. The sampling plan consists of this number of measurements to be taken in an inspection area, and is as follows:

Area/length of the inspected area

(m2 or m)

Minimum number of measurements

Maximum number of measurements

allowed to be repeated

up to 1 5 1

above 1 to 3 10 2

above 3 to 10 15 3

above 10 to 30 20 4

above 30 to 100 30 6

above 100 add 10 for every additional

100 m2 or 100 m or part thereof

20 % of the minimum

number of measurements

Areas above 1000 m2 or m should be divided into smaller inspection areas.

According to ISO 19840, the dry film thickness is accepted when:

(1) The arithmetic mean of all the individual dry film thicknesses is equal to or

greater than the nominal dry film thickness (NDFT); (2) All individual dry film thicknesses are equal to or above 80 % of the NDFT;

(3) Individual dry film thicknesses between 80 % of the NDFT and the NDFT are acceptable provided that the number of these measurements is less than 20 % of the total number of individual measurements taken

The NDFT is the dry film thickness specified for each layer or for the whole paint system.

The dry film thickness cannot exceed the maximum imposed by the coating manufacturer, or in absence of such a value may be three times the nominal dry film thickness.

13. Gloss

Gloss is measured according to ISO 2813, using incident light at an angle of 60.


22

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

a reference sample, both observed under the same viewing angle.

RESULT:

Low Gloss : (0 30) 5 units Semi-gloss : (31 70) 7 units

High Gloss : (71 100) 10 units

14. Determination of Dew Point

The substrate temperature must be at least 3C above the dew point.

15. Stoving Conditions

The temperature in the curing oven and also the object temperature must be measured with a 4-point measuring device. Three detectors must be attached to the

top, middle and lower parts of the oven and one to a reference panel mounted on the traverse amidst the parts.

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 temperature probes attached to the substrate. The thickest part of the steel must

reach the maximum temperature allowed by the coating manufacturer.

16. Appearance Test

Any visual inspection of coated parts should be done at a distance of 3 m for an interior setting and 5 m for an exterior setting, and with a normal unaided vision.

At these distances and in diffuse daylight, the coating must not show any wrinkles, runs, sags, craters, blisters and other surface irregularities. Irregularities that are an image of the steel surface or the hot dip galvanized zinc, visible through the coating,

must be disregarded.

Color and gloss may be measured if agreed upon between customer and coater.

17. Boiling Test

The objective of this test is to determine the resistance of the coating system to

cracking and loss of adhesion, or both, after accelerated aging by boiling water. The test must be performed according to EN 13438, A.4.11.

Procedure

Fill a pressure cooker with (25 3) mm de-ionized water with a maximum

conductivity of 30 S/cm at 20C. 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 100kPa 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 and

even pull.


23

There shall be neither defects nor any loss of adhesion. Some color change is however acceptable.

VIII. Environmental tests on Finished Products

1. Resistance to Mortar

This test is only applicable to powder coatings, and must be performed according to EN 12206-1.

Procedure

The mortar is a mixture of sand, lime and water. 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 3C and 95 5% relative humidity for 24 hours.

Then manually remove the mortar from the coated surface and remove any residue with a damp cloth. Allow the panel to dry, and examine the coating with normal or corrected vision.

The mortar must be easily removable without leaving any residue. Any mechanical damage to the coating caused by grains of sand must be disregarded.

The panel should not show any change in appearance or in color after the test.

2. Neutral Salt Spray Test

The objective of this test is to evaluate the corrosion resistance of the coating

system, and the test results will give an indication of the durability of the coating system.

All coating systems, powder coatings and liquid coatings, will be tested according to ISO 9227.

The exposure times are:


High durability

1 N/A

2 240 h

3 480 h

4 720 h

5I 1440 h

5M 1440 h

Test Panel Preparation

Three test panels shall be prepared, type B (Chapter VI A. 2) according to the technical specifications of chemical and coating suppliers.. Liquid coatings must

be allowed to cure for 21 days in an environment 23/50 or 20/65 according to ISO 554 before being submitted to the NSS. Test panels without a metallic zinc layer must be scratched; panels with a metallic zinc layer shall not be scratched.

The scratch shall expose the substrate. According to ISO 17872, the form of the scribe shall be a cross and shall have a length of at least 50 mm. Intersection will


24

be located in the middle of the panel. Diagonals will cross at an angle between 50 and 70. The scribe shall not be within 20 mm of the edge of the panel or of

any eventual holes in the panel.

Assessment of the coated panels

i. Calculate M according to:

M = C W

2

C= mean overall width of the zone of corrosion (mm)

W= width of the scribe (mm)

Assessment: M 1 mm

ii. Asses blistering, cracking and flaking immediately after the test

Standard Coating

defect

Assessment

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)

iii. Determine the ranking of the coating system:

Category # Panels OK # Panels NOK

A 3 0

B 2 1

C 1 2

D 0 3

iv. Determine the status of the license

Category Approval License

A OK Granted or continued

B OK Granted or continued but results will be submitted to the coating company

C NOK Momentarily not granted. Salt spray test must be repeated license granted only if the second test results in A or B

D NOK

Not granted, the whole qualification procedure must be

restarted. The corrosivity category must eventually be verified with the coating company

3. Resistance to Humidity

This resistance of paint films to conditions of high humidity is evaluated according

to ISO 6270-2. The test is not applicable to corrosivity category C1. The exposure time for the other corrosivity categories can be found in

ISO 12944-6, but is different for steel substrates and steel with a metallic zinc layer.


25


Steel substrate

Metallic Zinc layer

2 120 h 240 h

3 240 h 240 h

4 480 h 480 h

5I 720 h 720 h

5M 720 h 720 h

Assessment is done immediately after the test and with the unaided eye.

i. Asses blistering, cracking and flaking

Standard Coating defect

Assessment




ii. Determine the ranking of the coating system:


A 3 0

B 2 1

C 1 2

D 0 3

iii. Determine the status of the license




C NOK Momentarily not granted. Continuous condensation test must be redone

license granted only if the second test results in A or B

D NOK Not granted, the whole qualification procedure must be restarted. The corrosivity category must eventually be

verified with the coating company

4. Chemical Resistance Test

The chemical resistance of the coating system, corresponding to highly industrial

environments is determined according to ISO 2812-1, Method 1 Procedure A for 168 hours and only for the Corrosivity Category C5I. The following chemicals of

analytical quality shall be used:

a. NaOH 10 % (m/m) aqueous solution b. H2SO4 10 % (m/m) aqueous solution

c. Mineral Spirits, containing 18% of aromatic compounds

The samples are placed in a container holding the described test liquid.



26

i. Asses blistering, rusting, cracking and flaking

Standard Coating

defect

Assessment







A 3 0

B 2 1

C 1 2

D 0 3





C NOK Momentarily not granted. Chemical resistance test must be redone

license granted only if the second test results in A or B

D NOK

Not granted, the whole qualification procedure

must be restarted. The corrosivity category must eventually be verified with the coating company

5. Resistance to Humid Atmosphere Containing Sulfur Dioxide

The objective of this test is to determine the resistance of coating systems to

heavily polluted atmospheres, and therefore only applicable to the corrosion category C5I. The coated surface is exposed to 0.2 liter of SO2 in a test cabinet for

720 hours according tot ISO 3231.


i. Asses blistering, rusting, cracking and flaking

Standard Coating defect

Assessment





No surface defects or discoloration shall be observed.



27


A 3 0

B 2 1

C 1 2

D 0 3





C NOK Momentarily not granted. Chemical resistance test must be redone license granted only if the second test results in A or B

D NOK Not granted, the whole qualification procedure must be restarted. The corrosivity category must eventually

be verified with the coating company

6. Accelerated Weathering Test

This test simulates the resistance to discoloration and loss of gloss for an exterior

use of coated products, and is executed according to ISO 16474-2. This test is only required for coating systems in corrosivity categories C3-C5.

After 1000 h exposure, the test specimen is rinsed in demineralized water, and

the following criteria are verified:

Loss of gloss ISO 2813 at 60 Gloss must be above 50 % of the initial value

E* E* in accordance with ISO 11664

In accordance with E*-values of the table in Annex 1.

7. Natural Weathering

The resistance of a coating system to weathering as a result of solar radiation is evaluated. This test only applies to coating systems intended for outdoor exposure. The test is executed by exposing the coating materials in Florida

according to EN 13438, A.4.8.2 and following the procedures according to 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).

Dimensions of the samples: 27pprox.. 100 x 305 x 0.8 1 mm

After exposure, the exposed samples must 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


28

other method approved by the Technical Committee. This process must not scratch the surface.

Gloss must be measured in accordance with EN ISO 2813, at an angle of 60.

The colorimetric assessment must be conducted for the standard illuminate D65

and the 10 normal observer.

The color variation E* is determined with a CIELAB formula in accordance with ISO 11664, specular reflection included.

To assess gloss and color, three measurements will be made on the cleaned, weathered samples and on the unexposed reference panels. These measurements

must be made at different points at least 50 mm apart.

Since thermoplastic powder coatings might develop some brittleness, a mechanical test must be done before and after the exposure.

RESULTS:

Gloss: The remaining gloss must be above 50% of the original gloss.

Color change: The E* values must not exceed the maximum values in the table in Annex 1.

Annex 1 Admissible E* for RAL-numbers after Florida-exposure Adopted from QUALICOAT


29

RAL Delta E RAL Delta E RAL Delta E RAL Delta E 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

1020 6.0 3027 6.0 5020 5.0 6017 5.0 7023 3.0 8070 4.0

1021 6.0 5021 4.0 6018 4.0 7024 4.0

1023 3.0 5022 5.0 6019 2.0 7026 4.0

1027 3.0 5023 4.0 6020 2.0 7030 2.0

1028 8.0 6021 4.0 7031 4.0

1032 6.0 6024 3.0 7032 2.0

1038 2.0 6025 5.0 7033 3.0

6026 5.0 7034 3.0

6027 2.0 7035 2.0

6028 5.0 7036 3.0

6029 5.0 7037 3.0

6033 2.0 7038 2.0

6034 2.0 7039 4.0

7040 3.0

7043 3.0

Annex 1 Admissible E* for RAL-numbers after Florida-exposure Adopted from QUALICOAT


30

7044 2.0

Annex 2 Abbreviations used in the tables


31

A powder coating system is described as

Sys No I= inside systems

O= outside systems

P powder coating followed by system number

Primer Binder E=epoxy

P=polyester

S = Metal spray

Ef = Electrophoresis coat

Type C= colored

Z= zinc

Zinc or Zinc free Z/ZF

Different Substrates:

Substrate Explanation

ZE 50/50 Sheet electrolytic zinc on steel 5 m

ZE 100/100 Sheet electrolytic zinc on steel 10 m

Z100 Continuous hot dip galvanizing zinc 100 g/m2 double faced



HDG Steel thickness < 1.5 mm 250 g/m2/face approx. 35 m, Hot Dip Galvanizing HDG Steel thickness >1.5 and < 3.0 mm 325 g/m2/face approx. 45 m, Hot Dip Galvanizing

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

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

Surface preparation

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 and Sa 3 Blasting in accordance with ISO 8501-1

Annex 3 Powder Coating systems Interior (Will be replaced by French proposal)


32

No Substrate Surf. Prep.

Primer Intermediate

coats Topcoat Coating System Durability

B Type m resin Type m resin Type m Layers m (*) C1 C2 C3 C4 C5 I C5 M

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

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

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

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

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

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

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

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

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

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

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

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

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



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

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

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

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

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

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

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

(*) Total Coating thickness is without the thickness of the zinc layer

Annex 4 Powder Coating systems Exterior (Will be replaced by French proposal)


33

No Substrate Surface

Preparation

Primer Intermediate

coats Topcoat

Total coating

system Durability

Binder Type m Binder Type m Binder Type m Layers m (*) C2 C3 C4 C5-I C5-M

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

O-P 07 Bis

HDG 4 80 1 80 X X

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

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

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

O-P 10 Steel 3 E Z/ZF 70 P C 80 2 150 X X

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

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

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

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

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

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

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

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

O-P 06 HDG 4 E C 60 P C 60 2 120 X X X

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

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

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

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

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

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

(*)Total Coating thickness is without the thickness of the zinc layer

Annex 5 Powder Coating systems Thermoplastic Systems


34

N Substrate Preparation

Primer Intermediate

coats Topcoat

Total coating system

Durability

Binder Type m Binder Type m Binder Type m Coats m C2 C3 C4 C5-I C5-M

TPP1 Steel Sa 2 1/2 N C 250 N C 250 2 500

TPP2 HDG 4 or 5 A C 5 PVC C 250 2 255 X X X X X

TPP3

TPP4

TPP5

TPP6

P Polyester

V Vinyl

N Nylon (polyamide)

E Ethylene acid copolymer

PVC Polyvinyl chloride

Fl Fluorized

A Acryl

Annex 6 List of applicable standards The latest version of the standard is valid


35

N TITLE

EN 13438 Paints and varnishes - Powder organic coatings for galvanized or sherardized steel products for construction purposes

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

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

ISO 1518 Paints and varnishes - Scratch test (ISO 1518:1992)

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

ISO 2409 Paints and varnishes - Cross-cut test (ISO 2409:2007)

ISO 2808 Paints and varnishes - Determination of film thickness (ISO 2808:2007)

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

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

ISO 3231 Paints and varnishes - Determination of resistance to humid atmospheres containing sulphur dioxide (ISO 3231:1993)

ISO 3274 Geometrical product specifications (GPS) - Surface texture: Profile method - Nominal characteristics of contact (stylus) instruments (ISO 3274:1996)

ISO 9223 Corrosion of metals and alloys -- Corrosivity of atmospheres -- Classification

ISO 9227 Corrosion tests in artificial atmospheres - Salt spray tests (ISO 9227:2006)

ISO 15184 Paints and varnishes -- Determination of film hardness by pencil test

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

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

ISO/IEC 17025 General requirements for the competence of testing and calibration laboratories (ISO/IEC 17025:2005/Cor.1:2006)

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

ISO 11125-2 Preparation of steel substrates before application of paints and related products - Test methods for metallic blast-cleaning abrasives - Part 2: Determination of particle size distribution (ISO 11125-2:1993)

ISO 11127-2 Preparation of steel substrates before application of paints and related products - Test methods for non-metallic blast-cleaning abrasives - Part 2: Determination of particle size distribution (ISO 11127-2:1993)

ISO 11664 1-6 Colorimetry

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

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

ISO 12944-3 Paints and varnishes - Corrosion protection of steel structures by protective paint systems - Part 3: Design considerations (ISO 12944-3:1998)

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

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



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ISO 12944-6 Paints and varnishes - Corrosion protection of steel structures by protective paint systems - Part 6: Laboratory performance test methods (ISO 12944-6:1998)

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

ISO 12944-8 Paints 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)

ISO 16276-2

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

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

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

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

ISO 4628-4 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: Assessment of degree of cracking (ISO 4628-4:2003)

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

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

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

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

ISO 6270-2 Paints and varnishes - Determination of resistance to humidity - Part 2: Procedure for exposing test specimens in condensation-water atmospheres (ISO 6270-2:2005)

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

ISO 8501-1

Preparation of steel substrates before application of paints and related products - Visual assessment of surface cleanliness - Part 1: Rust grades and preparation grades of uncoated steel substrates and of steel substrates after overall removal of previous coatings (ISO 8501-1:2007)

ISO 8501-3

Preparation of steel substrates before application of paints and related products - Visual assessment of surface cleanliness - Part 3: Preparation grades of welds, edges and other areas with surface imperfections (ISO 8501-3:2006)

ISO 8502-3

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

ISO 8502-4 Preparation of steel substrates before application of paint and related products - Tests for the assessment of surface cleanliness - Part 4:



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Guidance on the estimation of the probability of condensation prior to paint application (ISO 8502-4:1993)

ISO 8503-1

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

ISO 8503-2

Preparation of steel substrates before application of paints and related products - Surface roughness characteristics of blast-cleaned steel substrates - Part 2: Method for the grading of surface profile of abrasive blast-cleaned steel - Comparator procedure (ISO 8503-2:1988)

ISO 8503-3

Preparation of steel substrates before application of paints and related products - Surface roughness 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)

ISO 8503-4

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

ISO 16474-1 Paints and varnishes -- Methods of exposure to laboratory light sources --

Part 1: General guidance

ISO 16474-2 Paints and varnishes -- Methods of exposure to laboratory light sources -- Part 2: Xenon-arc lamps

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