Qualisteelcoat Technical Specifications Version21 31102013

QUALISTEELCOAT Version 2.
1

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QUALISTEELCOAT
Technical Specifications

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

QUALISTEELCOAT Version 2.1

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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 the
text 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. Only
chapter 7 Approvals of coatings was revised completely.

Chapter 1 General information

Chapter 2 Quality assurance by the coating applicator
2.1 Expected performance
2.2 Test panels
2.3 In-house control
2.3.1 Procedures
2.3.2 Blasting surface preparation quality control
2.3.3 Chemical pre-treatment quality control
2.3.4 Finished products quality control
2.4 Tests of resistance to environmental impact

Chapter 3 Surface preparation

Chapter 4 Coating systems

Chapter 5 Requirements coating process and storage
5.1 Coating process
5.2 Storage

Chapter 6 (cancelled)

Chapter 7 Approval of coatings (revised)

Chapter 8 Licence for coating applicators

General remark for all appendixes:
- These are just for your information! -

Appendix 1 Corrosivity category
Appendix 2 Remark: this appendix does not exist anymore
Appendix 3a Information on substrates
Appendix 3b Removal of contamination
Appendix 3c Surface pre-treatment
Appendix 4a Liquid coating systems
Appendix 4b Powder coating systems
Appendix 10 Specification of the standards


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Chapter 1 GENERAL INFORMATION

QUALISTEELCOATs objective is to establish rules for coating applicators applying
protective coating on steel for new works executed in shops.

TERMINOLOGY
Licence: Permission for a coating applicator to use the QUALISTEELCOAT quality label.
Approval: Confirmation that a specific coating system meets the requirements of the
Specifications.
General Licensee (GL): National association holding the QUALISTEELCOAT Master
Licence for the whole country in question.
Testing laboratories: Independent quality testing laboratories duly approved by the general
licensee and/ or QUALISTEELCOAT.

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

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

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

The specifications laid down in this document concern:
1. The different processes used for steel protection;
2. In-house control by the coating applicators in connection to 1;
3. The performance of applied coating systems in relation to Corrosivity categories;
4. Inspection of licensees.

The regulations laid down in this document give the minimum requirements, which the
licensees, their finished coated products, as well as the applied coating materials have to
meet.

The QUALISTEELCOAT coating licences are divided into two categories:
! Interior use only (C-1 and 2 interior), called INTERIOR licence
! Interior/exterior use (C-1, 2, 3, 4 and 5), called EXTERIOR QUALISTEELCOAT
licence.

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


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QUALISTEELCOAT Interior Licence (I) C1 and C2:
The parts are briefly exposed to temperature changes or humid atmosphere. Such
pre-treated parts are mostly used indoors.
The applicable control level, based on which test samples are taken, is C-2 medium.

QUALISTEELCOAT Exterior Licence (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, the
substrate is grit blasted after galvanizing, or blasted and zinc/aluminium sprayed. The pre-
treated surface is coated with organic coating as specified in this document. The applicable
control level and test samples are based on compliance with the Corrosivity Category
specified in the applicators production documents.

Tests will be carried out in accordance with these specifications. Tests supplementary to
those laid down in these specifications must be agreed between the QUALISTEELCOAT
licensee and its customers.

QUALISTEELCOAT members production processes must be proven reliable, in accordance
with the stipulated minimum requirements. The members are obliged to comply with
QUALISTEELCOATs specifications and any additional specifications provided by the
customer.

If the system has not been approved previously by QUALISTEELCOAT this must be clearly
stated on the production forms for the benefit of the QUALISTEELCOAT inspector. The
system applied must be suitable for the Corrosivity Category stated on the production sheet.
Production samples may be tested for Corrosivity Category compliance by the
QUALISTEELCOAT inspector.


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Chapter 2 QUALITY ASSURANCE BY THE COATING APPLICATOR

2.1 Expected Performance
The durability of the coating system depends on the surface pre-treatment and the
composition of the coating system. The purchase order must, therefore, provide relevant
information as to the Corrosivity Category of the environment where the coated object will be
used. Reference is made to appendix 1.

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

In order to assess the characteristics of coating materials, they are tested on metal test
panels in accordance with EN ISO 1514. Test panels must be made of the same metal as
the substrate used in the system.

Testing of coating systems is executed on the test panels mentioned in the test standards.

The natural and the accelerated weathering test can be conducted on Aluminium AlMg1. The
coating system applied to the test panel shall show no scratches penetrating as far as the
substrate.

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
imposed on the applicator to ensure the quality of his product. In house control is vital for
being granted a QUALISTEELCOAT licence.

The applicator has to monitor his production methods and products by several tests to be
executed in house which are described in this chapter.

Technical information and instructions for use of every testing device, showing the
identification number and proof of calibration, must be available.

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 is to be maintained by the
laboratory supervisor and have to show all the measuring records of the in house laboratory
tests that are described hereafter. The control register must show the nominal values,
maximum values not to be exceeded, actual values recorded and the number of shifts
worked. If necessary, any corrective measures must be noted on the chart against the date
of the analysis, or recorded in the register.

In case of chemical pre-treatment a separate record must be kept for each bath.

The coating applicator must increase the frequency of the analyses of his own accord if
proven necessary on account of the analyses made.

For finished products a control register is to be kept at the production line. When the job is
finished a copy is sent to the laboratory supervisor. The register must show the following
information:
- The customer's name and the order or lot identification data;
- The production date of the different coating layers;

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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 colour
required 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 the
following frequency and methods.

Testing method Interior Exterior
Inspection of coatability of parts All parts All parts
Particle size of shot or grit
Inap
plica
ble
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
film thickness
None Once per shift
Dew point
Once a day At least 2 times per day and systematically
on a piece from outside before blasting
Blast cleanliness and dust
removal
Spot testing All production by spot testing
Conversion coating *1

Inapplicable
Visual inspection
Chemical assessment 4 times a year by
supplier
The temperature of conversion
and rinsing baths *1
Inapplicable

Once per shift
Conductivity of rinsing water *1*a Inapplicable If required once per shift
Drying temperature * 1 Inapplicable Once a week

*1 only applicable if conversion coating is applied > see chemical pre-treatment chapter 2.x.x
*A One measure in the bath before conversion and one measure in the drippings after final rinse

The control register must show all measurements and results of the tests shown in the table
including the charge number of the grit/shot when using new grit or shot.


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Laboratory and inspection equipment for Blasting Surface Preparation

Instruments Classification I or E Quantity
Set of sieves to determine grit seize
deviation *1
Exterior (1) From supplier
Roughness measurement equipment Exterior 1
Thickness tester, individual or multi-
purpose gauges
Interior + Exterior 2
Thermometer
Dew 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 coated
Careful 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 any
surface 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 must
be 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 for
welds, edges etc.

The second inspection concerns the determination whether the desired surface preparation
suits the requested pre-treatment.

Subsequently, it must be determined whether the requested coating system can be applied
to this substrate.

Finally, the suitability of the requested paint system for the corrosivity category at the
erection site must be evaluated.

RESULT:
Define the suitability of the object for a certain coating system.

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.

2.3.2.3 Loss of zinc
When blasting a hot dip galvanized steel substrate, a very smooth method of blasting must
be used. In order to determine how much zinc will be removed, a test part of the substrate
must be blasted. By measuring the film thickness of the zinc before and after blasting the
loss of film thickness can be determined.

The loss of zinc during the blasting stage must be tested at least once at the start of a hot dip
galvanised steel project, using the method described.

RESULT:
Blasting may not result in a loss of more than 10 % of the zinc layer thickness.


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2.3.2.4 Blast result of hot dip galvanized zinc
RESULT:
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 slight
roughening 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 and
impurities in accordance with EN ISO 8501-1. After visual inspection of the substrate an
additional test can be conducted to assess the surface cleanliness in accordance with EN
ISO 8502-3.

RESULT:
The result may not exceed Class 1, quantity and dust size. The tape may show no
discoloration and the particles visible under x 10 magnification but not with normal or
corrected 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 and
products.

Test method Interior Exterior
Inspection of coatability of
substrates
Every object Every object
Concentration of pre-treatment
baths
1)

Inapplicable Once a day
Assessment of pH value of baths
1)

If required once a
day
If required once a shift
Conductivity of dripping water
1)
*a
Inapplicable If required
Once per shift
Temperature of baths
1)
Once a day Once a day
Zn and Al content
1) 2)

Inapplicable If required once per shift
Measuring the objects drying
temperature
Inapplica
ble
Once a day *b
Assessment of the loss of zinc by
etching
Inapplicable Once per shift
Assessment of conversion coating
1)

Inapplicable Visual once a shift, and
Chrome free following the
chemical supplier's
recommendations
Once a month
Inspection of result of surface
preparation
Not applicable Visual

1)
In accordance with the chemicals suppliers instructions. The instruction from the supplier must be
presented to the inspector.
2)
Only applicable to companies using combined zinc and aluminium baths.
*a. One measure in the bath before conversion and one measure in the drippings after final rinse
*b. In the case of hot dip galvanized once per project but at least once per 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, the
coating 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-purpose
gauges
Conductivity meter Exterior 1
pH 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 testing
chemical conversion coating *1 *2
Exterior
1

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

RESULT:
If not otherwise prescribed by the chemicals supplier, the conductivity of dripping water shall
not exceed 30 S/cm at 20C.

2.3.3.3 Determination of etching degree
The objective is to determine the loss of zinc during surface preparation by etching. This is
determined by measuring the zinc film thickness before and after etching. Etching must be
carried out in an acid medium or an alkaline plus acid medium.

RESULT:
A zinc etching degree between 5 and 10 % of the original zinc layer thickness of hot dip
galvanized steel. The etching degree for rolled products or casting is not specified. The
chemicals supplier for such products advises etching.

2.3.3.4 Assessment of the conversion coating
The objective is to determine the quality of the conversion coating by means of visual
assessment of the layer. Visual once a shift and Chrome free following the chemical
supplier's recommendations.

If so desired by the application firm, the chromate or chromate-phosphate pre-treatment has
to be carried out in accordance with EN 13438. The conversion coating must comply with the
requirements of conversion coating for steel or hot dip galvanized steel as given by the
chemicals supplier. The weight of the chromate conversion layer must be accordance with
the information provided by the chemicals supplier.

The maximum drying temperatures for the different conversion layers are as follows:

Chromate treatment (yellow): 65C

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

The maximum drying temperature allowed for continuous treatment is 100C, but the
substrate 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 dried
thoroughly before the coating is applied, irrespective of the production method (continuous/
discontinuous).

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

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

2.3.3.5 Inspection of the result of the surface preparation
After 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 Procedures
This table is a concise list of the desired tests.

Test method
Powder
coating or
Liquid
coating
Interior Exterior
Cross-cut adhesion
test
2)
Once per shift

Once per shift

Impact test
3)

P Inapplicable Once a day
L Once per system on a test
panel
Once per system on a test
panel
Thickness
measurement
1)
*
In accordance with testing plan In accordance with testing plan
Gloss measurement
1)

Once per order and per shift Once per order >100 m2 and at
least once per shift
Dew point
P Inapplicable Before starting application
L Once per shift Once per shift
Measurement of
curing temperature
(object temperature
1))

P Once a month by an automatic
temperature test using
equipment to measure the
temperature curve on 4 spots
Once a week by an automatic
temperature test using
equipment to measure the
temperature curve on 4 spots
L Twice a day for actual
temperature using a surface
temperature meter.
Twice a day for actual
temperature using a surface
temperature meter.
Polymerization test
1)

P If requested If requested
L Once per order or per shift Once per order or per shift
Appearance test
1)
Every order Every order

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Test method
Powder
coating or
Liquid
coating
Interior Exterior
Boiling test
2)

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 panel
2)
On test panels
3)
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 cross
cutting
Interior +
Exterior
1
Equipment to execute the impact test Exterior 1
Wet thickness gauge* Interior +
Exterior
1
Thickness tester, individual or multi-purpose
gauges
Interior +
Exterior
2
Gloss meter 60 Interior +
Exterior
1
Equipment to determine dew point Exterior 1
Device for measuring the maximum substrate
drying temperature.
Interior +
Exterior
1 x or stickers
Recording instrument for object temperature
and curing time with 4 measuring points**
Interior +
Exterior
1 (External
may be used)
Test solutions for polymerization test Interior +
Exterior
If required
Equipment to conduct the boiling test Exterior 1

*Only for liquid coating
**For liquid coating only when forced drying or curing ovens are used

2.3.4.2 Adhesion
The following methods are used to determine the adhesion of the coating system to the
substrate and the expected results:
EN ISO 16276-2 Cross-cut, X-cut and pull-off test method
EN ISO 2409 Cross-cut test equipment and results

The cut distance for coating thickness up to 60 !m is 1 mm, for thickness up to 120 !m 2 mm
and 3 mm for greater thickness up to 250 !m. If the dry film thickness exceeds 250 !m, the
pull-off test is recommended.


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RESULT:
Result
Test
method
Dft Outdoor
Resis
tant
coati
ngs
Results
Indoo
r
resist
ant
coati
ngs
Results
Corrosivity
Category
!m C1
C2
C3
C5
C1
C2
C3
C5
C1
C2
C3
C5
C1
C2
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 tested
on sample panels once per shift

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

The term "impact resistance" is used in the title of this standard, but one important
characteristic of the device used is that it should produce rapid deformation rather than true
impact.

The method described can be applied:
! Either as a pass/fail test, the test being carried out from one drop height and with a
specified mass, so as to test compliance with a particular specification;
! Or as a classification test, to determine the minimum mass and/or drop height at which
the coating cracks or peels from its substrate by gradually increasing the drop height
and/or the mass.
QUALISTEELCOAT uses the test only for pass/fail testing.

The coating system supplier must give the minimum reverse impact resistance value for
liquid coatings in relation to the required coating thickness. For powder coatings the energy
of 2.5 Nm direct impact must be used.

For each colour shade, gloss category and supplier, the impact test must be conducted at
least once a shift.

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

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


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

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 paint
surfaces by using pencils

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

2.3.4.6 Determination of particle size distribution
The objective of the test is to determine the mixture and size of the blast grit or shot particles
used for surface preparation. The particle size distribution test is conducted in accordance
with EN ISO 11125-2 for metallic blast-cleaning abrasives and EN ISO 11127-2 for non-
metallic blast-cleaning abrasives.

Determine the mean mass value of two tests and report the result to the nearest 1%. The
result must be within the limits of the desired blast clean operation.

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

If requested, the particle size of the blast shot or grit has to be assessed. The objective is to
determine whether the blaster is using the proper size grit. If new grit is used, particle
distribution information can be taken from the packaging. The results of the roughness
measurements must be compared with the size analyses for the blasters information.

2.3.4.7 Determination of surface roughness
The objective of this measurement is to determine the roughness of the substrate after
blasting, prior to application of the first primer coat.

The assessment of the roughness is conducted in accordance with EN ISO 8503-2 for
grading of the surface profile, EN ISO 8503-1 for ISO surface profile comparators, EN ISO
8503-3 for profile focusing by microscope, and 8503-4 for profile, stylus instruments.

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

If the primer coating needs a specified roughness, the substrate must be measured using
surface roughness measuring equipment. This may be a comparator or by actually
measuring the roughness (EN ISO 3274 and EN ISO 5436-1 and 2).

2.3.4.8 Determination of wet film thickness (only for liquid coating)
The wet film thickness of the coating has to be monitored during the application. For this
purpose the thickness of the applied film is determined by a wet thickness comb immediately
after application of a liquid coating layer.


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RESULT:
The wet film thickness must be in accordance with the calculated wet thickness in order to
obtain 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 the
production chart.

2.3.4.9 Determination of dry film thickness
The dry film thickness of the individual coats in the system and the total dry film thickness
must be measured 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 rejected
samples
1 10 All 0
11 200 10 1
201 300 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
22,001 110,000 150 11
* Lot size: The number of items of similar shape and seize.

Alternative
Surface in m2 or m1 Number of measurements 1)
1 4
1 3 10
3 10 15
10-30 20
30-100 30
>100 2) For every 100 add 10 measurements
1) The measurements must be representative of the inspected area.
2) It is recommended to divide areas in excess of 1000 m2 into smaller inspection
parts

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


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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 PROTECTION
STRIPE COAT(S),

INTERMEDIATE COAT 1st
coat

INTERMEDIATE COAT
2nd coat

TOPCOAT 1
st
coat
Topcoat 2
nd
coat
TOTAL NOMINAL DRY FILM THICKNESS

2.3.4.10 Gloss
For 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 the
gloss meter, the gloss should be compared visually with the reference sample (from the
same viewing angle).

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

The results of these analyses must be recorded, showing the nominal values, maximum
values not to be exceeded, the actual values recorded and the number of work shifts.

2.3.4.11 Determination of dew point
The following steps determine the dew point:
a. Measuring the relative humidity of the air;
b. Measuring the substrate temperature;
c. Calculating the dew point or taking this from a table or graph.

RESULT:
The dew point must be at least three degrees Celsius lower than the substrate temperature
of the metal. If the coating supplier allows a lower temperature difference between dew point
and steel temperature, a written agreement must be available.

The dew point of the substrate to be blasted and of the substrate to be coated must be
determined.


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

For curing the temperature in the curing oven as well as the object temperature in the oven
must 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 substrate
and 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 attached
to the substrate. When drying at an ambient temperature, the curing temperature of the
products 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 60
degrees 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 data
sheet.

2.3.4.13 Polymerisation test
The 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.

For each supplier he polymerization test must be conducted on sample panels at least once
every eight-hour work shift, for each colour shade and gloss category.

Before testing, the liquid coating system must be cured for four hours at 60
o
C. The mixture
used must be tested first on a properly cured version of the coating system. A range of
solvent mixtures must be used to determine the proper mixture for the final coating in the
system. The solvents given below are an indication of solvents to be used.
Required solvent for liquid coatings: MEK (methyl ethyl keton) or as specified by the paint or
lacquer manufacturer and approved by the Technical Committee.
Required solvent for powder coatings: As specified by the powder coatings manufacturer and
approved by the Technical Committee.

Saturate a swab of cotton wool with solvent. Within 30 seconds, rub it lightly back and forth,
30 times in each direction, over the part to be tested. Wait 30 minutes before making the
assessment.

The Polymerization quality is assessed in accordance with the following ratings:
1. The coating is very dull and quite soft;
2. The coating is very dull and can be scratched with a fingernail;
3. Slight loss of gloss (less than 5 units);
4. No perceptible change the surface cannot be scratched with a fingernail.

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


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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 m
for 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 from
a distance of 1 meter in diffuse light.

RESULT:
At these distances, the coating should not show any wrinkles, runs, sags, craters, blisters
and other surface irregularities. Irregularities as a result of the steel substrate or the hot dip
galvanized zinc are not to be taken into account. The inspection must be conducted in diffuse
daylight.

When the end user desires other distances or inspection criteria, the client, applicator and
galvanizer 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 for
rejected samples
1 - 10 All 0
11 200 10 1
201 300 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
22,001 110,000 150 11
* Lot: a customer's complete order in one colour, or the part of the order that has already
been coated

2.3.4.15 Boiling test (Permeability)
Remark: Not applicable for thermal sprayed zinc layer

The objective of this test is to determine the adhesion properties of the coating system. The
test must be performed according EN 13438, A.4.11.

Fill a pressure cooker with de-ionized water with a maximum conductivity of 30 !S/cm at
20C to a depth of 25 mm 3 mm. Partially immerse the coated test panel in the water so
that a minimum length of 25 mm is immersed and secure the lid of the pressure cooker.
Apply heat to the pressure cooker until steam is emitted from the valve. Insert a weighted
needle valve to give a pressure of 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 even pull.

Exposure time for exterior use is 2 hours


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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 mortar
This test is used to assess the resistance of the coating system to fresh mortar. This test is
only used for powder coatings.

The test must be performed in accordance with EN 13438 part A.4.7. The required
composition of the mortar is sand, lime and water. The testing time is 24 hours. The mortar
must be prepared by mixing 15 g of hydrated lime, 41 g of cement and 224 g of sand with
sufficient tap water to make a soft paste. Apply four portions of the mortar, approximately 15
mm in diameter and 6 mm thick, to the test panel.
Place the test panel horizontally at 38 3C and 95 5% relative humidity for 24 hours.
At the end of the period, manually dislodge the mortar from the coating surface and remove
any residue with a damp cloth. Allow drying and examining the coating with normal or
corrected vision, to determine the incidence of visible detachment of the coating due to the
effect and removal of the mortar.

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

2.4.2 Neutral salt spray test

The objective of this test is to determine the corrosion resistance of the coating system. For
the corrosive categories the test results will give an indication of the durability of the coating
system. The test is similar for coated hot dip galvanized steel.
Test procedures are given for liquid coating material systems and powder coating material
systems.

EN ISO 9227 and EN 13438, 5.3.12
In the middle of the test panel, scribe a cross to expose, but not penetrate, the substrate. The
cross shall be a rectangular cross in which each of the diagonals has a length of 50 mm, the
intersection is centred in the middle of the panel and the scribe lines intersect at 90 . Place
the coated test piece in a spray cabinet complying with EN ISO 9227 continuous salt spray.
After testing, remove the sample carefully from the test cabinet, wash the test panels in de-
ionized water at a temperature of less than 35C, and dry immediately. Attempt to lift the
coating from the scribed line with a sharp tool. Examine the area around the scribed cross.
M=(C-W)/2
C= average of nine measurements of corrosion including the worst points of corrosion
W= width of the scratch

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

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

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RESULT:

Neutral salt spray
EN ISO 4628-2 Blistering 0 (S0)
Assessment immediately
after aging test
EN ISO 4628-3 Rusting Ri 0
EN ISO 4628-4 Cracking 0 (S0)
EN ISO 4628-5 Flaking 0 (S0)
Corrosion of the
substrate from
the scribe
Test regime
EN ISO 9227
M " 2 mm

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

Evaluation:

Approval Licence
A In order In order
B In order
In order with corresponding information to
be submitted to the coating company
C Not in order
Repetition of salt spray test only if result of
second test is A or B, the test will be
considered successful.
D Not in order
Not in order, the whole test must be
executed again.
Or class to be verified at coating company

2.4.3 Resistance to continuous condensation
This test is used to determine the adhesion of the coating system during prolonged periods
of high humidity, according EN ISO 6270-1.

Testing period:

Category Interior Exposure time Na
Category Exterior Exposure time 1000 h

RESULT:
Blister must not be visible to the naked eye.

Constant atmosphere of water condensation
after aging test


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Approval Licence
A In order In order
B In order
C Not in order
Repetition of constant atm. of condensation
test only if result of second test is A or B,
the test will be considered successful.
D Not in order
executed again.

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 in
accordance with EN ISO 2812-1. For the purpose of determining the chemical resistance, an
additional test for C5I in accordance with EN ISO 2812-1 is carried out. The following
chemicals of recognized analytical quality shall be used:
a) NaOH 10 % aqueous solution
b) H2SO4 10 % aqueous solution
c) Mineral spirits containing 18% aromatics

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

RESULT:

Chemical test
after aging test

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


Evaluation:

Approval Licence
A In order In order
B In order In order with corresponding information to

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C Not in order
Repetition of test only if result of second
test is A or B, the test will be considered
successful.
D Not in order
executed again.

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. The
coated 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 4
480 h (20 Cycles) for Medium durability Category 5
720 h (30 Cycles) for High durability Category 5

RESULT:

Colour resistance test (Kesternich)
after aging test
EN ISO 4628-5 Surface
changes
No Surface defects or discoloration


Evaluation:

Approval License
A In order In order
B In order
C Not in order
Repetition of test only if result of second
test is A or B, the test will be considered
successful.
D Not in order
executed again.

2.4.6 Accelerated weathering test

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

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This test is only required for coating systems intended for outdoor application. To be granted
approval for the coating system in question, Aluminium panels may be used.
The test serves to determine behaviour under EN ISO 11341 - weathering.
Loss of gloss and changes in colour are determined.

Intensity of light 550 20 W/m
2
(290 800 nm)

Black-standard temperature 65 5 C

De-ionized water max. 10 !S/cm

Special-UV filter (290 nm)
Cycles of 18 min. in humid and 102 min. in dry medium.
After 1000 h exposure, the test specimen is washed in entirely demineralised water.
The following criteria are verified
- Loss of gloss EN ISO 2813
Angle of incidence 60
- Total deviation in shade: #E resulting from CIELAB formula in
accordance with ISO 7724-3, included gloss

RESULT:

Loss of gloss Should not exceed 50 % of the initial value.
Total deviation in shade In accordance with #E-values of the attached
table.

2.4.7 Natural weathering

This test is conducted to determine the outdoor resistance of the coating system to
weathering as a result of solar radiation. This test only applies to coating systems intended
for outdoor application. The test is executed by exposing the coating materials in Florida
according EN 13438, A.4.8.2 (Paint-and Varnishes, Powder organic coatings for galvanized
or sherardized steel products for construction purposes) and following the procedures
according to EN ISO 2810 (Paints and varnishes Notes for guidance on the conduct of
natural weathering tests.)
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: approx. 100 x 305 x 0.8 - 1 mm
After exposure, the exposed samples are to be cleaned using the following method:
Wash the test panels prior to inspection with water containing 1% neutral detergent, using a
sponge and avoiding polishing. Afterwards rinse the panels with water with a maximum
electrical conductivity of 10 !S/cm, or using any other method approved by the Technical
Committee.
This process must not scratch the surface.
Gloss is to be measured in accordance with EN ISO 2813, at an angle of 60.
The colorimetric measurements are averaged. The conditions for measurement and
colorimetric assessment are:
- Colour variation: !E CIELAB formula in accordance with ISO 7724-3, with gloss.
- The colorimetric assessment must be conducted for the standard illuminate D65 and the
ten-degree normal observer.

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

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 the
following table:

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

RAL
Delt
a E
RAL
Delt
a E
RAL
Delt
a E
RAL
Delta
E
RAL
Delt
a E
RAL
Delt
a E
RAL
Delt
a E
RAL
Delt
a E
RAL
Delt
a 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
7044 2.0


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2.4.8 Colour difference
The nuances in colour between charges and coated parts may not differ beyond certain
levels. 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 be
determined at diffuse daylight.

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

2.4.9 Gloss difference
The objective is to measure the differences in gloss. Gloss is also used to determine the
polymerization of glossy powder coatings.

RESULT:
The gloss level difference in the production of QUALISTEELCOAT products shall be within
the 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 the
specified 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, detailed
information of the material to be treated is necessary.
In appendix 3-a information is given about different substrates, the special treatment required
and points of particular interest as regards pre-treatment.
When ordering a protective coating system it is advisable to read the instructions given in this
appendix and to carefully follow the advice.

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

3.3 Removal of contamination
Before the substrate is fit for surface preparation and the application of a coating system, any
surface contamination has to be removed.
Any surface contamination must be removed from the surface, paying special attention to
non-standard products like protective oils, markings, salt, dirt and burned production residue.
This is necessary to improve the effectiveness of chemical and mechanical treatment, to
prevent unnecessary pollution of pre-treatment baths and to prevent the sheer of marking
through the coating system.

This also involves the removal of signs and stickers from the substrate.
These activities may result in additional work if not mentioned in the tendering procedure.
More information is given in appendix 3-b: Removal of Contamination.

3.4 Pre-treatment for powder and liquid coating systems
The parts are handled in the plant the reliability of the process having been ascertained.
The existing facilities for pre-treatment serve as the standard. Any external treatment, like
chemical treatment or blasting, is excluded with the exception of hot dip galvanizing and
electro galvanizing.

The purpose of the pre-treatment is to prepare the substrate for application of the protective
system. Different methods are used to serve different purposes. This may vary from
removing mill scale or corrosion from the substrate, to roughening the substrate to improve
adhesion of the protective system. All contamination must be removed prior to the pre-
treatment of the substrate.


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Chapter 4 COATING SYSTEMS

4.1 Coating systems in different environments
Depending on the environment where the coated object is used, different coating systems
are defined. Solvent-containing coating systems are listed in EN ISO 12944-5. In appendix 4-
a the most recent solvent-based coating systems are defined, including their durability
properties in different environments.

Examples of coating systems are given in appendix 4-a: Liquid Coating Systems.
Powder coating systems are not included in EN ISO 12944-5. In appendix 4-b coating
systems based on powder coating are listed, including the durability properties in various
Corrosivity Categories.

The systems are based on first coats of galvanized zinc, zinc-spayed and zinc powder
containing epoxy powder coatings, and electro deposition coatings. Depending on the
environment, additional layers of powder coating are applied. Examples of powder coating
systems are given in appendix 4-b.

In addition to the Corrosivity Categories defined in EN ISO 12944-2, local environment is
very important. An outdoors environment in which no natural rain will clean the surface is
most demanding. In such a case, coating systems from a Corrosivity Category, one full level
higher than would be chosen under normal circumstances, is recommended.
It is also recommended to carefully clean the coated substrate at intervals as
mentioned in the following table:

Frequency of cleaning using hot
water (*a) and high pressure (*b)
Corrosivity Category
C2 C3 C4 C5
Rain washed surfaces Once a year 1-2 times a year
Surfaces not rain-washed naturally 1-2 times a year Twice a year
Frequency of cleaning using cold
water and low pressure
Corrosivity Category
C2 C3 C4 C5
Rain washed surfaces Once a year Twice a year
Surfaces not rain-washed naturally 2-3 times a year 3-4 times a year
*a the temperature of the cleaning water at the moment of impact must be approx.
60C. Take care not to use water at a temperature above 80C.
*b the high pressure of the water used for cleaning the coated areas must be approx. 4
Bar. The spraying of the surface must be carried out carefully. Openings and rubbers
in a faade must be avoided.

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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 Objects
Objects containing various metals are to be pre-tested. Pre-treatment requires extra
attention, to prevent making premature decisions on the use of pre-treatment products like
chemicals and blast grit.

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 dried
thoroughly 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 coatings
After surface pre-treatment the coating system must be applied. The substrate must be clean
and dry before application. One or more coats must be applied and the coats must be cured
or pre-cured depending on the system.

The manufacturers data sheet shall be observed and the recommendations must be
followed. Special attention must be paid to the use of the proper spraying nozzle and thinner.

Prior to using the coating, the materials have to be inspected:
- As to conformity with the container label;
- No damaged containers may be used;
- No skin formation on the coating;
- No dry particles on the bottom of the container;
- Any sediment present must be easily re-dispersed.

Any addition of thinner or solvent must be in accordance with the manufacturers instructions.
The coating must be mixed using mechanical mixers.
The charge number and names of the components must be recorded on the production
sheet.

Each coat of the system must be applied as uniformly as possible, leaving no areas
uncovered. Prior to application of the next coat, the film must be dried and cured as per the
manufacturers instructions.

Drying Procedure:
The coating must be left to dry in a clean environment and at a temperature sufficient for
drying and hardening. When more coats have to be applied, sufficient time must be left
between the applications of the coating layers. After application of the system, the coated
products must be left to harden sufficiently to allow transport.


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5.1.8 Coating application and curing powder coatings
After surface pre-treatment the coating system must be applied. The substrate must be clean
prior to application. One or more layers must be applied and the different layers must be
cured or pre-cured depending on the system.

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 sufficient
distance to ensure proper application of the powder coating. The powder coating must be dry
and free of clotted parts or dirt.
The parts must be installed and earthed sufficiently to ensure an even application of the
powder coating.

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

All powder coatings must be cured immediately after application. The oven must heat up the
metallic 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. The
oven must be equipped with an alarm system that immediately warns when the temperature
exceeds the agreed temperature range.

5.2. Storage

5.2.1 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 solvent
may be present in the coating application area.
Powder coating materials must be stored in a dry atmosphere and free of contamination in a
room separated from the production facilities.

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

5.2.3 Storage of pre-treated parts
Pre-treated parts must not be stored for more than 16 hours. As a rule, they should be
coated immediately after pre-treatment. The risk of insufficient adhesion increases as the
parts are stored longer.

Pre-treated parts must never be stored in an atmosphere that is dusty and potentially
detrimental. Good atmospheric conditions must always be maintained in the storage area. All
workers handling pre-treated parts must wear clean textile gloves to avoid contamination of
the surface.


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5.2.4 Storage of coated material
The coated products must be professionally stored in a dry and clean room to avoid damage
to 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 be
clearly 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:

The substrate is always STEEL
Before the eventual application of a metallic layer, the surface is prepared in a
mechanical or chemical way. For metal spray the surface is blasted. Galvanised steel
is chemically prepared. This chemical preparation is not subject of the scope of the
QUALISTEELCOAT-specifications. Some coating systems do not contain a metallic
layer.
Before the application of the organic layer, the substrate with or without the metallic
layer, is always pre-treated. The pre-treatment is part of the whole coating system
and is describes as a mechanical or chemical pre-treatment.
The organic layer is one or a combination of one or more powders coatings, liquid
coatings of has as a first layer a electrophoretic primer. The organic layer can also be
a thermoplastic coating. The complete composition of the organic layer(s) is well
defined in the QUALISTEELCOAT COATING SYSTEM.


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7.2 Scope of the approval
In order to maintain optimal performance of the paint systems applied by the
QUALISTEELCOAT licensed coating applicators, the quality of the coating supplied by
coating manufacturers is tested. In this part of the specification, the test methods and
acceptable test result limits are given.

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 systems
Examples 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 Rules
Any 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 new
product, which, consequently requires separate QUALISTEELCOAT approval. Furthermore,
the manufacturer must renew his application for approval should the visual appearance of
the 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. The
stipulation of textures is subject to QUALISTEELCOAT-drafts.

Any organization may submit a coating system for approval. The applicant has to provide
complete and accurate information of the system and the Corrosivity Category for which the
system has been tested. The information to be provided includes details on the successive
coating layers applied, film thickness and the products data sheets. If QUALISTEELCOAT is
satisfied that the test results comply with the Corrosion Category requirements in question,
approval will be granted, stating the relevant Corrosion Category.

For powder coating, Qualisteelcoat approvals of multi-layer systems with Qualicoat-approved
topcoats, can be extended. See 7.7.1.1. Additional Extensions of the approval of Coating
Systems

From the 1st of January 2015, the licensees shall use QUALISTEELCOAT-approved powder
coatings.

7.5 Laboratory
To have a coating system approved, an EN ISO 17025 accredited laboratory recognised by
QUALISTEELCOAT must be requested to test the system. The laboratory will prepare the
test panels. Technical data sheets and safety data sheets must be provided for all the
coatings in the system. The systems are accepted in accordance with the corrosivity
category stipulated by the applicant.
The laboratory submits the test report to the National Association. If there is no National
Association in the country in question, the report will be sent to QUALISTEELCOAT. The
Technical Committee evaluates the test report and decides whether the product will be
granted approval. Approval is granted provided that the test results meet the requirements.

Should approval be withheld based on unsatisfactory test results, the manufacturer of the
tested product will be informed in detail as to the reasons for withholding the approval.


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

7.6 Approval number
When approved, the system will obtain a QUALISTEELCOAT identification number with the
addition of PI for interior coating systems, PE for exterior coating system, and the
Corrosivity Category for which the system has been tested.

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

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

A visit by the general licensee or by QUALISTEELCOAT in countries without a national
association 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 the
table in 7.7.1.1.b. (yellow fields)
He has to define precisely the system targeted and to describe the process used to coat the
panels provided (Chemical pre-treatment or mechanical and complete pre-treatment process
including pre-treatment process steps).

Coating Systems

Additional extensions of the QUALISTEELCOAT APPROVAL
For systems with one organic layer, the Qualisteelcoat-approval is only valid for the
respective gloss category (cfr. Qualicoat categories) and finish (smooth or textured).
For multi-organic layers, the Qualisteelcoat-approval can be valid for different
Qualicoat-approved topcoats of the same supplier. Those Qualicoat-approvals (P-nrs)
need to be communicated to the laboratory before granting an approval or the
renewal.


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7.7.1.2. Type of test panels
Test panels Purpose Substrate Application Dimensions
Type A Mechanical
tests
Test panels +
Coating Systems
Applied by laboratory at
lowest curing conditions
(lowest temperature,
lowest corresponding time
according TDS)
105 x 190 x 0,75 mm
(ref. GB26S/W/OC
Etalon)
Bare steel + zinc
phosphate
Type B Corrosion
test
Substrate +
Surface
Preparation +
Coating Systems
Applied by the powder
supplier or by the
laboratory
140 x 70 x 2 mm
Type 12-03
Type C Florida EN AW5005 +
Coating Systems
Applied by laboratory at
lowest 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 metallic
and organic coatings
2-a-9 A, B, C ISO 2808 +
ISO 19840 +
ISO 12944-5
According to system description
Adhesion 2-a-1 B ISO 16276-2
+ ISO 2409
0 - 1
Direct Impact Test 2-a-3 A + B ISO 6272-1 > 2,5 Nm
Resistance to boiling water 2-b-3 B EN 13438 See 2.3.4.15
Resistance to mortar(*) 2-b-2 B ISO 2813 See 2.4.1.
Neutral Salt Spray
Test Neutral Salt Spray
Test
2-b-4 B ISO 9227 See table 7.7.1.3.a. below
Resistance to continuous
condensation
2-b-5 B ISO 6270 See table 7.7.1.3.b. below
Resistance to humid
atmosphere containing
sulpherdioxide
2-b-7 B ISO 3231 30 cycles only for C5I
Accelerated weathering
test (*)
2-a-8 A ISO 11341 See 2.4.6.
Natural weathering test
Florida (*)
2-a-9 C ISO 2810 See 2.4.7.
Determination of
resistance to liquids
2-b-6 B ISO 12944-6 only for C5I, see 2.4.4.


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Table 7.7.1.3.a. Requirements for the Neutral Salt Spray tests for the approval of
Powder 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 mm
after 480 h
No loss of adhesion, no blistering,
no rust breakthrough after 480 h
after 720 h
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 hours
in the test cabinet.

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

Adhesion 1
Direct impact 1 (substrate not too thick)
Resistance to boiling water 3 (not necessary for metal sprayed 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
sulpherdioxide
3 (only for C5I)
Resistance to liquids 9 (only for C5I)


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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 necessary
coating, test panels for the tests.

Tests
The 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 finish
Each two years, the WG Approval of PC defines the colour that has to be tested. Initial the
rotations of RAL 9005, 7016, 6005 is foreseen.

If there are different QUALICOAT P-numbers under the QUALISTEELCOAT-approval, a
rotation of the different P-numbers has to be done.

Procedure of renewal
The test report has to be submitted to QUALISTEELCOAT. The test report will be evaluated
by the Technical Committee, which decides on renewal or withdrawal of the approval. In
case the results of the tests meet the requirements, the approval is renewed. In case of non-
compliance, the tests are repeated on samples taken from another batch. In case the second
testing does not lead to satisfactory results, the approval is immediately withdrawn. The
supplier of the tested product can submit a new application for approval but not within three
months of the withdrawal.

7.7.2. Approval of liquid coatings

Under construction by Working Group Liquid Paints.

7.7.3. Approval of thermoplastics

Under construction by Working Group Thermoplastics.


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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. In
order to obtain a licence the procedure will be followed:

One inspection must be satisfactory before a licence is granted. This inspection will be made at
the coating applicators request. The inspection will be conducted by appointment.
The coating applicator must, before the initial inspection, identify the corrosion category of
the licence.
After obtaining a licence the inspection can be executed on a production up to the level of the
licence. If a higher licence is required by the coating applicator an inspection of the coating
applicator producing a higher level product is necessary to obtain a licence on the desired
level.

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 uses
coating systems approved by QUALISTEELCOAT (see chapter 7).

- Inspection of laboratory equipment; the inspector has to ensure that the equipment is
available 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
production lines, see in house control chapter 2.

- Inspection of pre-treatment, see Surface pre-treatment appendix 3-c.

- Inspection of coated products. Certain tests may be carried out on the finished products but
the full range of tests must be performed on test panels processed concurrently with a
production lot. Only parts that have been released by the quality control of the coating applicator
are to be tested (all parts ready for dispatch are deemed to have been released by the quality
control of the coating plant). The inspector must perform the following tests on the coated parts:
Appearance (to test the uniformity of production)
Coating thickness
Gloss (only topcoat)

- Inspection of the test panels; the full range of tests must be performed on test panels
processed concurrently with a production lot:
Gloss
Adhesion
Thickness
Impact test
Boiling water test
Neutral salt spray test

- In-house control and registers; the inspector will check that in-house control has been
carried out and that the coating plant maintains registers. In the in-house control register he
will check that the results recorded in the register coincide with the results of the test panels.
For this reason, all test panels must be kept and held at the inspectors disposal for one year.

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8.3 Final assessment for granting the licence
The inspector submits the inspection report to the general licensee or directly to
QUALISTEELCOAT in countries where there is no general licensee. The inspection reports
are 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 will
be 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 coating
applicator 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 a
year. 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 is
available the report will be sent to QUALISTEELCOAT. The inspection reports are
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, authorisation to use the quality label will
continue.

If the result of the inspection does not meet the requirements, another inspection must be made
within one month (allowing for holiday periods).

If the second inspection again produces unsatisfactory results, the licence to use the quality
label will be withdrawn immediately. The coating plant must wait at least three months before
making a new application for a licence to use the quality label.

8.5 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.

8.6 Training (former Chapter 7.4)
QUALISTEELCOAT licensees quality assurance staff is to be retrained within two years,
starting from 1 January 2012 (QUALISTEELCOAT in-house training).


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Appendix 1 CORROSIVITY CATEGORY

According to: EN ISO 12944 part 2


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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 gas
bubbles appearing as blisters or craters on the coated surface. Parting compounds
too could impair adhesiveness. Therefore, coating companies should be informed of
the presence of such parting compounds, enabling them to verify the coating
properties of the material in advance and thus avoiding ensuing faults.

3.a.2 Hot dip galvanized and electro zinc coated steel parts

Prior to applying a coating system to galvanized steel, the galvanizer must be
informed about the surface preparation needed after galvanizing. Hot dip galvanizing
must be executed in accordance with ISO 1461. The galvanized steel must be
cleaned and any smut, zinc runs and dirt must be removed.

Depending on the quality of the steel, thickness of the zinc coating and possible
hollows, galvanized steel parts are susceptible to gas bubbles during curing and
forced drying of powder and liquid coating material. Blisters and craters become
visible on the surface.
Deadening agents might cause insufficient coating film adherence on Sendzimir- and
electro zinc coated steel surfaces. This is the reason why only protective layers that
can be removed gently during chemical pre-treatment are suitable. The zinc layer
must be treated with care. The coating company has to be informed accordingly.
Prolonged storage and exposure to humidity may lead to visible white rust which has
to be removed before coating in some cases slight sweeping has proved efficient. If
agreed upon by the client, the parts have to undergo this preparatory treatment.

3.a.3 Laser (Oxygen) Cut Steel
One of the advanced methods to cut steel in desired shapes and lengths is the cutting
of steel using laser beams. The result of the cutting method is a very sharp cutting
edge. Another problem may occur at the cutting side. The steel substrate is extra hard
after cutting. This causes the need for extra attention during surface preparation.
Before any surface preparation takes place the sharp edges must be rounded and the
heat-changed surface must be ground or blasted to create a treatable substrate by
the customer. See also EN ISO 8501-3.

The techniques of laser cutting allow for burr-free cutting of a large variety of metal
substrates with extreme precision at high speed without any limit to shape. In
addition, laser cutting is even suitable for thicknesses of 18 mm and above.


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Substrate remarks before coating application

" Laminated steel cold
Low thickness
Clean aspect
Generally oiled
" Laminated steel hot
Average with strong thickness
Any type of aspect and cleanliness
Pickled oiled
With adherent calamine (IPS)
With blue or black calamine
" STAINLESS

Disadvantages to applying paint

The laser beam releases great energy, and assembles metal at very high
temperature under pulsated oxygen, resulting in brutal oxidation of metal. Iron
oxide Fe3O4, called Magnetite or blue calamine is formed along the laser
cutting edges. Calamine adheres very poorly to metal.

Applying paint to calamine involves a huge risk as regards adhesiveness and may
well result in chipping at the cutting areas, which, generally, are also the zones
most exposed to shocks.

Possible solutions

Underwater or inert gas laser cutting may solve the problem. (Parameters
unfortunately not controlled by the applicators painting).

Other solutions are:
Mechanical treatment
Chemical treatment

Mechanical treatment

Principle: mechanical treatment eliminates calamine by various techniques:
- Shot-blasting
- Sanding
- Brushing

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

Disadvantages:
On tack-welded units, some areas may be hard to reach.

Chemical treatment

Principles:
By passage in an acid medium, non-adherent laser calamine is detached
from the substrate by the hydrogen release created when the metal is
attacked. The products to be used can be made up of mineral acids and/or
organic:

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- Hydrochloric
- Sulphuric
- Phosphoric
- Citric
- Gluconic
- Phosphonic
They are additives of surfactants and inhibiters in accordance with the
required treatment (simple scouring, scouring-grease-remover, grease-
remover-paint remover-phosphatizer). Both soaking and sprinkling are
possible.

Advantages:

The treatment reaches laser calamine even in the inaccessible places of the
parts.
Several successive baths can be used.
Possibly enables the increase of anti-corrosive properties of coatings, by
means of conversion post-treatment

Disadvantages:

Implements chemicals and implies a treatment of the rejects.
Eliminated calamine is found in the bath and creates mud.
Total decarbonising of the mild steel is not achieved.
The phenomenon of clothing powder can settle on certain steels.

Conclusions:

To avoid adhesion problems in laser cutting areas, the surface must be properly
prepared.

The method to be used must be decided upon on a case-by-case basis,
depending on the restrictions of the workshop in question.

3.a.4 Special steel, stainless (Chromium-Plate)
The known types of pre-treatment do not result in suitable adhesion properties. Only
appropriately roughened surfaces ensure the adhesive strength of coating films.
Without such a manual roughening, the parts have to be coated with a suitable primer
and protective coating.

3.a.5 Various material combinations
Such types of substrates are critical in chemical pre-treatment. Because of different
metals and behaviour under chemical pre-treatment, corrosion may be stimulated.
Preliminary tests are, therefore, recommended.


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

QUALISTEELCOAT version 2.0
January 2012
33/87
3-a-4 Special steel, stainless (chromium-plate)

The known types of pre-treatment do not result in suitable adhesion properties. Only
appropriately roughened surfaces ensure the adhesive strength of coating films. Without
such a manual roughening, the parts have to be coated with a suitable primer and protective
coating.

3-a-5 Various material combinations

Such types of substrates are critical in chemical pre-treatment. Because of different metals
and behaviour under chemical pre-treatment, corrosion may be stimulated. Preliminary tests
are, therefore, recommended.

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

Types of parts E coat
Powder zinc
primer
Zinc spraying
50 a 200 !m
Sendzimir
15 a 30 !m
Hot dip
galvanized 50
a 200 !m
Portal
Secure the
dimensions
of the baths
Be careful with
the air-gaps
(volutes, rings,
beaten)
Be careful with
the air-gaps
(volutes, rings,
beaten)
Closed and
tight welds
Sheets and
nettings must
be separate
Keep body
Require
holes of
circulation
and
evacuation

Require a
recovery at
the level of
the welds
Require holes
of circulation
and evacuation
Plane sheet
Weakness anti-
corrosive on
the level of the
nozzles of
cutting
Adapted
Weakness
anti-
corrosive on
the level of
the nozzles
of cutting
Suitable for
large
thicknesses
Cut out Sheet
Suitable for
fine
thicknesses

Perforated
Sheet

Expanded
metal

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

The surface
quality can
present defects
Profile for
windows
Secure the
dimensions
of the baths


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QUALISTEELCOAT version 2.0
January 2012
34/87
Types of parts E coat
Powder zinc
primer
Zinc spraying
50 a 200 !m
Sendzimir
15 a 30 !m
Hot dip
galvanized 50
a 200 !m
Without Sheets
Require
holes of
circulation
and
evacuation
If no
precautions are
taken by the
metal sprayer
there a risk of
imprisonment
of the shot
during the
operation of
shot-blasting
If no
precautions are
taken by the
metal sprayer
there a risk of
imprisonment
of the shot
during the
operation of
shot-blasting
Require a
recovery at
the level of
the welding
and
machining
Require holes
of circulation
and evacuation.
Is likely to fill the
rabbets or
throats
Opening Sheet
If the sheets
are not
welded
uninterruptedl
y they must
be coated
separately, to
avoid the
absence of
protection
between
sheet and
tallies
If the sheets
are not welded
uninterruptedly
they must be
coated
separately, to
avoid the
absence of
protection
between sheet
and tallies
If the sheets
are not welded
uninterruptedly
they must be
coated
separately, to
avoid the
absence of
protection
between sheet
and tallies
Require a
recovery at
the level of
the welding
and
machining

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

In the case
of two
sheets,
second is
treated
separately

Profile hot roll
Possible after
shot-blasting
Shot blasting
DS 2,5 a DS 3
requirement
Recommended NA Recommended
UPN-IPN-IPE-
HEA-HEB
Secure the
dimensions
of the baths

Possible after
shot-blasting
Shot blasting
Sa 2,5 a Sa 3
requirement
Recommended NA Recommended
Unit mecano
welds in profile

Secure the
dimensions
of the baths
Little
practised
Do not stop the
air-gaps and
non-closed
weldings
Can protect
weak
interstices and
air-gaps

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


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

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3.b.6 Information on Procedures of Removal of Foreign Matter

Procedures for removal of extraneous layers and foreign matter
Matter to be
removed
Procedure
Grease and oil
Water cleaning
Fresh water with addition of detergents.
Pressure (< 70MPa) may be used. Rinse with
freshwater.
Steam cleaning Fresh water. If detergents are added, rinse
with freshwater.
Emulsion cleaning
Rinse with freshwater.
Alkaline cleaning Aluminium, zinc and certain other types of
metal coating may be susceptible to
corrosion if strong alkaline solutions are used
and should, therefore, be rinsed with fresh
water.
Organic-solvent
cleaning
Many organic solvents are hazardous to
health. If the cleaning is performed using
rags, they will have to be replaced at frequent
intervals, otherwise oil and grease
contaminants will not be removed, but will be
left as a smeared film after the solvent has
evaporated.

Water-soluble
contaminants,
e.g. salt
Water cleaning Freshwater Pressure (< 70 MPa) may be
used.
Steam cleaning
Alkaline cleaning Aluminium, zinc and certain other types of
metal coating may be susceptible to
corrosion if strong alkaline solutions are
used. Rinse with freshwater.
Coatings Stripping:
Dry abrasive
cleaning
Wet abrasive
cleaning
Water blast-
cleaning
Sweep blast-
cleaning
Spot blast-cleaning
Solvent-borne pastes for coatings sensitive to
organic solvents. Residue to be removed by
rinsing with solvents. Alkaline pastes for
specifiable coatings. Rinse thoroughly with
fresh water. Stripping is restricted to small
areas. Shot or grit abrasives. Residue of dust
and loose deposits will have to be removed
by blowing off with dry oil-free compressed
air or by vacuum cleaning. Rinse with fresh
water. For removal of poorly adhering paint
coatings. Ultra-high-pressure cleaning may
be used for firmly adhering coatings. For
roughening coatings or removal of the
outermost coating layer. For localized
removal of coatings.


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Appendix 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 be
removed using a suitable mechanical pre-treatment method (abrasive-blasting, grinding,
brushing) or chemical cleaning.

These methods are also applied to burrs caused by cutting or other punching devices. Sharp
edges result in a considerably lower film thickness, thus severely diminishing the corrosion
resistance in this area.

Corrosion products have the same unwanted properties as the problems mentioned above.
Complete removal is absolutely necessary. Slight formation of red rust on steel substrates as
well as slight formation of white rust on zinc-coated steel substrates can often be removed by
special acidic etching.

Considerable rust formation necessitates mechanical removal (e.g. sweeping) or heavy
chemical cleaning. Preliminary tests are recommended.

The quality of the surface preparation and the methods available depend highly on the shape
and thickness of the steel used. In most cases abrasive blasting is not recommended if the
steel sheet is less than 1.5 mm thick.

The required quality of blast cleaning methods is given in EN ISO 12944-4 types of
surfaces and surface preparation. This standard also refers to EN ISO 8501-1 preparation
of steel substrates before application of paint and related products.


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3.c.2 Part 4 of EN ISO 12944 deals with the following types of surfaces of steel
structures consisting of carbon or low-alloy steel, and their preparation:
- Uncoated surfaces;
- Surfaces thermally sprayed with zinc, aluminium or their alloys;
- Hot-dip galvanized surfaces;
- Zinc-electroplated surfaces;
- Sherardized surfaces;
- Surfaces painted with prefabrication primer;
- Other painted surfaces.

This part of EN ISO 12944 defines a number of surface preparation grades but does not
specify any requirements for the condition of the substrate prior to surface preparation.

Highly polished surfaces and work-hardened surfaces are not covered by this part of ISO
12944.

In appendix 3-b the cleaning and removal of all foreign matter is discussed. In this appendix
the surface preparation prior to application is given.

The different methods are presented in the table referring to the expected lifetime of a
system using this type of pre-treatment.

For chemical methods the composition of the chemicals is the responsibility of the chemicals
manufacturer. The composition of the baths is only defined in general terms.

A chemical bath may be used for one type of substrate only. If a chemical bath composed for
aluminium is also used for steel or galvanized steel, the chemicals manufacturer must inform
the coating applicator of the maximum concentration of zinc and aluminium allowed. The
baths must be tested on a regular basis; these test results must include the concentration of
these components.


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

Matter to
be
removed
Procedure

Mill scale
Chemical Cleaning The process is generally not performed on site.
Dry abrasive blast-
cleaning
Shot or grit abrasives. Residue of dust and
loose deposits will have to be removed by
blowing off with dry oil-free compressed air or
by vacuum cleaning.
Wet abrasive blast-
cleaning
Flame cleaning Mechanical cleaning will be required to remove
residue from the combustion process, followed
by removal of dust and loose deposits.
Rust

Chemical Cleaning
The process is generally not performed on site.
Power-tool cleaning Mechanical brushing may be used in areas
with loose rust. Grinding may be used for firmly
adhering rust; residue of dust and loose
deposits will have to be removed.
Water blast-cleaning For removal of loose rust. The surface profile
of the steel is not affected.
Spot blast-cleaning For localized removal of rust.
Zinc Hot dip
Galvanized
Light surface blast to
improve adhesion
The objective is to clean the surface and to
cause a slight roughening of the surface.
- Sharp inert non-metallic grit;
- Stainless steel grit;
- Grain size up to 0,5 mm;
- Pressure up to 0,3 MPa;
- Blasting distance at least 60 cm;
- Blasting angle 50 to 70.
Zinc
corrosion
products
Sweep blast-cleaning

Sweep blast cleaning on zinc may be
performed with aluminium oxide (corundum),
silicates or olivine sand: an ammonia solution
in combination with a synthetic-fabric pad with
embedded abrasives may be used for localized
spots of zinc corrosion.
When removing all the zinc corrosion products
(white rust) the amount of zinc removed by the
procedure may not exceed 10% of the zinc
layer thickness.
Chemical cleaning Chemical cleaners may be used for larger
surfaces. All zinc corrosion products must be
removed. The process has to be executed
carefully, not to dissolve the zinc. No more
than 10 % of the zinc thickness may be lost
due to the process.
When rinsing and drying, structures with slots or rivets shall be treated with particular
care.

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3.c.4 Pre-treatment (Category 1)
Abrasive - abrasive-blasting Sa 2, or
Chemical - degreasing, or
Chemical - phosphating or alternative processes.

3.c.5 Pre-treatment (Category 2)
Abrasive - abrasive blasting Sa 2, or
Chemical - phosphating, or alternative processes.
3.c.6 Pre-treatment (Category 3 + 4 + 5):
Abrasive - Abrasive blasting to Sa 2 1/2 or
Abrasive/chemical - Abrasive blasting Sa 2 1/2 + passivation or
Chemical - De-oxidation and passivation, phosphating or
alternative processes.

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


51/64
Appendix 4a LIQUID COATING SYSTEMS
All the systems given are examples.
4.a.1 Liquid coating systems on steel


52/64

4.a.2 Liquid coating systems on galvanized steel


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


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4b POWDER COATING SYSTEMS
All the systems given are examples
4.b.1 Powder coating systems interior

* Total film thickness exclusive zinc thickness Sys No = I= inside systems O= outside systems, 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 coat
Type: C= colour Z= zinc
Sys No Sub-
strate
Surf.
Prep.
Primer Intermediate coats Topcoat Coating
System
Durability
Cat
1
Cat
2
Cat
3
Cat
4
Cat5
I
Cat5
M
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 Ef C 15 P C 60 2 75 X X X X X X X
I-P-23 Steel 1 Ef C 15 P C 60 2 75 X X X X X X X
I-P-24 Steel 1 Ef C 15 P C 80 2 95 X X X X X X X X

55/64
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 Bi s HDG 4 80 1 80 X X X X
O-P 09 St eel 3 E Z/ZF 50 P C 60 2 110 X X X X X
O-P 11 St eel 3 E Z/ZF 50 E/P C 60 P C 80 3 190 X X X X X X
O-P 12 St eel Sa 2,5 E Z/ZF 50 P C 60 2 110 X X X X X
O-P 13 St eel Sa 2,5 E Z/ZF 70 P C 80 2 150 X X X X X X
O-P 14 St eel 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 St eel Sa 3 S Z 35 P C 80 1 115 X X X X X
O-P 16 St eel Sa 3 S Z 50 P C 80 1 130 X X X X X X
O-P 17 St eel Sa 3 S Z 35 E C 60 P C 60 2 155 X X X X X X X X
O-P 18 St eel Sa 3 S Z 100 P C 80 1 180 X X X X X X X X
O-P 19 St eel 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 St eel 1 Ef C 15 P C 60 2 75 X X X X X X
O-P 21 St eel 1 Ef C 15 P C 80 2 95 X X X X X X X X
O-P 22 St eel 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 coati ng
system
Durabi l i ty
!m Bi nder Type
Topcoat
!m Bi nder Type !m
Cat5-M Cat 4 Cat5-I
Syst No Substrate
Surface
Preparati on
Pri mer Intermedi ate coats
Bi nder Type

X in the previous table
X No X in the previous table
O-P 07
Bis
This 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 St eel Sa 2,5 E Z/ZF 50 P C 60 2 110 X X X X X
O-P 15 St eel 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 St eel 3 E Z/ZF 50 E/P C 60 P C 80 3 190 X X X X X X
O-P 13 St eel Sa 2,5 E Z/ZF 70 P C 80 2 150 X X X X X X
O-P 16 St eel Sa 3 S Z 50 P C 80 1 130 X X X X X X
O-P 20 St eel 1 Ef C 15 P C 60 2 75 X X X X X X
O-P 14 St eel 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 St eel Sa 3 S Z 35 E C 60 P C 60 2 155 X X X X X X X X
O-P 18 St eel Sa 3 S Z 100 P C 80 1 180 X X X X X X X X
O-P 21 St eel 1 Ef C 15 P C 80 2 95 X X X X X X X X
O-P 19 St eel 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 22 St eel 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 coati ng
system
Durabi l i ty
Bi nder Type !m Bi nder Type Bi nder Type
Topcoat
!m
Cat5-M
Layers !m
Cat 2 Cat 3 Cat 4
Syst No Substrate
Surface
Preparati on
Pri mer Intermedi ate coats
!m

QUALISTEELCOAT Version 2.1 November 2013
57/64
Table 4.b.3
Table 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
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

Table 4.b.4
4.b.1 and 4.b.2 explanations
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" Blasting in accordance with EN ISO 8501-1

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Appendix 10 Specification of the standards

N YEAR TITLE SPECIFICATIONS

EN 13438 2005
Paints and varnishes - Powder organic coatings for galvanized or sherardized steel
products 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 2009
Industrial application of powder organic coatings to hot dip galvanized or sherardized
steel articles [duplex systems] - Specifications, recommendations and guidelines
4.b.4

EN ISO 1461 2009
Hot dip galvanized coatings on fabricated iron and steel articles - Specifications and test
methods (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 2003
Non-conductive coatings on non-magnetic electrically conductive basis materials -
Measurement of coating thickness - Amplitude-sensitive eddy current method (ISO
2360:2003)
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
59/64

EN ISO 2810 2004
Paints and varnishes - Natural weathering of coatings - Exposure and assessment (ISO
2810:2004)
2.b.9

EN ISO 2812-1 2007
Paints and varnishes - Determination of resistance to liquids - Part 1: Immersion in liquids
other than water (ISO 2812-1:2007)
2.3.6; 2.b.6

EN ISO 2813 1999
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)
2.a.10; 2.b.8; 2.b.9;
6.c.2.4; 6.d.2.5

EN ISO 3231 1997
Paints and varnishes - Determination of resistance to humid atmospheres containing
sulphur dioxide (ISO 3231:1993)
2.3.7; 2.b.7

EN ISO 3274 1997
Geometrical product specifications (GPS) - Surface texture: Profile method - Nominal
characteristics of contact (stylus) instruments (ISO 3274:1996)
6.b.2.3

EN ISO 4628 -2 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 2: Assessment
of degree of blistering (ISO 4628-2:2003)
2.b.4; 2.b.5; 2.b.6; 2.b.7

EN ISO 4628-3 2003
of degree of rusting (ISO 4628-3:2003)
2.b.4; 2.b.6; 2.b.7

EN ISO 4628-4 2003
of degree of cracking (ISO 4628-4:2003)
2.b.4; 2.b.5; 2.b.6; 2.b.7
60/64

EN ISO 4628-5 2003
of degree of flaking (ISO 4628-5:2003)
2.b.4; 2.b.5; 2.b.6; 2.b.7

EN ISO 5436-1 2000
Geometrical 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 2001
Measurement standards - Part 2: Software measurement standards (ISO 5436-2:2001)
2.a.7; 6.b.2.3

EN ISO 5436-2/AC: 2001/2008
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 2005
Paints 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 2004
Paints 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 - 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)
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 other
areas with surface imperfections (ISO 8501-3:2006)
3.a.3; 3.b.5; 5.b.1
61/64

EN ISO 8502-3 1999
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)
6.b.2.7

EN ISO 8502-4 1999
Preparation of steel substrates before application of paint and related products - Tests for
the 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 - 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)
2.a.7

EN ISO 8503-2 1995
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)
2.a.7

EN ISO 8503-3 1995
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
calibration 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 size
distribution (ISO 11125-2:1993)
2.2.6; 2.a.6
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EN ISO 11127-2 1997
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)
2.2.6; 2.a.6

EN ISO 11341 2004
Paints and varnishes - Artificial weathering and exposure to artificial radiation - Exposure
to filtered xenon-arc radiation (ISO 11341:2004)
2.b.8

EN ISO 12944-1 1998
Paints 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 1998
- Part 2: Classification of environments (ISO 12944-2:1998)
1; 4.1

EN ISO 12944-3 1998
- Part 3: Design considerations (ISO 12944-3:1998)
1

EN ISO 12944-4 1998
- 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 2007
- Part 5: Protective paint systems (ISO 12944-5:2007)
4.1; 7

EN ISO 12944-6 1998
- 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 1998
- Part 7: Execution and supervision of paint work (ISO 12944-7:1998)
5a

EN ISO 12944-8 1998
- Part 8: Development of specifications for new work and maintenance (ISO 12944-
8:1998)
1

EN ISO 16276-2 2007
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)
2.2.1; 2.a.1; 6.c.2.1;
6.d.2.1

EN ISO/IEC 17025 2005
General requirements for the competence of testing and calibration laboratories (ISO/IEC
17025:2005)
7

EN ISO/IEC
17025:2005/AC
2006
General requirements for the competence of testing and calibration laboratories (ISO/IEC
17025:2005/Cor.1:2006)
7

ISO 105-AO2 1993
Textiles - 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
64/64

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

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