QSTC2012

QUALISTEELCOAT version 2.
0
January 2012
QUALISTEELCOAT
Technical Specifications
Version 2.0
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QUALISTEELCOAT version 2.0

January 2012
QUALISTEELCOAT
Technical Specifications
The objective is to establish an internationally recognized quality label for liquid and
powder coating of steel-based material.
Chapter 1 General information!.................................................................................................!3!

Chapter 2 Test methods!..............................................................................................................!5!
Chapter 3 Surface preparation (EN ISO 12944-4)!..............................................................!9!
Chapter 4 Coating systems!.....................................................................................................!10!
Chapter 5 Application of coatings!........................................................................................!11!
Chapter 6 Applicators in-house control!.............................................................................!13!
Chapter 7 Approval of coating systems!............................................................................!14!
Chapter 8 Licence for coating applicators!........................................................................!15!
Appendixes
Appendix 1-a Corrosivity category!.....................................................................................................!16!
Appendix 2-a Mechanical test and results!.......................................................................................!17!
Appendix 2-b Chemical test methods and results!........................................................................!22!
Appendix 3-a Information on substrates!..........................................................................................!30!
Appendix 3-b Removal of contamination!.........................................................................................!35!
Appendix 3-c Surface pre-treatment!..................................................................................................!37!
Appendix 4-a Liquid coating systems!...............................................................................................!41!
Appendix 4-b Powder coating systems!............................................................................................!47!
Appendix 5-a Application of liquid coatings!...................................................................................!51!
Appendix 5-b Application of powder coatings!...............................................................................!53!
Appendix 6-a In-house control for chemical surface preparation!.........................................!55!
Appendix 6-b In-house control for blasting surface preparation!...........................................!59!
Appendix 6-c In-house control for powder coating applicators!.............................................!63!
Appendix 6-d In-house control for liquid coating applicators!.................................................!69!
Appendix 7-a Approval of powder coating systems!....................................................................!74!
Appendix 7-b Approval of liquid coating systems!.......................................................................!77!
Appendix 8-a Issuing a QUALISTEELCOAT licence!....................................................................!80!
Appendix 9-a Table RAL/DELTA E (adm. colour deviation after weathering in Fl.)!........!83!
Appendix 10-a Specification of the standards!...............................................................................!84!
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January 2012
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 solventborne coatings. To supplement these standards, the QUALISTEELCOAT specification also
applies to powder coating systems. These systems durability data are collected in a table
similar to the EN ISO 12944-5 solvent-containing coating systems table.
These standards provide the specifications of the quality level with which coating application
firms must comply in order to be granted a QUALISTEELCOAT certificate.
At least twice a year, inspections will be carried out by a QUALISTEELCOAT Inspector
to evaluate the licensees sustained compliance with the required quality levels.
The specifications laid down in this document concern:

1.
the different processes used for steel protection;
2.
in-house control by the coating applicators in connection to 1;
3.
the performance of applied coating systems in relation to Corrosivity categories;
4.
Inspection of licensees.
The regulations laid down in this document give the minimum requirements which the
licensees, their finished coated products, as well as the applied coating materials have to
meet.
The QUALISTEELCOAT coating licences are divided into two categories:
interior use only (C-1 and 2 interior), called INTERIOR licence
interior/exterior use (C-1, 2, 3, 4 and 5), called EXTERIOR QUALISTEELCOAT

licence.
The exact definitions of the Corrosivity Categories are given in ISO EN 12944- 2.
The atmospheric corrosivity categories applicable to QUALISTEELCOATs standards are
given in appendix 1.
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QUALISTEELCOAT Interior Licence
C 1/2 (I):
The parts are briefly exposed to temperature changes or humid atmosphere. Such
pre-treated parts are mostly used indoors.
The applicable control level, based on which test samples are taken, is C-2 medium.
QUALISTEELCOAT Exterior Licence
C1, C2, 3, 4 and 5 (E):
(also including interior)
The parts have undergone extensive chemical pre-treatment, allowing exposure to
slightly and severely corrosive and humid atmosphere for a prolonged period.
Alternatively, the substrate is grit blasted after galvanizing, or blasted and
zinc/aluminium sprayed.
The pre-treated surface is coated with organic coating as specified in this document.
The applicable control level and test samples are based on compliance with the
Corrosivity Category specified in the applicators production documents.
Tests will be carried out in accordance with these specifications. Tests supplementary to
those laid down in these specifications must be agreed between the QUALISTEELCOAT
licensee and its customers.
QUALISTEELCOAT members production processes must be proven reliable, in accordance
with the stipulated minimum requirements. The members are obliged to comply with
QUALISTEELCOATs specifications and any additional specifications provided by the
customer.
If the system has not been approved previously by QUALISTEELCOAT this must be clearly
stated on the production forms for the benefit of the QUALISTEELCOAT inspector. The
system applied must be suitable for the corrosivity category stated on the production sheet.
Production samples may be tested for corrosivity category compliance by the
QUALISTEELCOAT inspector.
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January 2012
Chapter 2 Test methods

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

In order to assess the characteristics of coating materials, they are tested on metal test
panels in accordance with EN ISO 1514. Test panels must be made of the same metal as
the substrate used in the system.
Testing of coating systems is executed on the test panels mentioned in the test standards.
The natural and the accelerated weathering test can be conducted on aluminium AlMg1. The
coating system applied to the test panel shall show no scratches penetrating as far as the
substrate. When a coated test panel is examined, no blisters, craters, pinholes or scratches
shall be visible from a distance of 1 meter in diffuse light.
2.2 Mechanical tests (appendix 2-a)

2.2.1 Adhesion (2-a-1)
The following methods are used to determine the adhesion of the coating system to the
substrate and the expected results:
EN ISO 16276-2 Cross-cut, X-cut and pull-off test method
EN ISO 2409 Cross-cut test equipment and results
2.2.2 Determination of chip resistance by falling hexagonal nuts (2-a-2)

cancelled
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2.2.3 Impact resistance test (2-a-3)

EN ISO 6272-1 describes a method for assessing the resistance of a dry film of paint,
coating material or related product to cracking or peeling from a substrate when it is
subjected to deformation caused by a falling weight, using a 20 mm diameter spherical
indenter dropped under standard conditions.
2.2.4 Resistance to scratching (2-a-4)
The objective of this test is to determine the resistance of the coating system to scratching
(EN ISO 1518).
2.2.5 Determination of surface hardness (2-a-5)
The objective of this test is to determine the resistance of the coating system to scratching.
The method is described in ISO 15184 - determination of surface hardness by means of
pencils.
2.2.6 Determination of particle size distribution (2-a-6)
The objective of the test is to determine the mixture and size of the blast grit or shot particles
used for surface preparation (EN ISO 11125-2 and EN ISO 11127-2).
2.2.7 Determination of surface roughness (2-a-7)
The objective of this measurement is to determine the roughness of the substrate after
blasting, prior to application of the first primer.
2.2.8 Determination of wet film thickness (2-a-8)
The wet film thickness of the coating has to be monitored during the application. The method
of determining the wet film thickness has been specified.
2.2.9 Determination of dry film thickness (2-a-9)
The dry film thickness of the individual coats in the system and the total dry film thickness
must be measured.
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2.3 Chemical and environment tests (appendix 2-b)

2.3.1 Polymerisation test (2-b-1)
The purpose of this test is to determine the polymerization for powder and liquid coating
systems. Before testing the liquid coating system must be cured for four hours at a
temperature of 60 oC.
2.3.2 Resistance to mortar (2-b-2)
This test is used to assess the resistance of the coating system to fresh mortar.
2.3.3 Boiling test (permeability) (2-b-3)
This test is used to determine the adhesion properties of the coating system.
2.3.4 Neutral salt spray test (2-b-4)
The purpose of this test is to determine the corrosion resistance of the coating system. For
the corrosive categories the test results will give an indication of the durability of the coating
system. The test is similar for coated hot dip galvanized steel.
Test procedures are given for liquid coating material systems and powder coating material
systems.
2.3.5 Resistance to continuous condensation (2-b-5)
This test is used to determine the adhesion of the coating system during prolonged periods
of high humidity (EN ISO 6270).
2.3.6 Chemical resistance test (2-b-6)
The objective of his test is to assess the chemical resistance of the coating system.
The chemicals used are 10 % NaOH, 10 % H2SO4, and mineral spirits containing 18 %
aromatics. (EN ISO 12944-6, test EN ISO 2812-1).
2.3.7 Resistance to humid atmosphere containing sulphur dioxide test (2-b-7)
The objective of this test is to determine the resistance to heavily polluted atmospheres. The
coated surface is exposed to SO2 in a test cabinet (EN ISO 12944-6, test EN ISO 3231).
2.3.8 Accelerated weathering test (2-b-8)
This test is used to determine the resistance to discoloration and loss of gloss during use
outdoors. This is a laboratory test and can only be used to give an indication of the durability
outside. Aluminium and steel panels may not be tested in the same batch.
2.3.9 Natural weathering (2-b-9)
This test is conducted to determine the outdoor resistance of the coating system to
weathering as a result of solar radiation. The test is executed by exposing the coating
materials in Florida.
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2.3.10 Colour difference (2-b-10)

The nuances in colour between charges and coated parts may not differ beyond certain
levels. The objective is to determine the nuances in colour.
2.3.11 Gloss difference (2-b-11)
The difference in gloss level of the coated material must remain within the given tolerance
levels. Gloss is also used to determine the polymerization of glossy powder coatings.
2.3.12 Determination of etching degree (2-b-12)
The objective is to determine the loss of zinc during surface preparation by etching. This is
determined by measuring the film thickness before and after etching.
2.3.13 Assessment of the conversion coating (2-b-13)
The objective is to determine the quality of the conversion coating by means of visual
assessment of the layer. Twice a year the actual thickness must be measured jointly with the
chemicals supplier.
2.3.14 Determination of the conductivity of dripping water (2-b-14)
The purpose is to determine the result of the final rinse by demineralised water.
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Chapter 3 Surface preparation (EN ISO 12944-4)

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

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

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

The parts are handled in the plant - the reliability of the process having been ascertained.
The existing facilities for pre-treatment serve as the standard. Any external treatment, like
chemical treatment or blasting, is excluded with the exception of hot dip galvanizing and
electro galvanizing.
The purpose of the pre-treatment is to prepare the substrate for application of the protective
system. Different methods are used to serve different purposes. This may vary from
removing mill scale or corrosion from the substrate, to roughening the substrate to improve
adhesion of the protective system. All contamination must be removed prior to the pretreatment of the substrate.
More information can be found in appendix 3-c.
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Chapter 4 Coating systems

4.1 Coating systems in different environments
Depending on the environment where the coated object is used, different coating systems
are defined.
Solvent-containing coating systems are listed in EN ISO 12944-5. In appendix 4-a the most
recent solvent-based coating systems are defined, including their durability properties in
different environments.
Examples of coating systems are given in appendix 4-a: Liquid Coating Systems.
Powder coating systems are not included in EN ISO 12944-5. In appendix 4-b coating
systems based on powder coating are listed, including the durability properties in various
corrosivity categories.
The systems are based on first coats of galvanized zinc, zinc-spayed and zinc powder
containing epoxy powder coatings, and electro deposition coatings.
Depending on the environment, additional layers of powder coating are applied.
Examples of powder coating systems are given in appendix 4-b.
In addition to the corrosivity categories defined in EN ISO 12944-2, local environment is very
important. An outdoors environment in which no natural rain will clean the surface is most
demanding. In such a case, coating systems from a corrosivity category, one full level higher
than would be chosen under normal circumstances, is recommended.
It is also recommended to carefully clean the coated substrate at intervals as
mentioned in the following table:
Corrosivity category
Frequency of cleaning using hot
*a)
*b)
water (60C ) and high pressure
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
Corrosivity category
Frequency of cleaning using
cold water and low pressure
C2 - C3
C4 - C5
Rain washed surfaces
Once a year
Twice a year
Surfaces not rain-washed naturally
2 - 3 times a year
3 - 4 times a year
*a)
The temperature of the cleaning water at the moment of impact must be

approx. 60 C. Take care not to use water at a temperature above 80 C.
*b)
The high pressure of the water used for cleaning the coated areas must be approx.
4 Bar. The spraying of the surface must be carried out carefully. Openings and
rubbers in a facade must be avoided.
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Chapter 5 Application of coatings

5.1 Liquid coating
5.1.1 Testing the coatability of objects (5-a-1)
Objects containing various metals are to be pre-tested. Pre-treatment requires extra
attention, to prevent making premature decisions on the use of pre-treatment products like
chemicals and blast grit.
Careful processing is required to avoid split or pockets in which non-removable pre-treatment
residue could cause damage, corrosion or insufficient adhesion.
If there is any doubt about the suitability of the object for a certain coating system, it is
necessary to discuss this problem with the coating applicator beforehand.
5.1.2 Coating application and curing (5-a-2)
After surface pre-treatment the coating system must be applied. The substrate must be clean
and dry before application. One or more coats must be applied and the coats must be cured
or pre-cured depending on the system.
Additional information is given in appendix 5-a: Application and Curing of Coatings.
5.1.3 Drying procedure (5-a-3)
The coating must be left to dry in a clean environment and at a temperature sufficient for
drying and hardening. When more coats have to be applied sufficient time must be left
between the application of coating layers.
5.1.4 Storage of coating material (5-a-4)
The storage of coating materials must comply with the applicable safety requirements. Only
the coating used during the application and the additional solvent may be present in the
coating application area.
5.1.5 Storage of coated material (5-a-5)
The coated material must be professionally stored to avoid damage and dirt collection on the
coated surfaces.
5.2 Powder coating

5.2.1 Testing the coatability of objects (5-b-1)
Objects containing various metals are to be pre-tested. The pre-treatment requires extra
care, to prevent making premature decisions on the use of pre-treatment products like
chemicals and blast grit.
Careful processing is required to avoid split or pockets in which non-removable pre-treatment
residue could cause damage, corrosion or insufficient adhesion.
necessary to discuss this problem with the coating applicator before starting the operation.
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5.2.2.Oven drying (5-b-2)

After chemical surface pre-treatment, the substrate must be dried prior to applying the
coating system.
5.2.3 Application of powder coating (5-b-3)
prior to application. One or more layers must be applied and the different layers must be
cured or pre-cured depending on the system.
5.2.4 Curing the powder coating (5-b-4)
After application the coating must be cured. The objects must be placed in an oven. Care
must be taken as regards the temperature of the substrate. The coating applicator must
check whether the curing temperature suffices.
5.2.5 Storage of coating material (5-b-5)
The storage of coating materials must comply with the applicable safety requirements.
Coating materials must be stored in a dry atmosphere and free of contamination.
5.2.6 Storage of coated material (5-b-6)
The coated products must be stored in a dry area and packed in accordance with the
instructions.
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Chapter 6 Applicators in-house control

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

The applicator certified for Interior must have a dedicated space for testing the results of the
companys coating activities.
Applicators certified for Exterior must have a laboratory separated from the production
facilities. The laboratory must be equipped for the purpose of assessing the quality of the
production method used.
For applicators using chemical baths this means that the contents of baths (solutions) as well
as the finished products must be tested and verified.
In appendix 6-a, the requirements applicable to applicators using chemical pre-treatment are
given.
In appendix 6-b, the requirements applicable to applicators using abrasive blasting are given.
Companies using a combination of blasting and chemical passivation must conduct the
combined test.
In appendix 6-c, the requirements for in-house control related to companies using powder
application are given.
In appendix 6-d, the requirements for in-house control related to companies applying liquid
coatings are given.
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Chapter 7 Approval of coating systems

A system is defined by:
type of surface pre-treatment;
number of layers;
minimal dry film thickness per layer;
coating products for primer, midcoat and topcoat;
application method.
In appendix 4-b, examples of powder coating systems are given.

In appendix 4-a, examples of liquid coating systems are given in accordance with ISO EN
12944-5.
The coating systems used by QUALISTEELCOAT approved licensees must be approved by
1st January 2012.
To have a coating system approved, an EN ISO 17025 accredited laboratory recognised by
QUALISTEELCOAT must be requested to test the system. The test panels will be prepared
by the laboratory. Technical data sheets and safety data sheets must be provided for all the
coatings in the system.
The systems are accepted in accordance with the corrosivity category stipulated by the
applicant.
If the application for approval of a coating system applies to corrosivity category 1 then the
approval will only apply to category 1.
If the application is for example for corrositivity category 3 - high durability - then the approval
is given for corrosivity categories 1, 2 and 3 - high durability, as well as 4 - medium durability.
In appendix 2-a, and 2-b, the test methods and required results are given.
In appendix 7-a, and 7-b, further information is given as regards the approval of coating
systems.
Certain test results from approved laboratories, collected to obtain other quality labels, may
be used as test results for QUALISTEELCOAT. This only applies to artificial weathering and
outdoor exposure tests.
A visit by the general licensee - or by QUALISTEELCOAT in countries without a national
association - may be required. The costs of such a visit will be paid by the applicant.
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Chapter 8 Licence for coating applicators

Any coating applicator working in the field of QUALISTEELCOAT can apply for a licence. In
order to obtain a licence the procedure will be followed:
One inspection must be satisfactory before a licence is granted. This inspection will be made
at the coating applicators request. The inspection will be conducted by appointment.
The coating applicator must, before the initial inspection, identify the corrosion category of
the licence.
After obtaining a licence the inspection can be executed on a production up to the level of the
licence. If a higher licence is required by the coating applicator an inspection of the coating
applicator producing a higher level product is necessary to obtain a licence on the desired
level.
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Appendix 1-a Corrosivity category

According to: EN ISO 12944 part 2
Table 1 - Atmospheric-corrosivity categories and examples of typical environments:
Mass loss per unit surface/thickness loss
(after first year of exposure)
Corrosivity
category
Low-carbon steel
Mass
loss
g/m
C1
very low
C2
low
10
> 10 to
200
C3
medium
> 200 to
400
C4
high
> 400 to
650
C5-I
very high
(industrial)
> 650 to
1500
C5-M
very high
(marine)
> 650 to
1500
Zinc
Thickness
loss
Mass
loss
g/m
1,3
> 1,3 to 25
Examples of typical environments

in a temperate climate (informative only)
0,7
> 0,7 to 5
> 25 to 50
> 5 to 15
> 50 to 80
> 15 to
30
> 80 to 200
> 30 to
60
> 80 to 200
> 30 to
60
Thickness
loss
Exterior
Interior
0,1
Heated buildings with

clean atmospheres,
e.g. offices, shops,
schools, hotels.
> 0,1 to 0,7
Atmospheres with
low level of
pollution. Mostly
rural areas.
Unheated buildings
where condensation
may occur, e.g.
depots, sports halls.
> 0,7 to 2,1
Urban and
industrial
atmospheres,
moderate sulfur
dioxide pollution.
Coastal areas with
low salinity
Production rooms with

high humidity and
some air pollution, e.g.
food-processing
plants, laundries,
breweries, dairies.
> 2,1 to 4,2
Industrial areas and

coastal areas with
moderate salinity.
Chemical plants,
swimming pools,
coastal ship- and
boatyards.
> 4,2 to 8,4
Industrial areas
with high humidity
and aggressive
atmosphere.
Buildings or areas with

almost permanent
condensation and with
high pollution.
> 4,2 to 8,4
Coastal and
offshore areas with
high salinity.
Buildings or areas with

almost permanent
condensation and with
high pollution.
NOTES:
1. The loss values used for the corrosivity categories are identical to those given in ISO 9223.
2. In coastal areas in hot, humid zones, the mass or thickness losses can exceed the limits of
category C5-M. Special precautions must therefore be taken when selecting protective paint
systems for strucures in such areas.
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Appendix 2-a Mechanical test and results
2-a-1 Adhesion test
EN ISO 16276-2 Cross-cut, X-cut test and pull-off method
EN ISO 2409 Cross-cut test equipment and results
This method describes the adhesiveness of the coating films to the substrate.
The cut distance for coating thickness up to 60 m is 1 mm, for thickness up to 120 m 2 mm
and 3 mm for greater thickness up to 250 m. If the dry film thickness exceeds 250 m, the
pull-off test is recommended.
Acceptable Results:
Result
Test method
Corrosivity
Category
Adhesion
NA
Dft
Outdoor
resistant
coatings
C1 - C2 C3 - C5 C1 - C2 C3 - C5 C1 - C2 C3 - C5 C1 - C2 C3 - C5
< 60
< 120
< 250
> 250
X
X
-
Indoor resistant
Results
coatings
Results
X
X
X
X
0-1
0-1
-
0-1
0-1
5 MPa
X
X
-
na
na
na
na
0-1
0-1
-
0-1
0-1
0-1
5 MPa
2-a-2 Determination of chip resistance by falling hexagonal nuts NEN 5335

cancelled
2-a-3 Impact resistance test
EN ISO 6272-1 describes a method for assessing the resistance of a dry film of paint,
coating material or related product to cracking or peeling from a substrate when it is
subjected to deformation caused by a falling weight, using a 20 mm diameter spherical
indenter, dropped under standard conditions.
The term "impact resistance" is used in the title of this standard, but one important
characteristic of the device used is that it should produce rapid deformation rather than true
impact.
The method described can be applied:
either as a pass/fail test, the test being carried out from one drop height and with a
specified mass, so as to test compliance with a particular specification;
or as a classification test, to determine the minimum mass and/or drop height at

which the coating cracks or peels from its substrate by gradually increasing the
drop height and/or the mass.
QUALISTEELCOAT uses the test only for pass/fail testing.

The minimum reverse impact resistance value for liquid coatings in relation to the required
coating thickness must be given by the coating system supplier. For powder coatings the
energy of 2.5 Nm reverse impact must be used.
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RESULT:
Coating systems must show no detachment of the system and no crack formation up
to the substrate.
2-a-4 Resistance to scratching EN ISO 1518
The resistance of the coating system to scratching is determined in accordance with EN ISO
1518 using a load of 2000 g on a tungsten-carbide ball with a diameter of 1 mm.
RESULT:
With this load, no more than 50 % of the scratch mark should penetrate as far as the
substrate.
2-a-5 Determination of the surface hardness ISO 15184
The resistance of the coating system to scratching is determined in accordance with ISO
15184 - the determination of surface hardness by means of pencils. This standard specifies a
method of comparing the surface hardness of dried paint surfaces by using pencils.
RESULT:
The result of the test must be in accordance with the information provided by the
coating manufacturer.
2-a-6 Determination of particle size distribution
The objective of the test is to determine the size and the mixture of the blast grit or shot
particles used for surface preparation.
The particle size distribution test is conducted in accordance with EN ISO 11125-2 for
metallic blast-cleaning abrasives and EN ISO 11127-2 for non - metallic blast-cleaning
abrasives.
Determine the mean mass value of two tests and report the result to the nearest 1 %. The
result must be within the limits of the desired blast clean operation.
RESULT:
Information about the amount of blast medium left in the various sieves gives
information about the size distribution of the blast medium.
2-a-7 Determination of surface roughness
The purpose of this measurement is to determine the roughness of the substrate after
blasting and prior to application of the first primer coat.
The assessment of the roughness is conducted in accordance with EN ISO 8503-2 for
grading of the surface profile, EN ISO 8503-1 for ISO surface profile comparators, EN ISO
8503-3 for profile focusing by microscope, and 8503-4 for profile, stylus instruments.
RESULT:
The result of the test must comply with the desired results of the primer coating or
metal layer to be applied.
18/87

January 2012
2-a-8 Determination of wet film thickness

The wet film thickness of the coating has to be monitored during the application. For this
purpose the thickness of the applied film is determined by a wet thickness comb immediately
after application of a liquid coating layer.
RESULT:
The wet film thickness must be in accordance with the calculated wet thickness in
order to obtain the desired dry film thickness.
2-a-9 Determination of dry film thickness
The dry film thickness of the individual coats in the system and the total dry film thickness
must be measured as shown in EN ISO 2808.
The number of measurements to be taken depends on the number of parts in the batch.
Number of parts in the
batch
Number of samples
1 - 10
11 - 200
201 - 300
301 - 500
501 - 800
> 800
Every
10
15
20
30
40
Permissible number of
non-complying
samples
0
1
1
2
3
3
Alternative:
Surface in m2 or m
Number of measurements *1)
1
4
1-3
10
3 - 10
15
10 - 30
20
30 - 100
30
2)
>100 *
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
19/87

January 2012
The minimum acceptable dry film thickness is 80 % of the requested dry film thickness.
Dry film thickness between 80 and 100 % of the requested dry film thickness is acceptable if
the average dry film thickness is equal to or higher than the requested dry film thickness.
The maximum dry film thickness may be three times the requested average dry film
thickness.
The results are given in the following table:
Coating layers
Name
Average dry film thickness

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

Primer coat(s) 2nd coat
Edge protection
stripe coat(s)
Intermediate coat
1st coat
Intermediate coat
2nd coat
Topcoat 1st coat
Topcoat 2nd coat
Total nominal dry film thickness
2-a-10 Gloss meter

Gloss EN ISO 2813 - using incident light at an angle of 60 .
Note: if the significant surface is too small or unsuitable for gloss to be measured with the
gloss meter, the gloss should be compared visually with the reference sample (from the
same viewing angle).
RESULT:
Category 1:
0 - 30
+/- 5 units
Category 2:
31 - 70
+/- 7 units
Category 3:
71 - 100
+/- 10 units
(Permissible variation from the nominal value specified by the coating supplier)
2-a-11 Determination of dew point
The dew point is determined by the following steps:
20/87
1.
measuring the relative humidity of the air;
2.
measuring the substrate temperature;
3.
calculating the dew point or taking this from a table or graph.

January 2012
RESULT:
The dew point must be at least three degrees Celsius above the substrate
temperature of the metal.
2-a-12 Testing the stoving conditions
The equipment to be used must be a 4-temperature measuring point device. Three detectors
must be attached to the top, middle and lower parts of the substrate and one to a reference
panel mounted on the traverse.
The results of these tests should be recorded and retained and the stoving curves should be
recorded in a register readily accessible to the inspector.
RESULT:
A curve resulting from the results measured. In this curve, times and temperatures
provide the requested information on the curing process.
2-a-13 Testing the drying temperature
The temperature of the substrate in the drying oven must be measured. This may be done by
means of a 4-point measuring device, using indication tablets attached to the substrate.
RESULT:
In the drying oven the thickest part of the steel must reach a temperature of at least
60 C.
2-a-14 Appearance test (visual inspection)
Visual inspection should take place using normal or corrected vision at a distance of 3 m for
indoors application. In case of outdoors application the distance is to be 5 m.
RESULT:
At these distances, the coating should not show any wrinkles, runs, sags, craters,
blisters and other surface irregularities. Irregularities as a result of the steel substrate
or the hot dip galvanized zinc are not to be taken into account. The inspection must
be conducted in diffuse daylight.
When the end user desires other distances or inspection criteria, these should be
agreed in advance by the client, applicator and galvanizer.
21/87

January 2012
Appendix 2-b Chemical test methods and results

2-b-1 Polymerization test
This test serves to determine the degree of polymerization for powder and liquid coatings.
This test is useful as compare the test of the panel with a fully cured coating layer.
Procedure:
Before testing, the liquid coating system must be cured for four hours at 60 C.
The mixture used must be tested first on a properly cured version of the coating system.
A range of solvent mixtures must be used to determine the proper mixture for the final
coating in the system. The solvents given below are an indication of solvents to be used.
Required solvent for liquid coatings:
MEK (methyl ethyl keton) or as specified by the paint or lacquer manufacturer and approved
by the Technical Committee.
Required solvent for powder coatings:
As specified by the powder coatings manufacturer and approved by the Technical
Committee.
Saturate a swab of cotton wool with solvent. Within 30 seconds, rub it lightly back and forth,
30 times in each direction, over the part to be tested. Wait 30 minutes before making the
assessment.
The Polymerization quality is assessed in accordance with the following ratings:
1.
the coating is very dull and quite soft;
2.
the coating is very dull and can be scratched with a finger-nail;
3.
slight loss of gloss (less than 5 units);
4.
no perceptible change - the surface cannot be scratched with a finger-nail.
RESULT:
Ratings 3 and 4 are satisfactory.
Ratings 1 and 2 are not satisfactory.
2-b-2 Resistance to mortar
This test is only used for powder coatings.
The test must be performed in accordance with EN 13438 part A.4.7. The required
composition of the mortar is sand, lime and water. The testing time is 24 hours.
The mortar must be prepared by mixing 15 g of hydrated lime, 41 g of cement and 224 g of
sand with sufficient tap water to make a soft paste. Apply four portions of the mortar,
approximately 15 mm in diameter and 6 mm thick, to the test panel.
Place the test panel horizontally at 38 3 C and 95 5 % relative humidity for 24 hours.
22/87

January 2012
At the end of the period, manually dislodge the mortar from the coating surface and remove
any residue with a damp cloth. Allow to dry and examine the coating with normal or corrected
vision, to determine the incidence of visible detachment of the coating due to the effect and
removal of the mortar.
RESULT:
It must be easy to remove the mortar without leaving any residue. Any mechanical
damage to the coating caused by grains of sand should be disregarded. There must
be no change in appearance/colour after the mortar test.
2-b-3 Permeability
EN 13438, A.4.11
Fill a pressure cooker with de-ionized water with a maximum conductivity of 30 S/cm at 20
C to a depth of 25 mm 3 mm. Partially immerse the coated test panel in the water so that
a minimum length of 25 mm is immersed and secure the lid of the pressure cooker.
Apply heat to the pressure cooker until steam is emitted from the valve. Insert a weighted
needle valve to give a pressure of 100 kPa and continue heating for two hours from the time
the steam was first emitted.
Cool the apparatus with care.
Remove the sample and allow it to cool down to room temperature. Examine the test piece
for signs of blistering.
Apply an 18 mm wide strip of Scotch 610, Permacel 99 or equivalent adhesive tape to the
surface, ensuring that no air is trapped. After one minute, remove the tape at an angle of 45
with a sharp even pull.
Exposure time for exterior use is 2 hours
The test is not applicable for interior coating
RESULT:
There must be no defects or detachment. Some colour change is acceptable.
2-b-4 Neutral salt spray test
EN ISO 9227 and EN 13438, 5.3.12
In the middle of the test panel, scribe a cross to expose, but not penetrate, the substrate. The
cross shall be a rectangular cross in which each of the diagonals has a length of 50 mm, the
intersection is centred in the middle of the panel and the scribe lines intersect at 90 . Place
the coated test piece in a spray cabinet complying with EN ISO 9227 - continuous salt spray.
After testing, remove the sample carefully from the test cabinet, wash the test panels in deionized water at a temperature of less than 35 C, and dry immediately. Attempt to lift the
coating from the scribed line with a sharp tool. Examine the area around the scribed cross.
M
C
W
= (C-W)/2
= average of nine measurements of corrosion including the worst points of corrosion
= width of the scratch
23/87

January 2012
There should be no difference between steel substrate and hot dip galvanized substrate.
Category
1
2
3
4
5I
5M
medium
Na
Na
240 h
480 h
720 h
720 h
Exposure time
Exposure time
Exposure time
Exposure time
Exposure time
Exposure time
high
Na
240 h
480 h
720 h
1440 h
1440 h
RESULT:
EN ISO 4628-2
EN ISO 4628-3
EN ISO 4628-4
EN ISO 4628-5
Corrosion of the
substrate from
the scribe
A.
B.
C.
D.
Neutral salt spray

Blistering
0 (S0)
Rusting
Ri 0
Assessment immediately
after aging test
Cracking
0 (S0)
Flaking
0 (S0)
Test regime
M 2 mm
EN ISO 9227
3 samples in order
2 samples in order
1 sample in order
0 sample in order
Evaluation:
Approval
A
in order
=
=
=
=
0 sample not in order

2 samples not in order
Licence
in order
in order with corresponding information to
be submitted to the coating company
in order
not in order
not in order
Repetition of salt spray test - only if result of

second test is A or B, will the test be
considered successful.
Not in order, the whole test must be
executed again.
Or class to be verified at coating company
2-b-5 Constant atmosphere of water condensation

EN ISO 6270-1
Testing period:
Category
Category
Interior
Exterior
Exposure time
Exposure time
RESULT:
Blister must not be visible to the naked eye.
24/87
Na
1000 h

January 2012
EN ISO 4628-2
EN ISO 4628-4
EN ISO 4628-5
A.
B.
C.
D.
Constant atmosphere of water condensation

Blistering
0 (S0)
Cracking
0 (S0)
after aging test
Flaking
0 (S0)
3 samples in order
2 samples in order
1 sample in order
0 sample in order
Approval
in order
in order
not in order
not in order
=
=
=
=

Licence
in order
Repetition of constant atm. of condensation
test - only if result of second test is A or B,
will the test be considered successful.
executed again.
2-b-6 Determination of resistance to liquids other than water

The objective of this test is to assess the chemical resistance of the coating system.
See also EN ISO 12944-6.
For atmospheric Corrosivity Categories C2, C3, C4 and C5 tests are carried out in
accordance with EN ISO 2812-1. For the purpose of determining the chemical resistance, an
additional test for C5I in accordance with EN ISO 2812-1 is carried out. The following
chemicals of recognized analytical quality shall be used:
NaOH 10 % aqueous solution
H2SO4 10 % aqueous solution
Mineral spirits containing 18 % aromatics
This test is not used for the assessment of corrosion protection properties but to determine
the ability of a system to withstand highly industrial environments. Therefore, the test
duration remains the same for Medium and High durability.
The samples are placed in a container holding the described test liquid for 168 hours.
There is no difference between steel substrate and hot dip galvanized substrate except no
scribe is made for hot dip galvanized substrate (reference is made to annex A of ISO 129446).
RESULT:
EN ISO 4628-2
EN ISO 4628-3
EN ISO 4628-4
EN ISO 4628-5
25/87
Blistering
Rusting
Cracking
Flaking
Chemical test
0 (S0)
Ri 0
0 (S0)
0 (S0)
after aging test

January 2012
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.
A.
B.
C.
D.
3 samples in order
2 samples in order
1 sample in order
0 sample in order
=
=
=
=
Evaluation:
Approval
A
in order
B
in order
not in order
not in order

Licence
in order
Repetition of test - only if result of second
test is A or B, will the test be considered
successful.
executed again.
2-b-7 Resistance to sulphur dioxide

In accordance with EN ISO 3231 using 0.2 litre SO2 and the following test duration:
240 h (10 cycles) for medium durability category 4
480 h (20 cycles) for medium durability category 5
720 h (30 cycles) for high durability category 5
RESULT:
EN ISO 4628-2
EN ISO 4628-3
EN ISO 4628-4
EN ISO 4628-5
EN ISO 4628-5
A.
B.
C.
D.
26/87
colour resistance test (Kesternich)

Blistering
0 (S0)
Rusting
Ri 0
after aging test
Cracking
0 (S0)
Flaking
0 (S0)
Surface
No Surface defects or discoloration
changes
3 samples in order
2 samples in order
1 sample in order
0 sample in order
=
=
=
=


January 2012
Evaluation:
Approval
A
in order
B
in order
not in order
not in order
Licence
in order
Repetition of test - only if result of second
test is A or B, will the test be considered
successful.
executed again.
2-b-8 Accelerated weathering test

This test is only required for coating systems intended for outdoor application. To be granted
approval for the coating system in question, Aluminium panels may be used.
The test serves to determine behaviour under EN ISO 11341 - weathering.
Loss of gloss and changes in colour are determined.
Intensity of light
Black-standard temperature
De-ionized water
550 20 W/m2 (290 - 800 nm)

65 5 C
max. 10 S/cm
special-UV filter (290 nm)

Cycles of 18 min. in humid and 102 min. in dry medium.
After 1000 h exposure, the test specimen is washed in entirely demineralised water.
The following criteria are verified
- Loss of gloss
EN ISO 2813
Angle of incidence 60
- Total deviation in shade:
E resulting from CIELAB formula in
accordance with ISO 7724-3, included gloss
RESULT:
Loss of gloss
Should not exceed 50 % of the initial value.
Total deviation in shade
In accordance with E-values of the attached

table.
2-b-9 Natural weathering

EN 13438, A.4.8.2
This test only applies to coating systems intended for outdoor application.
Weathering Test in Florida in Accordance with EN ISO 2810
The test must start in April.
The samples must be exposed to the elements facing 5 south for one year. For approval,
four test panels are required (three for weathering purposes and one reference panel).
27/87

January 2012
Dimensions of the samples: approx. 100 x 305 x 0.8 - 1 mm
After exposure, the exposed samples are to be cleaned using the following method:
Wash the test panels prior to inspection with water containing 1 % neutral detergent, using a
sponge and avoiding polishing. Afterwards rinse the panels with water with a maximum
electrical conductivity of 10 S/cm, or using any other method approved by the Technical
Committee.
This process must not scratch the surface.
Gloss is to be measured in accordance with EN ISO 2813, at an angle of 60 .
The colorimetric measurements are averaged. The conditions for measurement and
colorimetric assessment are:
Colour variation: E CIELAB formula in accordance with ISO 7724-3, with gloss.
The colorimetric assessment must be conducted for the standard illuminate D65 and
the ten-degree normal observer.
To assess gloss and colour, three measurements will be made on the cleaned, weathered
samples and on the unexposed reference panels. These measurements are to be made at
different points at least 50 mm apart.
RESULT:
Gloss
The remaining gloss must be at least 50 % of the original gloss.
Colour change
The E values must not exceed the maximum values laid down in the attached table
(reference is made to appendix 8-a).
2-b-10 Colour difference
The difference in colour between charges of coated parts may not exceed certain levels. The
purpose is to determine the acceptable nuances in colour. The colour nuances may only be
determined at diffuse daylight.
The nuances in colour can be measured in the field by the standard grey scale.
In this scale, colour nuances are expressed in grey tones. The acceptable level is 3/4 of the
EN 20105-AO2 scale.
2-b-11 Gloss difference
The gloss level difference in the production of QUALISTEELCOAT products shall be within
the tolerance limits indicated by the manufacturer. If no tolerance limits have been indicated
by the manufacturer the gloss level of the coating shall be in accordance with the table below.
This method is also used to determine sufficient curing of a powder coating.
Gloss requirements:
Specific gloss level
>50
50
28/87
Acceptable variation from the

specified gloss level
10
7

January 2012
2-b-12 Determination of etching degree

An initial zinc etching or blasting stage must be carried out as pre-treatment for any powder
and liquid coating.
The etching degree is determined by measuring the difference in the zinc film thickness
before and after etching.
RESULT:
Etching carried out in an acid medium or an alkaline plus acid medium must result in
a zinc etching degree between 5 and 10 % of the original zinc layer thickness of hot
dip galvanized steel. The etching degree for rolled products or casting is not specified.
Etching is advised by the chemicals supplier for such products.
2-b-13 Assessment of conversion coating
If so desired by the application firm, the chromate or chromate-phosphate pre-treatment has
to be carried out in accordance with EN 13438. The conversion coating must comply with the
requirements of conversion coating for steel or hot dip galvanized steel as given by the
chemicals supplier. The drying temperature of the chrome conversion layer must be approx.
60 C.
The chemicals supplier in question must provide the application firm with the relevant
information on the desired test method, equipment, chemicals and conductivity of dripping
water.
RESULT:
A sufficient layer of conversion coating must be applied to the substrate, resulting in a
uniformly coloured surface, showing no powdering.
2-b-14 Determination of conductivity of dripping water
The conductivity of the final rinse preceding chromate pre-treatment must comply with the
suppliers instructions and be checked by the inspector. Demineralised water must be used
for the final rinse after chromate treatment, prior to drying.
RESULT:
If not otherwise prescribed by the chemicals supplier, the conductivity of dripping
water shall not exceed 30 S/cm at 20 C. Conductivity should only be measured for
open sections and not for hollow sections. Certain chrome pre-treatment processes
require varying and lower coating weight to be deposited on the clean galvanized
surfaces and should be rinsed in water with relatively high conductivity, e.g. 2500
S/cm. This must be clearly stated by the chemicals supplier and agreed with the
coating material supplier.
29/87

January 2012
Appendix 3-a Information on substrates

To ensure the pre-treatment will be performed to requirement, detailed information of the
material to be treated is necessary.
Types of substrates
3-a-1 Cast parts
Depending on the kind and quality of cast, the curing of coating powder in particular, or - to
some extent - the forced drying of liquid coating material could lead to gas bubbles appearing
as blisters or craters on the coated surface. Parting compounds too could impair
adhesiveness. Therefore, coating companies should be informed of the presence of such
parting compounds, enabling them to verify the coating properties of the material in advance
and thus avoiding ensuing faults.
3-a-2 Hot dip galvanized and electro zinc coated steel parts
Prior to applying a coating system to galvanized steel, the galvanizer must be informed about
the surface preparation needed after galvanizing. Hot dip galvanizing must be executed in
accordance with ISO 1461. The galvanized steel must be cleaned and any smut, zinc runs
and dirt must be removed.
Depending on the quality of the steel, thickness of the zinc coating and possible hollows,
galvanized steel parts are susceptible to gas bubbles during curing and forced drying of
powder and liquid coating material. Blisters and craters become visible on the surface.
Deadening agents might cause insufficient coating film adherence on Sendzimir- and electro
zinc coated steel surfaces. This is the reason why only protective layers that can be removed
gently during chemical pre-treatment are suitable. The zinc layer must be treated with care.
The coating company has to be informed accordingly. Prolonged storage and exposure to
humidity may lead to visible white rust which has to be removed before coating - in some
cases slight sweeping has proved efficient. If agreed upon by the client, the parts have to
undergo this preparatory treatment.
3-a-3 Laser (oxygen) cut steel
One of the advanced methods to cut steel in desired shapes and lengths is the cutting of
steel using laser beams. The result of the cutting method is a very sharp cutting edge.
Another problem may occur at the cutting side. The steel substrate is extra hard after cutting.
This causes the need for extra attention during surface preparation.
Before any surface preparation takes place the sharp edges must be rounded and the heat
changed surface must be ground or blasted to create a treatable substrate by the customer.
(EN ISO 8501-3)
The techniques of laser cutting allow for burr-free cutting of a large variety of metal
substrates with extreme precision at high speed without any limit to shape. In addition, laser
cutting is even suitable for thicknesses of 18 mm and above.
30/87

January 2012
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.
31/87

January 2012
Disadvantages:
On tack welded units, some areas may be hard to reach.
Chemical treatment
Principles:
By passage in an acid medium, non-adherent laser calamine is detached from the
substrate by the hydrogen release created when the metal is attacked. The products to be
used can be made up of mineral acids and/or organic:
Hydrochloric
Sulphuric
Phosphoric
Citric
Gluconic
Phosphonic
They are additives of surfactants and inhibiters in accordance with the required treatment
(simple scouring, scouring-grease-remover, grease-remover-paint remover-phosphatizer).
Both soaking and sprinkling are possible.
Advantages:
The treatment reaches laser calamine even in the inaccessible places of the parts.
Several successive baths can be used.
Possibly enables the increase of anti-corrosive properties of coatings, by means of

conversion post-treatment.
Disadvantages:
Implements chemicals and implies a treatment of the rejects.
Eliminated calamine is found in the bath and creates mud.
Total decarbonising of the mild steel is not achieved.
The phenomenon of clothing powder can settle on certain steels.
Conclusions:
To avoid adhesion problems in laser cutting areas, the surface must be properly prepared.
The method to be used must be decided upon on a case-by-case basis, depending on the
restrictions of the workshop in question.
32/87

January 2012
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
Weakness anticorrosive on
the level of the Adapted
nozzles of
cutting
Plane sheet
Cut out Sheet
Weakness
antiSuitable for
corrosive on
large
the level of
thicknesses
the nozzles
of cutting
Suitable for
fine
thicknesses
Perforated
Sheet
Risk
deformation
due to shotblasting for
sheets < = to
1.5 mm
Expanded
metal
Profile for
windows
33/87
Secure the
dimensions
of the baths
Risk
deformation
due to shotblasting for
sheets < = to
1.5 mm
The surface
quality can
present defects

January 2012
Types of parts
E coat
Require
holes of
Without Sheets circulation
and
evacuation
If the sheets
are not
welded
uninterruptedl
y they must
be coated
Opening Sheet separately, to
avoid the
absence of
protection
between
sheet and
tallies
In the event
of insulation
the 2 sheets
One face
are coated
two faces
separately the insulator
being burnt
after heating
Powder zinc
primer
Zinc spraying
50 a 200 m
Sendzimir
15 a 30 m
Hot dip
galvanized 50
a 200 m
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
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
In the event of
insulation the 2
sheets are
coated
separately - the
insulator being
burnt after
heating
Shot blasting
Possible after
Profile hot roll
DS 2,5 a DS 3 Recommended
shot-blasting
requirement
Secure the
UPN-IPN-IPEdimensions
HEA-HEB
of the baths
Shot blasting
Possible after
Recommended
Sa 2,5 a Sa 3
shot-blasting
requirement
Secure the
Do not stop the Can protect
Unit mecano
dimensions
air-gaps and
weak
welds in profile of the baths
non-closed
interstices and
Little
weldings
air-gaps
practised
34/87
In the case
of two
sheets,
second is
treated
separately
NA
Recommended
NA
Recommended
can clog weak
interstices and
air-gaps, risk of
sweating

January 2012
Appendix 3-b Removal of contamination
Surface treatment before pre-treatment
3-b-1 Old coating (coated substrates)
All residue of prior coatings should be completely removed prior to renewed pre-treatment.
Different methods, such as blasting, pyrolysis or chemical stripping can be used. Remaining
phosphate or chromate layers on the stripped substrates must be removed by mechanical or
chemical pre-treatment as well.
3-b-2 Adherent residue, silicone and labels
Adherent residue and silicone have a negative effect on the visual appearance after coating,
they cause clearly visible craters and smears and reduce the adhesive power of the coating
material on the surface. Therefore, application of silicone parting agents has to be avoided
during processing on the untreated part. In case such agents have been applied, the coating
company is to be informed unsolicited. If possible, adherent residue is to be removed by
suitable solvents before the pre-treatment.
3-b-3 Weld seam
Oxide films in the area of weld seams should be removed by suitable methods e.g. abrasive
blasting, mechanical pre-treatment or chemical acidic etching.
3-b-4 Water-soluble residue
This type of residue, such as salts, should be removed by using water (e.g. application of
steam jet) or hot water-based cleaning systems.
3-b-5 Sharp edges and cuts
All sharp edges and laser cuts have to be rounded. This is absolutely necessary to enable
the application of sufficient film thickness on these parts of the substrate. This can be carried
out by grinding or sweep brushing the edges of the objects. (EN ISO 8501-3)
35/87

January 2012
3-b-6 Information on procedures of removal of foreign matter

Procedures for removal of extraneous layers and foreign matter
Matter to be
removed
Grease and oil
Procedure
Water cleaning
Fresh water with addition of detergents. Pressure (<

70 MPa) may be used. Rinse with freshwater.
Steam cleaning
Fresh water. If detergents are added, rinse with

freshwater.
Emulsion
cleaning
Rinse with freshwater.
Alkaline cleaning
Organic-solvent
cleaning
Water-soluble
contaminants,
e.g. salt
Water cleaning
Freshwater Pressure (< 70 MPa) may be used.
Steam cleaning
Alkaline cleaning
Coatings
36/87
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.
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.
Stripping:
Dry abrasive
cleaning
Wet abrasive
cleaning
Water blastcleaning
Sweep blastcleaning
Spot blastcleaning
Aluminium, zinc and certain other types of metal

coating may be susceptible to corrosion if strong
alkaline solutions are used. Rinse with freshwater.
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.

January 2012
Appendix 3-c Surface pre-treatment
3-c-1 Surface pre-treatment
Mill scale has a negative effect on the durability of the coating system. Therefore, it has to be
removed using a suitable mechanical pre-treatment method (abrasive-blasting, grinding,
brushing) or chemical cleaning.
These methods are also applied to burrs caused by cutting or other punching devices. Sharp
edges result in a considerably lower film thickness, thus severely diminishing the corrosion
resistance in this area.
Corrosion products have the same unwanted properties as the problems mentioned above.
Complete removal is absolutely necessary. Slight formation of red rust on steel substrates as
well as slight formation of white rust on zinc-coated steel substrates can often be removed by
special acidic etching.
Considerable rust formation necessitates mechanical removal (e.g. sweeping) or heavy
chemical cleaning. Preliminary tests are recommended.
The quality of the surface preparation and the methods available depend highly on the shape
and thickness of the steel used. In most cases abrasive blasting is not recommended if the
steel sheet is less than 1.5 mm thick.
The required quality of blast cleaning methods is given in EN ISO 12944-4 - types of
surfaces and surface preparation. This standard also refers to EN ISO 8501-1 - preparation
of steel substrates before application of paint and related products.
3-c-2 Part 4 of EN ISO 12944 deals with the following types of surface of steel structures
consisting of carbon or low-alloy steel, and their preparation:
uncoated surfaces;
surfaces thermally sprayed with zinc, aluminium or their alloys;
hot-dip galvanized surfaces;
zinc-electroplated surfaces;
sherardized surfaces;
surfaces painted with prefabrication primer;
other painted surfaces.
This part of EN ISO 12944 defines a number of surface preparation grades but does not
specify any requirements for the condition of the substrate prior to surface preparation.
Highly polished surfaces and work-hardened surfaces are not covered by this part of ISO
12944.
In appendix 3-b the cleaning and removal of all foreign matter is discussed. In this appendix
the surface preparation prior to application is given.
The different methods are presented in the table referring to the expected lifetime of a
system using this type of pre-treatment.
37/87

January 2012
For chemical methods the composition of the chemicals is the responsibility of the chemicals
manufacturer. The composition of the baths is only defined in general terms.
A chemical bath may be used for one type of substrate only. If a chemical bath composed for
aluminium is also used for steel or galvanized steel, the chemicals manufacturer must inform
the coating applicator of the maximum concentration of zinc and aluminium allowed. The
baths must be tested on a regular basis, these test results must include the concentration of
these components.
3-c-3 Surface pre-treatment methods
Procedures for removal of rust and mill scale:
Matter to be
Procedure
removed
The process is generally not performed on site.
Chemical Cleaning
Shot or grit abrasives. Residue of dust and loose
Dry abrasive blastdeposits will have to be removed by blowing off with
cleaning
dry oil-free compressed air or by vacuum cleaning.
Mill scale
Wet abrasive blastRinse with freshwater.
cleaning
Mechanical cleaning will be required to remove
Flame cleaning
residue from the combustion process, followed by
removal of dust and loose deposits.
The process is generally not performed on site.
Chemical Cleaning
Mechanical brushing may be used in areas with
loose rust. Grinding may be used for firmly adhering
Power-tool cleaning
rust; residue of dust and loose deposits will have to
Rust
be removed.
For removal of loose rust. The surface profile of the
Water blast-cleaning
steel is not affected.
Spot blast-cleaning
Zinc Hot dip

Galvanized
Light surface blast to

improve adhesion
Zinc
corrosion
products
Sweep blastcleaning
38/87
For localized removal of rust.

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 .
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.

January 2012
Matter to be
removed
Procedure
Chemical cleaning
Chemical cleaners may be used for larger surfaces.

All zinc corrosion products must be removed. The
process has to be executed carefully, not to dissolve
the zinc. No more than 10 % of the zinc thickness
may be lost due to the process.
When rinsing and drying, structures with slots or rivets shall be treated with particular care.
3-c-4 Pre-treatment (category 1)
Abrasive
Chemical
Chemical
abrasive-blasting Sa 2, or
degreasing, or
phosphating or alternative processes.
3-c-5 Pre-treatment (category 2)

Abrasive
Chemical
abrasive blasting Sa 2, or
phosphating, or alternative processes.
3-c-6 Pre-treatment (category 3 + 4 + 5)

Abrasive
Abrasive/chemical Chemical
-
abrasive blasting to Sa 2 1/2 or

abrasive blasting Sa 2 1/2 + passivation or
de-oxidation and passivation, phosphating or
alternative processes.
The purpose of the pre-treatment process is to remove all corrosion products from the
substrate and to produce a substrate suitable for the application of a coating system.
3-c-7 Rinsing
Rinsing water quality has to comply with the instructions of the pre-treatment agents
manufacturer. The chemicals suppliers process working instruction must be available on
demand.
3-c-8 Drying of pre-treated parts
If required, forced drying has to be effected. Drying has to be executed in accordance with
the instructions of the pre-treatment agents manufacturer.
3-c-9 Conversion coating of pre-treated parts
If desired by the application firm, conversion by chrome free, chromate or chromatephosphate pre-treatment must be carried out in accordance with EN 13438 appendix B.3.1
The weight of the conversion coating and the conversion method chosen have to be in
accordance with the chemicals suppliers requirements related to conversion coating of steel
or hot dip galvanized steel.
This chemicals supplier must also provide the application firm with the relevant information
about the desired test method, equipment and chemicals.
39/87

January 2012
The conductivity of the final rinse preceding chromate pre-treatment must comply with the
suppliers instructions and be checked by the inspector.
Demineralised water must be used for the final rinse after chromate treatment, prior to
drying. If not advised otherwise by the chemicals supplier, the conductivity of the dripping
water must not exceed a maximum of 30 S at 20 C. The conductivity should only be
measured for open sections and not for hollow sections.
The weight of the chromate conversion layer must be accordance with the information
provided by the chemicals supplier.
Pre-treated parts must not be stored for more than 16 hours. As a rule, they should be
coated immediately after pre-treatment. The risk of insufficient adhesion increases as the
parts are stored longer.
Pre-treated parts must never be stored in an atmosphere that is dusty and potentially
detrimental. Good atmospheric conditions must always be maintained in the storage area. All
workers handling pre-treated parts must wear clean textile gloves to avoid contamination of
the surface.
The parts must be dried at the following temperatures:
Chromate treatment (yellow): maximum 65 C
Chromate-phosphate treatment (green): maximum 85 C
Chrome-free treatment: maximum as stipulated by the supplier
The maximum drying temperature allowed for continuous treatment is 100 C, but the
substrate must be heated to a minimum of 60 C. The specified temperatures apply to the
temperature of the metallic parts and not to the air temperature. The products must be dried
thoroughly before the coating is applied, irrespective of the production method (continuous/
discontinuous).
3-c-10 Temperature of conversion and rinsing baths
The temperature of the conversion bath and - in case of a hot water rinse - the final rinse,
must be measured during production using a dip thermometer. When using a spray tunnel,
the temperature at the level of the treated product has to be measured. An even temperature
in the entire pre-treatment bath and sufficient rotation of the chemicals are important.
40/87

January 2012
Appendix 4-a Liquid coating systems
All the systems given are examples
4-a-1 Liquid coating systems on steel
The paint sytems given in tables A.1 - A.8 are only examples. Other paint systems having the same performance are possible. If these
examples are used, it shall be ensured that the paint systems chosen comply with the indicated durbility when execution of the paint work takes
place as specified. See also 5.5
Shading of every second line in the text part of the table is added for increased readability
Table A.1 - Paint systems summary table for corrosivity categories C2, C3, C4, C5-I and C5-M:
Substrate: low alloy carbon steel.
Surface preparation: For Sa 2 1/2 rust grade A, B or C (ISO 8504-1).
Subsequent
coat(s)
Priming coat(s)
Syst.
No.
Expected durability
(see 5.5 and ISO 12944-1)
Paint system
Cat 2
Cat 3
Cat 4
Corresponding systems in table
Cat 5-I
Cat 5-M
Binder
Type of
1)
primer *
No. of
coats
NDFT
2)
m *
Binder
No. of
coats
NDFT
2)
m *
A 1.01
AK, AY
Misc.
1-2
100
---
1-2
100
A 2.08
A 1.02
EP, PUR,
ESI
60
---
60
A 2.18
A 1.03
AK
Misc.
1-2
80
AK
2-3
120
A 1.04
AK
Misc.
1-2
80
AK
2-4
160
A 1.05
AK
Misc.
1-2
80
AK
3-5
200
A 1.06
EP
Misc.
160
AY
200
A 1.07
AK, AY,
CR, PVC
Misc.
1-2
80
AY, CR,
PVC
2-4
160
A 2.06,
A 3.12
A 2.14
60
AY, CR,
PVC
2-3
160
A 3.23
A 4.16
A 4.25
1-2
80
AY, CR,
PVC
3-5
200
A 3.07
A 3.13
A 4.04
A 4.08
A 1.08
A 1.09
EP, PUR,
ESI
AK, AY,
3)
CR * ,
PVC
41/87
Zn (R) *
Zn (R) *
Misc.
6)
6)
A. 2
A. 3
A. 4
A 3.20
A 3.02
A 2.06
A 3.04
A 3.06
A 4.01
A 4.10
A. 5-I
A. 5-M

January 2012
Syst.
No.
A 1.10
A 1.11
A 1.12
A 1.13
Subsequent
coat(s)
Priming coat(s)
Binder
Type of
1)
primer *
No. of
coats
NDFT
2)
m *
EP, PUR
Misc.
80
60
1-2
80
60
160
60
EP, PUR,
ESI
AK, AY,
3)
CR * ,
PVC
EP, PUR,
ESI
Zn (R) *
6)
Misc.
Zn (R) *
6)
AY, CR,
PVC
AY, CR,
PVC
AY, CR,
PVC
AY, CR,
PVC
AY, CR,
PVC
AY, CR,
PVC
Cat 2

Cat 5-M
No. of
coats
NDFT
2)
m *
3-4
200
3-4
200
A 4.17
3-5
240
A 4.05
A 4.09
3-5
240
A 4.18
2-3
280
A 5I.02
4-5
320
A 5I.11
A. 2
A. 3
A. 4
A 3.18
A 4.12
A. 5-I
A. 5-M
A 1.14
EP
A 1.15
EP, PUR,
ESI
A 1.16
EP
Misc.
1-2
80
EP, PUR
2-3
120
A 2.15
A 3.16
A 1.17
EP
Misc.
1-2
80
EP, PUR
2-4
160
A 2.16
A 3.17
A 1.18
EP, PUR,
ESI
60
EP, PUR
2-3
160
A 3.21
A 4.19
A 4.28
A 1.19
EP
1-2
80
EP, PUR
3-5
200
A 3.18
A 4.12
A 1.20
EP, PUR,
ESI
Zn (R) *
6)
60
EP, PUR
3-4
200
A 4.20
A 4.29
A 1.21
EP, PUR,
ESI
Zn (R) *
6)
60
EP, PUR
3-4
240
A 4.21
A 5I.06
A 4.30
A 5M.07
A 5M.12
A 1.22
EP
1-2
80
EP, PUR
3-5
280
A 4.14 A 5I.03
A 5M.04
42/87
Misc.
Binder
Expected durability
(see 5.5 and ISO 12944-1)
Cat 3
Cat 4
Cat 5-I
Paint system
Zn (R) *
Zn (R) *
6)
6)
Misc.
Misc.

January 2012
Subsequent
coat(s)
Priming coat(s)
Syst.
No.
Cat 2
Binder
Type of
1)
primer *
No. of
coats
NDFT
2)
m *
Binder
No. of
coats
NDFT
2)
m *
A 1.23
EP
Misc.
150
EP, PUR
A 1.24
EP, PUR,
ESI
Zn (R) *
60
EP, PUR
A 1.25
EP, PUR
Misc.
80
A 1.26
EP, PUR
Misc.
250
A 1.27
EP, PUR
Misc.
A 1.28
EPC
Misc.
A 1.29
EP, PUR
43/87
Zn (R) *
6)
6)
Expected durability
(see 5.5 and ISO 12944-1)
Paint system
L
Cat 3
H
Cat 4
H
Cat 5-I
H
Cat 5-M
L
A. 2
A. 3
A. 4
A. 5-I
A. 5-M
300
A 5I.04
A 5M.01
3-4
320
A 4.23 A 5I.08
A 5M.09
A 5M.14
EP, PUR
3-4
280
A 5I.04
A 5M.04
EP, PUR
500
A 5M.06
400
---
400
A 5M.05
100
EPC
300
A 5M.16
60
EPC
3-4
400
A 5M.11

January 2012
Paints (liquid)
Binder for priming
coat(s)
No. of
components
1-Pack
AK
Alkyd
CR
Chlorinated
rubber
AY
Acrylic
PVC
Polyvinyl
chloride
EP
Epoxy
2-Pack
Paints (liquid)
Waterborne
possible
X
No. of
components
Binders for top coat(s)
1-Pack
AK
Alkyd
CR
Chlorinated
rubber
AY
Acrylic
PVC
Polyvinyl
chloride
EP
Epoxy
ESI
Ethyl silicate
PUR
Polyurethane
aliphatic
PUR
Polyurethane
aromaticor
aliphatic
EPC
Epoxy
combination
2-Pack
Waterborne
possible
X
X
X
X
X
*1) Zn (R) = Zinc rich primer, see 5.2.

Misc
= Primers with miscellaneous types of anticorrosive pigments.
*2) NDFT = Nominal Dry Film Thickness, see 5.4 for further details.
*3) It is recommended that compatibility is checked with the paint manufacturer.
*6) It is also possible to work with a NDFT of 40 m provided that the EP or PUR zinc rich
primer chosen is suitable for such a NDFT. In this case, the NDFT of the complete paint
system can be adjusted by subsequent coats.
44/87

January 2012
4-a-2 Liquid coating systems on galvanized steel
Table A.7 - Paint systems for hot-dip-galvanized steel for corrosivity categories C2 to C5-I and C5-M:
Substrate: Hot-dip-galvanized steel.
ISO 12944-4 gives some examples of surface preparation. The type of surface preparation depends on the type of paint system, and should be stated by the paint
manufacturer.
5)
Expected durability *
Subsequent
(see
5.5
and
ISO
12944-1)
Priming coat(s)
Paint system
Syst.
coat(s)
Cat 2
Cat 3
Cat 4
Cat 5-I
Cat 5-M
No.
No. of coats
NDFT m *
---
PVC
80
40
PVC
120
PVC
80
PVC
160
PVC
80
PVC
240
A 7.05
---
---
---
AY
80
A 7.06
AY
40
AY
120
A 7.07
AY
80
AY
160
A 7.08
AY
80
AY
240
A 7.09
---
---
---
EP, PUR
80
A 7.10
EP, PUR
60
EP, PUR
120
A 7.11
EP, PUR
80
EP, PUR
160
A 7.12
EP, PUR
80
EP, PUR
240
A 7.13
EP, PUR
80
EP, PUR
320
No. of coats
A 7.01
---
---
A 7.02
PVC
A 7.03
A 7.04
Binder for priming

coat(s)
NDFT m *
2)
Binder
Binder
No. of
components
AY
Acrylic
1 Pack
PVC
Polyvinyl
chloride
1 Pack
EP
PUR
45/87
Epoxy
Polyurethane
aromatic or
aliphatic
2 Pack
1 or 2 Pack
Waterborne
possible
X
Binders for priming coat(s)
2)
No. of
components
AY
Acrylic
1 Pack
PVC
Polyvinyl chloride
1 Pack
EP
Epoxy
2 Pack
PUR
Polyurethane aliphatic
1 or 2 Pack
Waterborne
possible
X

January 2012
*5) The durability is in this case related to the adhesion of the paint system to the hot-dip galvanized substrate
4-a-3 Liquid coating systems on metal sprayed steel substrates
Substrate: Thermally sprayed metal (zinc, zinc/aluminium alloys and aluminium) surfaces.
Surface preparation: See ISO 12944-4:1998, clause 13.
It is recommended that sealing or application of the first coat of the paint system is carried out within 4 hours.
If used, sealers should be compatible with the subsequent paint system.
5)
Subsequent
coat(s)
Sealer coat
Syst. No.
Binder
EP, PUR *
3)
A 8.02
EP, PUR *
3)
A 8.03
EP *
A 8.01
A 8.04
3)
EP, PUR
Binder for sealing coat

and priming coat(s)
No. of
coats
1
NDFT m
2)
*
7)
NA *
NA *
7)
NA *
7)
NA *
7)
No. of
components
EP
Epoxy
2 Pack
EPC
EP combination
PUR
Polyurethane
aromatic
Paint system
Cat 4
NDFT m
2)
*
160
EP, PUR
No. of
coats
2
EP, PUR
240
EP, EPC
450
320
Binder
Waterborne
8)
possible *
X
Expected durability *
(see 5.5 and ISO 12944-1)
Cat 5-I
Cat 5-M
Binders for top coat(s)
No. of
components
EP
Epoxy
2 Pack
2 Pack
EPC
EP combination
2 Pack
1 or 2 Pack
PUR
Polyurethane aliphatic
Waterborne
possible
X
1 or 2 Pack
*3) It is recommended that compatibility is checked with the paint manufacturer.
*5) The durability is in this case related to the adhesion of the paint system to thermally sprayed substrate.
*7) The dry film thickness of the sealer coat will not significantly contribute to the total dry film thickness of the system.
*8) Water-borne products are in general not suited for immersion.
46/87
Im 1-3
H

January 2012
Appendix 4-b Powder coating systems
All the systems given are examples
4-b-1 Powder coating systems interior
Syst. No.
I-P 01
I-P 02
I-P 03
I-P 04
I-P 05
I-P 06
I-P 07
I-P 08
I-P 09
I-P 10
I-P 11
I-P 12
I-P 13
I-P 14
I-P 15
I-P 18
I-P 19
I-P 20
I-P 21
I-P 22
I-P 23
I-P 24
Substrate
Surface
preparation Binder
Primer
Type
Intermediate coats
m
Steel
1
ZE 50/50
1
ZE 50/50
1
ZE 100
1
Z100
1
Z100
2
Z225
3
Z275
3
HDG
3
HDG
3
HDG
3
HDG
3
Steel
3
E
Z
50
Steel
3
E
Z
50
Steel
3
E
Z
50
Steel
Sa 2
E
Z
50
Steel
Sa 2
S
Z
50
Steel
Sa 2
S
Z
50
Steel
Sa 2
S
Z
50
Steel
1
Ef
C
15
Steel
1
Ef
C
15
Steel
1
Ef
C
15
*) total film thickness exclusive zinc thickness Sys No;
resin
Type
Topcoat
Durability
Coating system
resin
Type
Layers
P/E
P/E
P
P
P
P
P
P
P
P
P
P
P
P
P
P
P
P
P
P
P
P
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
60
60
60
80
60
60
80
80
60
60
80
80
60
60
80
80
60
60
80
60
60
80
1
1
1
1
1
1
1
1
1
1
1
1
2
2
2
2
2
2
2
2
2
2
60
60*
60*
80*
60*
60*
80*
80*
60*
60*
80*
80*
110
110
130
130
110
110
130
75
75
95
Cat 1
M H
X X
X X
X X
X X
X X
X X
X X
X X
X X
X X
X X
X X
X X
X X
X X
X X
X X
X X
X X
X X
X X
X X
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;
47/87
Cat 2
M H
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Cat 3
M
H
Cat 4
M
H
Cat 5-I
M
H
Cat 5-M
M
H
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X

January 2012
4-b-2 Powder coating systems exterior
Syst. No.
O-P 01
O-P 02
O-P 03
O-P 04
O-P 05
O-P 06
O-P 07
O-P 07 Bis
O-P 08
O-P 09
O-P 10
O-P 11
O-P 12
O-P 13
O-P 14
O-P 15
O-P 16
O-P 17
O-P 18
O-P 19
O-P 20
O-P 21
O-P 22
Surface
Substrate
preparation
Z 225
Z 275
HDG
HDG
HDG
HDG
HDG
HDG
HDG
Steel
Steel
Steel
Steel
Steel
Steel
Steel
Steel
Steel
Steel
Steel
Steel
Steel
Steel
X
O-P 07 Bis
Z/ZF
48/87
3
3
3
3
3
4
3
4
4
3
3
3
Sa 2,5
Sa 2,5
Sa 2,5
Sa 3
Sa 3
Sa 3
Sa 3
Sa 3
1
1
1
Primer
Binder
Type
Intermediate coats
m
E
E
E
C
C
C
60
60
60
E
E
E
E
E
E
E
S
S
S
S
S
Ef
Ef
Ef
C
Z/ZF
Z/ZF
Z/ZF
Z/ZF
Z/ZF
Z/ZF
Z
Z
Z
Z
Z
C
C
C
60
50
70
50
50
70
50
35
50
35
100
150
15
15
15
Binder
Type
Binder
Type
Layers
P
P
P
P
P
P
P
C
C
C
C
C
C
C
P
P
P
P
P
P
P
P
P
P
P
P
P
P
P
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
60
80
60
80
60
60
60
80
60
60
80
80
60
80
80
80
80
60
80
80
60
80
60
1
1
1
1
2
2
3
1
3
2
2
3
2
2
3
1
1
2
1
2
2
2
2
60
80*
60*
80*
120*
120*
180*
80
180*
110
150
190
110
150
190
115
130
155
180
290
75
95
135
E/P
60
E/P
60
E/P
60
E/P
60
60
60
E/P
60
X in the previous table

No X in the previous table
This process cycle doesnt exist in the previous table
Zinc or Zinc free
Total coating
system
Topcoat
Durability
Cat 2
M
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
H
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Cat 3
M
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
H
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Cat 4
Cat 5-I
Cat 5-M
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X

January 2012
Syst. No.
Surface
Substrate
preparation
Primer
Binder
Type
Intermediate coats
m
O-P 01
Z 225
3
O-P 07 Bis
HDG
4
O-P 02
Z 275
3
O-P 03
HDG
3
O-P 09
Steel
3
E
Z/ZF
50
O-P 10
Steel
3
E
Z/ZF
70
O-P 12
Steel
Sa 2,5
E
Z/ZF
50
O-P 15
Steel
Sa 3
S
Z
35
O-P 04
HDG
3
O-P 11
Steel
3
E
Z/ZF
50
O-P 13
Steel
Sa 2,5
E
Z/ZF
70
O-P 16
Steel
Sa 3
S
Z
50
O-P 20
Steel
1
Ef
C
15
O-P 05
HDG
3
E
C
60
O-P 06
HDG
4
E
C
60
O-P 14
Steel
Sa 2,5
E
Z/ZF
50
O-P 17
Steel
Sa 3
S
Z
35
O-P 18
Steel
Sa 3
S
Z
100
O-P 21
Steel
1
Ef
C
15
O-P 07
HDG
3
E
C
60
O-P 08
HDG
4
E
C
60
O-P 19
Steel
Sa 3
S
Z
150
O-P 22
Steel
1
Ef
C
15
*) total film thickness exclusive zinc thickness Sys No;
Binder
E/P
Type
60
E/P
E
C
C
60
60
E/P
E/P
E
E/P
C
C
C
C
60
60
60
60
Total coating
system
Topcoat
Binder
Type
Layers
P
P
P
P
P
P
P
P
P
P
P
P
P
P
P
P
P
P
P
P
P
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
60
80
80
60
60
80
60
80
80
80
80
80
60
60
60
80
60
80
80
60
60
80
60
1
1
1
1
2
2
2
1
1
3
2
1
2
2
2
3
2
1
2
3
3
2
2
60
80
80*
60*
110
150
110
115
80*
190
150
130
75
120*
120*
190
155
180
95
180*
180*
290
135
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;
49/87
Durability
Cat 2
M
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
H
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Cat 3
M
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
H
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Cat 4
Cat 5-I
Cat 5-M
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X

January 2012
4-b-3 Table 4-b-1 and 4-b-2 explanation (substrate)

Substrate
ZE 50/50
ZE 100/100
Z100
Z225
Z275
HDG
HDG
HDG
HDG
Explanation
Sheet electrolytic zinc on steel 5 m
Sheet electrolytic zinc on steel 10 m
Sendzimir zinc 100 g/m2 double faced
Steel thickness < 1.5 mm 250 g/m2/face approx. 35 m, Hot Dip
Galvanizing
Steel thickness >1.5 and < 3.0 mm 325 g/m2/face approx. 45 m, Hot
Dip Galvanizing
Steel thickness >3 mm and < 6.0 mm 395 g/m2/face approx. 55 m, Hot
Dip Galvanizing
Steel thickness > 6.0 mm 505 g/m2/face approx. 70 m, Hot Dip
Galvanizing
4-b-4 Table 4-b-1 and 4-b-2 explanation (surface preparation)

Surface
preparation
1
2
3
4
Sa 2
50/87
Explanation
Only degreasing of substrate
De-oxidation
Phosphating EN 13438 + passivation or alternative processes
Blasting zinc substrate in accordance with EN 15773
Blasting in accordance with EN ISO 8501-1

January 2012
Appendix 5-a Application of liquid coatings

EN ISO 12944-7 provides a great deal of information on the application of coating systems.
5-a-1 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 the blast grit.
Careful processing is required to avoid split or pocket borings in which non-removable pretreatment residue could cause damage, corrosion or insufficient adhesion.
necessary to discuss this problem with the coating applicator prior to starting the process.
The surface to be treated must be safely accessible and well illuminated.
5-a-2 Coating application
and dry prior to application. One or more coats must be applied and the coats must be cured
or pre-cured depending on the system.
Additional information is given in appendix 5-a Application and Curing of Coatings.
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.
The application conditions must be measured and the data must be recorded. If necessary
the conditions must be adapted to meet the requirements related to the coating to be applied.
Coating material shall not be applied at temperatures below 3 C above the dew point in
accordance with EN ISO 8502-4. Wet surfaces shall only be painted with coating materials
approved for use in the technical data sheet or by the manufacturer.
51/87

January 2012
5-a-3 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 application of the coating layers. After application of the system, the coated
products must be left to harden sufficiently to allow transport.
5-a-4 Storage of coating materials
The storage of coating materials must comply with the applicable safety requirements.
Only the coating used during application and additional solvent may be present in the
coating application area.
5-a-5 Storage of coated material
The coated material must be stored professionally to avoid damage and dirt collection on the
coated surfaces.
52/87

January 2012
Appendix 5-b Application of powder coatings
5-b-1 Coatability of objects
Before the coating system is applied the substrate must be inspected for its coatability
properties. Welding spatters, sharp edges and non-treatable parts of the substrate must be
inspected with extra care.
necessary to discuss this problem with the applicator and the customer.
(EN ISO 8501-3 for welds, edges etc.)
5-b-2 Oven drying
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-b-3 Application of powder coatings
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.
5-b-4 Curing of powder coatings
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 20 C.
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-b-5 Storage of powder coating
Powder coating must be stored in a room separated from the production facilities. It must be
stored dry and free from contamination.
53/87

January 2012
5-b-6 Storage of coated material
The coated products must be stored in a dry and clean room. 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.
54/87

January 2012
Appendix 6-a In-house control for chemical surface preparation

The results of in-house control must be recorded and readily accessible to the inspector.
6-a-1 Equipment
The chemical pre-treating company must have the following devices at its disposal:
Instruments
Thickness tester, individual or
multi-purpose gauges
Conductivity meter
pH meter and thermometer
Type of licence Quantity

Interior +
2
Exterior
Exterior
1
Interior +
1
Exterior
Chemicals to determine the

bath strengths
Exterior
Test solutions for Zn and Al

*1)
content
Exterior
(only with mixed
bath)
Test solutions and equipment

for testing chemical
*1) *2)
conversion coating
Temperature paths for drying
oven
Exterior
Exterior
*1) If combined Zinc and Aluminium baths are used.

*2) If recommended by the chemicals supplier.
Technical information and instructions of every testing device, showing the identification
number and proof of calibration, must be available.
6-a-2 Applicator in-house control
The chemical pre-treating company has to monitor his production process, method
and products.
Reference
Test method
6-a-2.1
Inspection of coatability of substrates
6-a-2.2
Concentration of pre-treatment baths
6-a-2.2
Assessment of pH value of baths
6-a-2.3
Conductivity of dripping water
6-a-2.4
6-a.2.5
Temperature of baths
Zn and Al content
(2-b-17)
Measuring the objects drying
temperature
Assessment of the loss of zinc by
etching
*1) *2)
6-a-2.6
6-a-2.7
*a)
Interior
Every object
Inapplicable
If required
once a day
Exterior
Every object
Once a day
If required once a shift
Once a day
If required
Once per shift
Once a day
Inapplicable
If required once per shift
inapplicable
Once a day
Inapplicable
Once per shift
Inapplicable
*b)
*1)
Assessment of conversion coating
Inapplicable
Visual once a shift, and Chrome

free following the chemical
supplier's recommendations
(Once a month)
6-a-2.9
Inspection of result of surface

preparation
Not
applicable
Visual
6-a-2.8
55/87

January 2012
*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.
6-a-2.1 Coatability of objects (5-a-1)
The coatability of the object to be treated must be inspected.
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 sharp edges and extra hardened steel at the edges.
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 environment class at the site must
be evaluated.
The results of this test must be recorded and kept on file.
6-a-2.2 Concentrations of pre-treatment baths (2-b-15)
The chemical concentrations and pH value of each bath as defined by the chemicals supplier
must be analysed at least once a day (24 hours).
If the results of earlier analyses necessitate an increase in the frequency of analyses, the
coating applicator must do so of his own accord.
The results of these analyses must be entered into charts or a record. They must show the
nominal values and maximum values not to be exceeded as specified by the chemicals
supplier. The actual values and the number of shifts worked must be recorded. A separate
record must be kept for each bath.
If necessary, any corrective measures must be noted on the chart against the date of the
analysis, or recorded in the register.
56/87

January 2012
6-a-2.3 Conductivity of dripping water (2-b-14)

The conductivity of the final rinse preceding chromate bath and the demineralised rinsing
water must be measured at least once a day (24 hours).
The coating applicator must increase the frequency of the analyses of his own accord if
proven necessary on account of the analyses made.
nominal values, maximum values not to be exceeded, actual values recorded and the
number of shifts worked.
analysis. If not, they must be recorded in the register.
6-a-2.4 Temperature of pre-treatment baths (2-b-16)
The temperature of each of the pre-treatment baths and the final rinse - in case of a hot
water rinse - must be measured at least once a day (24 hours).
The results of these measurements must be entered into charts or a record. They must show
the nominal values, maximum values not to be exceeded, actual values recorded and the
6-a-2.5 Zn and Al content
Additional tests are required if surface treatment takes place in baths where both zinc and
aluminium are treated.
The Zn and Al content has to be determined once per shift. The maximum concentrations
allowed and the method of assessment must be specified by the chemicals supplier.
analysis. If not, they must be recorded in the register.
6-a-2.6 Measuring the drying temperature
The objects drying temperature must be measured at least once a week.
The temperature of the production metal and, simultaneously, the temperature shown on the
visual display unit must be read and recorded.
The temperature should be measured using a recording instrument or some other means
such as thermo chromic pencils or tablets.
The results of these measurements and the drying curves should be recorded and kept on
file.
57/87

January 2012
6-a-2.7 Testing the etching degree (2-b-10)

When etching a hot dip galvanized steel substrate, a very smooth etching method must be
used. In order to determine the amount of zinc removed, the film thickness of the zinc layer
must be measured before and after etching. From these results the decrease in film
thickness can be determined. No more than 10 % of the zinc thickness may be lost as a
result of etching. The loss of zinc during the etching stage must be tested at least once at the
start of a hot dip galvanized steel project, using the method described.
The results of these measurements should be recorded and kept on file.
6-a-2.8 Assessment of conversion coating (2-b-11)
The quality of the conversion coating must be tested. The treated product must be visually
inspected as regards even surface appearance. The conversion layer shall show no
powdering. It is advisable to regularly test the quality of the conversion coating together with
the chemicals supplier.
The results of these measurements should be recorded and kept on file.
6-a-2.9 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.
The result must be a clean corrosion-free substrate fit for the application of a coating.
6-a-3 Quality control registers
6-a-3.1 Production process control registers
This register with numbered pages, or a computer record - is to be maintained by the
laboratory supervisor. If the test results do not comply with the standards, corrective actions
taken must be recorded.
The register must show the following information:
58/87
coatability;
temperature of the baths;
concentrations of baths: requested concentrations and measuring results;
conductivity of dripping water;
temperature of pre-treatment baths;
Zn and Al content in combination baths;
drying temperature;
loss of zinc as a result of pre-treatment;
appearance of conversion coating;
inspection of surface preparation.

January 2012
Appendix 6-b In-house control for blasting surface preparation

The results of the in-house control must be recorded and readily accessible to the inspector.
6-b-1 Equipment
Instruments
Set of sieves to determine grit seize
*1)
deviation
Roughness measurement equipment
Thickness tester, individual or multipurpose gauges
Thermometer
Dew Point
Equipment and chemicals for testing
*2)
the conversion coating
*2)
Conductivity meter
Temperature paths for drying oven
Classification I or E
Quantity
Exterior
(1) From supplier
Exterior
Interior + Exterior
Interior + Exterior
Exterior
Exterior
Exterior
1
1
*1) when reusing shot or grit

*2) if conversion coating is applied
Technical information and instructions for use of every testing device, showing the
identification number and proof of calibration, must be available.
6-b-2 In-house control
The applicator has to monitor his production methods and products in accordance
with the following frequency and methods:
Reference
Test method
Interior
6-b-2.1
Inspection of coatability of parts All parts
6-b-2.2
Particle size of shot or grit
inapplicable
6-b-2.3
Surface roughness
None
All parts
Twice a year by supplier
Once per order at least once a day
Once per order and at least once a shift
Visual once a shift, and Chrome free
following the chemical supplier's
recommendations
(Once a month)
Once per shift and at least once per
order
At least 2 times per day and
systematically on a piece from outside
before blasting
6-b-2.4
Loss of zinc due to blasting
6-b-2.5
Assessment of blasted zinc and

None
film thickness
6-b-2.6
Dew point
Once a day
6-b-2.7
Blast cleanliness and dust

removal
Spot testing
All production by spot testing
6-b-2.8
Conversion coating
Inapplicable
Visual inspection
chemical assessment 4 times a year by
supplier
Inapplicable
Once a day
Inapplicable
If required once a shift
Inapplicable
Once a week
6- b-2.9
6-b-2.10
6.b-2.11
59/87
*1)
The temperature of conversion

*1)
and rinsing baths
*1)
Conductivity of rinsing water
*a)
drying temperature
*1)
Inapplicable
Exterior

January 2012
*1) Only applicable if conversion coating is applied.
*a) One measure in the bath before conversion and one measure in the drippings after final
rinse.
6-b-2.1 Coatability (5-a-1)
The objects to be treated must be inspected for coatability.
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.
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.
6-b-2.2 Grit or shot particle size (2-a-6)
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.
6-b-2.3 Surface roughness (2-a-7)
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).
6-b-2.4 Loss of zinc (3-c-3)
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. Blasting may not result in a loss of more than 10 %
of the zinc layer thickness.
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.
60/87

January 2012
6-b-2.5 Blast result of hot dip galvanized zinc (3-c-3)

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.
6-b-2.6 Dew point determination (2-a-11)
The dew point of the substrate to be blasted must be determined. This is done by measuring
the temperature of the air and the substrate and by measuring the relative humidity of the air.
From these test results the dew point can be calculated. The temperature of the substrate
must be at least 3 C higher than the air dew point temperature.
When applying a coating:
The coating supplier may accept a smaller difference between dew point and steel
temperature; such acceptance of a new limit must be confirmed in writing.
6-b-2.7 Inspection of surface cleaning after blasting (3-c-1)
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. 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).
6-b-2.8 Conversion coating (2-b-11)
If a conversion coating is used, the coating must be tested at least once a day (24 hours) in
accordance with the results specified by the chemicals supplier, using the test method
described in section 3.2.2. or the method advised by the chemicals supplier.
6-b-2.9 Conversion and rinsing baths temperature (3-c-10)
The temperature of each conversion bath and the final rinse, in case of a hot water rinse,
must be measured at least once a day (24 hours).
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January 2012
6-b-2.10 Conductivity of rinsing water (3-c-9)
The conductivity of the final rinse preceding the conversion bath and the demineralized
rinsing water must be measured. The coating applicator must increase the frequency of the
analyses of his own accord if proven necessary on account of the analyses made.
nominal values, maximum values not to be exceeded, actual values recorded and the
analysis, or recorded in the register.
6-b-2.11 Measuring the drying temperature (3-c-8 and 9)
The drying temperature must be measured at least once a week.
The temperature of the production metal and, simultaneously, the temperature shown on the
visual display unit must be read and recorded.
The temperature should be measured using a recording instrument or some other means
such as thermo chromic pencils or tablets. The results of these measurements and drying
curves should be recorded and kept on file.
6-b-3 Quality control registers
6-b-3.1 Production process control registers
This register with numbered pages, or a computer record - is to be maintained by the
laboratory supervisor.
charge number of the grit/shot when using new grit or shot;
blast and coatability of the substrate;
particle size of the grit (if requested);
surface roughness after blasting;
dew point and substrate temperature;
the loss of zinc film thickness as a result of pre-treatment;
inspection of blast result of surface;
cleanliness of the substrate after blasting;
the test results of the conversion coating;
temperature of baths;
conductivity of the rinsing water;
drying temperature.
62/87

January 2012
Appendix 6-c In-house control for powder coating applicators

6-c-1 Powder coatings laboratory equipment
Powder coatings inspection Equipment
To conduct the tests the powder coating applicator must have the following devices at
its disposal:
Instruments
Cutting devices and accessories for
cross cutting
Equipment to execute the impact test
Thickness tester, individual or multipurpose gauges
Gloss meter 60
Equipment to determine dew point
Device for measuring the maximum
substrate drying temperature.
Recording instrument for object
temperature and curing time with 4
measuring points
Test solutions for polymerization test
Equipment to conduct the boiling test
Type of license
Quantity
Interior + Exterior
Exterior
Interior + Exterior
Interior + Exterior
Exterior
1
1
Interior + Exterior
1 x or stickers
Interior + Exterior
1 (External may be
used)
Interior + Exterior
Exterior
If required
1
6-c-2 Finished products quality control
The applicator has to monitor his production methods and products. This table is a
concise list of the desired tests.
Reference
6-c-2.1
6-c-2.2
6-c-2.3
Test method
Cross-cut adhesion test
*2)
3)
Impact test *
Thickness
1)
measurement *
1)
6-c-2.4
Gloss measurement *
6-c-2.5
Dew point
6-c-2.6
Measurement of curing
temperature (object
1)
temperature * )
6-c-2.7
6-c-2.8
6-c-2.9
Polymerization test *
1)
Appearance test *
2)
Boiling test *
63/87
1)
Interior
Exterior
Once per shift
Once per shift
Inapplicable
In accordance with
testing plan
Once per order and per
shift
Inapplicable
Once a month by an
automatic temperature
test - using equipment to
measure the temperature
curve on 4 spots
If requested
Every order
Inapplicable
Once a day
According to testing plan
2
Once per order >100 m and at

least once per shift
Before starting application
Once a week by an automatic
temperature test - using
equipment to measure the
temperature curve on 4 spots
If requested
Every order
Once a week

January 2012
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
6-c-2.1 Adhesion (2-a-1) (EN ISO 16276-2)
Adhesion properties must be tested on sample panels for each colour shade and gloss
category and for each supplier of orders exceeding 100 m2.
The results must be recorded and kept on file.
6-c-2.2 Impact (EN ISO 6272 / ASTM D 2794)
(Tests 2-a-2 or 2-a-3)
The impact test must be conducted on sample panels for each colour shade and gloss
category and for each supplier of for orders exceeding 100 m2.
6-c-2.3 Coating thickness (2-a-9) (EN ISO 2360)
The coating thickness must be measured on the following number of samples:
Lot size *)
1 - 10
11 - 200
201 - 300
301 - 500
501 - 800
801 - 1,300
1,301 - 3,200
3,201 - 8,000
8,001 - 22,000
22,001 - 110,000
Number of samples
(random selection)
All
10
15
20
30
40
55
75
115
150
*) The number of items of similar shape and seize.
64/87
Acceptance limit for rejected

samples
0
1
1
2
3
3
4
6
8
11

January 2012
Alternative:
Coated parts in m2 or m
Number of measurements *1)
1
4
1-3
10
3 - 10
15
10 - 30
20
30 - 100
30
>100 *2)
For every 100 add 10 measurements
*1) The measurements must be representative of the inspected area.
*2) It is recommended to divide areas in excess of 1000 m2 into smaller
inspection parts
A minimum dry film thickness of 80 % of the requested dry film thickness is acceptable.
Dry film thicknesses of 80 to 100 % of the requested dry film thickness is acceptable if the
average dry film thickness is equal to or higher than the requested dry film thickness.
The maximum dry film thickness may be three times the requested average dry film
thickness.
The results are presented in the table:
Coating layers
Name
Average dry film thickness

Spec m
Remarks
Found m
st
primer coat(s) 1 coat

primer coat(s) 2nd coat
Edge protection
stripe coat(s),
Intermediate coat 1st coat
Intermediate coat 2nd coat
Topcoat 1st coat
Topcoat 2nd coat
Total nominal dry film thickness
The results of these measurements (minimum and maximum values) must be recorded and
kept on file.
6-c-2.4 Gloss (2-a-10) (EN ISO 2813)
For every order in excess of 100 m2 and every supplier of such an order, the coating gloss of
each colour shade on finished products must be tested at least once.
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.
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January 2012
6-c-2.5 Dew point (2-a-11)

Once per shift the dew point of the substrate to be coated must be determined. This is done
by measuring the temperature of the air and the substrate, as well as the relative humidity of
the air. From these test results the dew point can be calculated. The difference between the
air dew point and the surface temperature of the substrate must be at least 3 C. If the
coating supplier allows a lower temperature difference between dew point and steel
temperature, a written agreement must be available.
The results of these measurements must be recorded and kept on file.
6-c-2.6 Stoving conditions (2-a-12)
Once every week the curing temperature must be measured, using an electronic device
attached to the products in the oven on three height levels, and to one reference point.
kept on file.
6-c-2.7 Polymerization test (2-b-1)
Test to be carried out if requested by the costumer or coating material supplier.
This test is used to check that the coating polymerization suffices. 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.
6-c-2.8 Appearance (2-a-14)
The result must be inspected in accordance with the customers requirements.
Lot size *)
1 - 10
11 - 200
201 - 300
301 - 500
501 - 800
801 - 1,300
1,301 - 3,200
3,201 - 8,000
8,001 - 22,000
22,001 - 110,000
Number of samples
(random selection)
All
10
15
20
30
40
55
75
115
150
Acceptance limit for

rejected samples
0
1
1
2
3
3
4
6
8
11
*) a customer's complete order in one colour, or the part of the order that has already been
coated.
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January 2012
6-c-2.9 Boiling test (2-b-3)
Once a day, a boiling test must be conducted on test samples to determine the quality and
the adhesion of the system. The results of this test must be recorded and kept on file.
6-c-3 Quality control registers
6-c-3.1 Control registers for the production process
This register with numbered pages or a computer record - is to be maintained by the
dew point;
coatability.
General remark: the drying and stoving temperature curves must be archived.
6-c-3.2 Control registers for powder coating tests
production date;
references of the powder used;
system used;
RAL colour;
lot number;
producer's name;
corrosivity category.
The test results:
67/87
adhesion test;
impact test;
coating thickness;
gloss, required and result;
stoving conditions;
polymerization (if requested);
appearance;
boiling test results.

January 2012
6-c-3.3 Control registers for finished products

This register with numbered pages or a computer record - is to be kept at the end of the
production line.
After production, a copy must be sent to the laboratory supervisor.
the customer's name and the order or lot identification data;
the production date;
the reference of the powder used;
the Corrosivity Category of the environment in which the product will be 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).
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January 2012
Appendix 6-d In-house control for liquid coating applicators

6-d-1 Liquid coatings laboratory equipment
In order to be able to conduct the necessary tests, the coating applicators laboratory should
have the following devices and gauges at its disposal.
Instruments
Cutting devices and
accessories for cross cutting
Equipment to execute the
impact test
Wet thickness gauge
Thickness tester, individual
or multi-purpose gauges
Gloss meter 60
Equipment to determine dew
point
Temperature stickers for
measuring the maximum
temperature.
Recording instrument for
object temperature and
curing time with 4 measuring
points
Test solutions for
polymerization test
Equipment to conduct the
boiling test
Type of licence
Quantity
Interior + exterior
Exterior
Interior + Exterior
Interior + Exterior
Interior + Exterior
Exterior
Interior + Exterior
1
*1)
*1)
Interior and Exterior

(External equipment may be
used)
Interior + Exterior
Exterior
*1) Only when forced drying or curing ovens are used.

6-d-2 Production quality control
The applicator has to monitor his production methods and products. This table shows a
concise list of the desired tests.
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January 2012
Reference
Test method
Interior
6-d-2.1
Cross-cut adhesion test

2)
*
6-d-2.2
Impact test *
6-d-2.3
6-d-2.4
Dry and wet thickness

1)
measurement *
6-d-2.5
Gloss measurement *
6-d-2.6
Dew point
6-2-2.7
Measurement of curing
temperature (object
1)
temperature * )
6-d-2.8
6-d-2.9
6-d-2.10
Polymerization test
Appearance test
2)
Boiling test *
2)
1)
Exterior

Once per order and per shift
shift
Once per system on a test
Once per system on a test
panel
panel
In accordance with testing
In accordance with testing
plan
plan
2
Once per order > 100 m
and per shift
shift
Once per shift
Once per shift
Twice a day for actual
Twice a day for actual
temperature using a
temperature using a surface
surface temperature
temperature meter.
meter.
Once per order or per shift Once per order or per shift
Every order
Every order
Once a day
Once a day
The tests must be preferably done on products used in production.

*1) On production
*2) On test panel
6-d-2.1 Adhesion test (2-a-1) (EN ISO 16276-2)
For each colour shade, gloss category and supplier, the adhesion properties must be tested
on sample panels at least once every eight-hour work shift.
6-d-2.2 Impact test (EN ISO 6272) (2-a-3)
For each colour shade, gloss category and supplier, the impact test must be conducted on
sample panels at least once every eight-hour work shift.
6-d-2.3 Wet thickness test (2-a-8)
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.
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January 2012
6-d-2.4 Dry coating thickness test (2-a-9) (EN ISO 2360)

The coating thickness of the following number of samples must be measured.
Lot size *)
1 - 10
11 200
201 300
301 500
501 800
801 1,300
1,301 3,200
3,201 8,000
8,001 22,000
22,001 110,000
Number of samples
(random selection)
All
10
15
20
30
40
55
75
115
150

rejected samples
0
1
1
2
3
3
4
6
8
11
coated.
kept on file.
6-d-2.5 Gloss test (2-a-10) (EN ISO 2813)
For each colour shade and supplier, the finished products and sample panels coating gloss
must be tested at least once every 8-hour work shift.
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.
6-d-2.6 Dew point determination (2-a-11)
Once per shift the dew point of the substrate to be coated must be determined by measuring
the air and substrate temperatures as well as the relative humidity of the air. From these test
results the dew point can be calculated. The difference between the air dew point and the
temperature of the substrate must be at least 3 C. The results must be recorded and kept on
file.
6-d-2.7 Measurement of the drying temperature (2-a-13)
When drying at an ambient temperature, the curing temperature of the products must be
measured twice a day using a surface temperature gauge.
The substrate temperature of the substrate must be in accordance with the curing
temperature specified in the product data sheet.
The result has to be recorded and kept on file.
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January 2012
6-d-2.8 Polymerization test (2-b-1)

This test is only to be conducted if requested.
This test is used to check that the coating polymerization suffices. For each colour shade,
gloss category and supplier, the polymerization test must be conducted on sample panels at
least once every 8-hour work shift.
6-d-2.9 Appearance test (2-a-14)
Lot size *)
1 - 10
11 - 200
201 - 300
301 - 500
501 - 800
801 - 1,300
1,301 - 3,200
3,201 - 8,000
8,001 - 22,000
22,001 - 110,000
Number of samples
(random selection)
All
10
15
20
30
40
55
75
115
150

rejected samples
0
1
1
2
3
3
4
6
8
11
coated.
6-d-2.10 Boiling test (2-b-3)
Once a day a boiling test on test panels must be conducted for the complete system, to
determine the quality and the adhesion of the system.
6-d-3 Quality control registers
6-d-3.1 Production process control registers
72/87
wet film thickness;
dry film thickness;
drying conditions.

January 2012
6-d-3.2 Control registers for tests on liquid coatings
The register must show the following results:
adhesion;
impact test;
fry film thickness (final thickness);
gloss (if requested);
polymerization (if requested);
appearance;
boiling test;
a copy of the productions results register.
6-d-3.3 Finished products control registers

This register with numbered pages or a computer record - is to be kept at the production line.
When the job is finished a copy is sent to the laboratory supervisor.
73/87
the production date of the different coating layers;
the references of the coating used;
RAL colour;
lot number;
producer's name;
product name;
corrosivity category of the environment in which the product will be used;
coating system used.

January 2012
Appendix 7-a Approval of powder coating systems

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.
7-a-1 Test for approval of powder coating systems
The following tests must be conducted to assess the coating systems compliance:
1.
gloss (2-a-10);
2.
thickness of coating (2-a-9);
3.
adhesion (2-a-1);
4.
impact test (2-a-2 or 2-a-3);
5.
polymerization test (2-b-1) (solvent mixture information);
6.
resistance to mortar (2-b-2);
7.
resistance to boiling water (2-b-3);
8.
neutral salt spray test (2-b-4);
9.
constant atmosphere of condensation (2-b-5);
10. colour resistance test (2-b-7);

11. accelerated weathering test (2-b-8);
12. weathering test (Florida) (2-b-9).
Coating systems have to be approved in accordance with the quality labels requirements by
1st January 2012, prior to being applied.
The QUALISTEELCOAT coating material system will be tested in accordance with the
requirements of the Corrosivity Category for which approval is sought.
When approved, the system will obtain a QUALISTEELCOAT identification number
with the addition of I for interior coating systems, E for exterior coating system,
and the Corrosivity Category for which the system has been tested 4m.
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.
Any change in the formula of the powder 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).
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January 2012
7-a-2 Granting approval of a powder coating system

The following tests have to be conducted to obtain approval for a powder coating system
when used in specific environments in accordance with EN ISO 12944-2.
Environment
Test
1. gloss
2. thickness of coating
3. adhesion
4. impact test
5. polymerization test
6. resistance to mortar
7. resistance to boiling water
8. neutral salt spray test
9. const. atm. of condensation
10. colour resistance test
11. accelerated weathering test
12. weathering test (Florida)
Categories 1-2
interior
X
X
X
X
-
Category 2
exterior
X
X
X
X
X
X
X
X
X
X
X
X
Categories
3, 4, 5
X
X
X
X
X
X
X
X
X
X
X
X
The tests have to be conducted in triplicate (mechanical tests) with the required basic
material (corrosion tests) coated in cooperation with the testing institute. The average value
of the three samples is used to evaluate the results.
The following colour has to be tested:
white RAL 9010
The test panels are prepared by the testing institute conducting the coating materials tests.
The test panels may be coated elsewhere provided that the laboratory inspector is present
during the whole operation. The inspector always chooses the lowest curing temperature and
shortest time specified by the manufacturer.
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 (see appendix 3-c and 3-d) meet
the requirements.
The paint manufacturer must inform the Committee of the solvent mixture used for
the Polymerization test.
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.
Tests 1 to 12 can be repeated upon demand.
Weathering resistant systems granted temporary approval will receive final approval upon
receipt of satisfactory weathering test results. If not, the temporary approval is withdrawn.
75/87

January 2012
7-a-3 Annually recurrent test approval

The permanent quality of the approved systems for coating powder is tested annually by
performing tests 3, 7 and 8 salt spray. The test panels are prepared using commercial
products collected by the QUALISTEELCOAT inspector during inspection. When the
samples are collected three additional sample panels are prepared and sent to the coating
supplier.
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.
76/87
In case the results of the stipulated tests 3, 7 and 8 meet the requirements, the
approval is renewed.
In case of non-compliance, the tests are repeated on samples taken from another
batch within one month.
In case the second testing does not lead to satisfactory results, the approval is
immediately withdrawn. The manufacturer of the tested product can submit a new
application for approval but not within three months of the withdrawal.

January 2012
Appendix 7-b Approval of liquid coating systems

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.
7-b-1 Test for approval of liquid coating systems
The following tests must be conducted to assess the coating systems compliance.
1.
gloss (2-a-10);
2.
thickness of coating (2-a-9);
3.
adhesion (2-a-1);
4.
impact test (2-a-2 or 2-a-3);
5.
polymerization test (2-b-1) (solvent mixture information);
6.
resistance to mortar (2-b-2);
7.
resistance to boiling water (2-b-3);
8.
neutral salt spray test (2-b-4);
9.
constant atmosphere of condensation (2-b-5);
10. colour resistance test (2-b-7);

11. accelerated weathering test (2-b-8);
12. weathering test (Florida) (2-b-9).
The QUALISTEELCOAT paint system will be tested in accordance with the
requirements of the Corrosivity Category for which approval is sought.
When approved, the system will obtain a QUALISTEELCOAT identification number
with the addition of I for interior coating systems, E for exterior coating system,
and the Corrosivity Category for which the system has been tested 4 m.
Coatings have to be approved in accordance with the quality labels requirements prior to
being applied.
Any change in the formula of the coating systems, (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.
The manufacturer must not use the approval for a smooth surface.
The systems finished using a full colour is different from systems using MIO finishes. The
stipulation of textures is subject to QUALISTEELCOAT-drafts.
7-b-2 Granting approval of a liquid coating system
The following tests have to be conducted to obtain approval for a liquid coating system when
used in specific environments in accordance with EN ISO 12944-2.
77/87

January 2012
Environment
Test
1. gloss
2. thickness of coating
3. adhesion
4. impact test
5. polymerization test
6. resistance to mortar
7. resistance to boiling water
8. neutral salt spray test
9. const. atm. of condensation
10. colour resistance test
11. accelerated weathering test
12. weathering test (Florida)
Categories 1-2
interior
X
X
X
X
-
Category 2
exterior
X
X
X
X
X
X
X
X
X
X
X
X
Categories
3, 4, 5
X
X
X
X
X
X
X
X
X
X
X
X
The tests have to be conducted in triplicate (mechanical tests) with the required basic
material (corrosion tests), having undergone appropriate surface preparation, coated by an
application firm. The testing institute is closely involved in the entire process. The average
value of the three samples is used to evaluate the results.
The following colours have to be tested:
white RAL 9010
or Mio coat medium grey
The test panels are manufactured by the testing laboratory in the production facilities of an
application firm chosen by the paint supplier on the basis of the application firms surface
preparation. The application must be executed in close cooperation with the testing institute
that will conduct the tests on the coating materials. The testing laboratory inspector must be
present during the whole operation. The inspector always chooses the shortest drying time
between the subsequent layers as specified by the manufacturer.
The laboratory submits the test report to the National Association. If there is no National
Association in the country in question, the report is 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 (see appendix 3-c and 3-d) meet the
requirements.
The committee is to be informed of the solvent mixture used for the Polymerization
test.
Should approval be withheld based on dissatisfactory test results, the manufacturer of
the tested product will informed in detail as to the reasons for withholding approval.
Tests 1 to 12 can be repeated upon demand.
Weathering resistant systems granted temporary approval will receive final approval upon
receipt of satisfactory weathering test results. If not, the temporary approval is withdrawn.
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January 2012
7-b-3 Annually recurrent test approval

The permanent quality of the approved systems is tested annually by performing tests 3, 7
and 8, salt spray. The test samples are collected annually and prepared from paint products
used by QUALISTEELCOAT licensees.
The QUALISTEELCOAT inspector will collect these samples and send a set of tree sample
panels to the coating manufacturer for reference.
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 stipulated tests 3, 7 and 8 meet the requirements, the
approval is renewed.
In case of non-compliance, the tests are repeated on samples taken from another
batch within one month.
In case the second testing does not lead to satisfactory results, the approval is
immediately withdrawn. The manufacturer of the tested product can submit a new
application for approval but not within three months of the withdrawal.
7-b-4 Training
QUALISTEELCOAT licensees quality assurance staff is to be retrained within two years,
starting from 1st January 2012 (QUALISTEELCOAT in-house training).
79/87

January 2012
Appendix 8-a Issuing a QUALISTEELCOAT licence

During the inspection, the inspector will check the following points using the inspection
form approved by QUALISTEELCOAT.
8-a-1 Inspection of coating materials
The inspector will check that the coating applicator uses coating systems approved by
QUALISTEELCOAT (chapter 7).
8-a-2 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.
8-a-3 Inspection of process, production and equipment
8-a-3.1 Inspection of test equipment
Equipment at the laboratory;
Equipment at the production lines.
See In-house control (6-a, b, c and d)

8-a-3.2 Inspection of pre-treatment
See Surface pre-treatment (appendix 3-c)
8-a-3.3 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 which 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:
80/87
Appearance (to test the uniformity of production)
Coating thickness
Gloss (only topcoat)

January 2012
8-a-4 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
8-a-5 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.
8-a-6 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 meet 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-a-7 Routine inspections of licensees
After a plant has been granted a licence to use the quality label, it will be inspected at least
twice a year. Routine inspections must be made without prior notice and must include the same
items as for granting a license.
The inspector submits the inspection report to the general licensee. If no general licensee is
available the report will be sent to QUALISTEELCOAT.
81/87

January 2012
The inspection reports are assessed by the general licensee or by QUALISTEELCOAT in
countries where there is no general licensee.
If the results of the inspection meet the requirements, authorisation to use the quality
label will continue.
If the results of the inspection do 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-a-8 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.
82/87

January 2012
Appendix 9-a Table RAL/DELTA E (adm. colour deviation after weathering in Fl.)
RAL
Delta E RAL
Delta E RAL
Delta E RAL
Delta E RAL Delta E RAL
Delta E RAL
Delta E RAL
Delta E RAL
Delta E
1000
1001
1002
1003
1004
1005
1006
1007
1011
1012
1013
1014
1015
1016
1017
1018
1019
1020
1021
1023
1027
1028
1032
1038
3.0
3.0
3.0
2.0
6.0
6.0
6.0
6.0
3.0
3.0
2.0
3.0
2.0
6.0
3.0
6.0
3.0
6.0
6.0
3.0
3.0
8.0
6.0
2.0
6.0
8.0
8.0
6.0
8.0
6.0
4.0
6.0
6.0
4.0
4.0
4.0
4.0
4.0
6.0
8.0
6.0
4.0
3.0
5.0
8.0
8.0
4.0
8.0
6.0
4.0
4.0
8.0
5.0
4.0
5.0
4.0
5.0
5.0
5.0
5.0
5.0
3.0
4.0
4.0
5.0
4.0
5.0
4.0
4.0
3.0
4.0
4.0
5.0
5.0
4.0
2.0
2.0
4.0
3.0
5.0
5.0
2.0
5.0
5.0
2.0
2.0
4.0
3.0
4.0
4.0
4.0
4.0
4.0
4.0
4.0
4.0
4.0
4.0
4.0
4.0
3.0
4.0
4.0
3.0
4.0
4.0
2.0
4.0
2.0
3.0
3.0
2.0
3.0
3.0
2.0
4.0
3.0
3.0
2.0
4.0
4.0
4.0
4.0
4.0
4.0
4.0
4.0
4.0
4.0
4.0
4.0
3.0
5.0
4.0
4.0
3.0
4.0
2.0
2.0
2.0
5.0
2.0
2.0
2.0
5.0
2.0
2.0
83/87
2000
2001
2002
2003
2004
2008
2009
3000
3002
3003
3004
3005
3007
3009
3011
3012
3013
3014
3015
3016
3017
3018
3020
3022
3027
4001
4002
4003
4004
4005
4007
4009
5000
5001
5002
5003
5004
5007
5008
5009
5010
5011
5012
5013
5014
5015
5017
5018
5019
5020
5021
5022
5023
4.0
4.0
4.0
5.0
5.0
4.0
5.0
4.0
4.0
5.0
4.0
5.0
4.0
3.0
5.0
5.0
4.0
5.0
4.0
5.0
4.0
6000
6001
6002
6003
6004
6005
6006
6007
6008
6009
6010
6011
6012
6013
6014
6015
6016
6017
6018
6019
6020
6021
6024
6025
6026
6027
6028
6029
6033
6034
7000
7001
7002
7003
7004
7005
7006
7008
7009
7010
7011
7012
7013
7015
7016
7021
7022
7023
7024
7026
7030
7031
7032
7033
7034
7035
7036
7037
7038
7039
7040
7043
7044
8000
8001
8003
8004
8007
8008
8011
8012
8014
8015
8016
8017
8019
8022
8024
8025
8028
8070
9001
9002
9003
9005
9006
9007
9010
9011
9016
9018

January 2012
Appendix 10-a Specification of the standards

N
YEAR
TITLE
SPECIFICATIONS
EN 13438
2005
Paints and varnishes - Powder organic coatings for galvanized

or sherardised steel products for construction purposes
EN 15773
2009
Industrial application of powder organic coatings to hot dip

galvanized or sherardized steel articles [duplex systems] Specifications, recommendations and guidelines
2-b-2; 2-b-3; 2-b-4;

2-b-9; 2-b-13; 3-b-c;
4-b-4
4-b-4
EN ISO 1461
2009
Hot dip galvanized coatings on fabricated iron and steel

articles - Specifications and test methods (ISO 1461:2009)
EN ISO 1514
2004
Paints and varnishes - Standard panels for testing

(ISO 1514:2004)
EN ISO 1518
2000
Paints and varnishes - Scratch test (ISO 1518:1992)
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)
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
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
EN ISO 2813
1999
Paints and varnishes - Determination of resistance to liquids Part 1: Immersion in liquids other than water
(ISO 2812-1:2007)
Paints and varnishes - Determination of specular gloss of nonmetallic paint films at 20, 60 and 85 (ISO 2813:1994,
including Technical Corrigendum 1:1997)
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
degree of rusting (ISO 4628-3:2003)
2-b-4; 2-b-6; 2-b-7
EN ISO
4628-4
2003
degree of cracking (ISO 4628-4:2003)
2-b-4; 2-b-5; 2-b-6;

2-b-7
84/87
3-a-2
2.1
2.2.4; 2-a-4
6-c-2.3; 6-d-2.4
2-3-6; 2-b-6
2-a-10; 2-b-8; 2-b-9;

6-c-2.4; 6-d-2.5

January 2012
YEAR
EN ISO
4628-5
2003
degree of flaking (ISO 4628-5:2003)
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
Geometrical Product Specifications (GPS) - Surface texture:

Profile method; Measurement standards - Part 2: Software
measurement standards (ISO 5436-2:2001)
2-a-7; 6-b-2.3
2001/2 Geometrical Product Specifications (GPS) - Surface texture:

008
Profile method; Measurement standards - Part 2: Software
measurement standards (ISO 5436-2:2001/Cor 1:2006/
Cor 2:2008)
2-a-7; 6-b-2.3
EN ISO
5436-2/AC:
TITLE
SPECIFICATIONS
2-b-4; 2-b-5; 2-b-6;
2-b-7
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

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
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

related products - Surface roughness characteristics of blastcleaned 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

related products - Surface roughness characteristics of blastcleaned 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
85/87

January 2012
YEAR
TITLE
SPECIFICATIONS
EN ISO
8503-3
1995
2-a-7
EN ISO
8503-4
1995

related products - Surface roughness characteristics of blastcleaned steel substrates - Part 3: Method for the calibration of
ISO surface profile comparators and for the determination of
surface profile-Focusing microscope procedure
(ISO 8503-3:1988)
related products - Surface roughness characteristics of blastcleaned steel substrates - Part 4: Method for the calibration of
ISO surface profile comparators and for the determination of
surface profile - Stylus instrument procedure
(ISO 8503-4:1988)
EN ISO 9227
2006
Corrosion tests in artificial atmospheres - Salt spray tests

(ISO 9227:2006)
2-b-4
EN ISO
11125-2
1997

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
EN ISO
11127-2
1997

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)
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

by protective paint systems - Part 2: Classification of
environments (ISO 12944-2:1998)
1; 4.1
EN ISO
12944-3
1998

by protective paint systems - Part 3: Design considerations
(ISO 12944-3:1998)
EN ISO
12944-4
1998

by protective paint systems - Part 4: Types of surface and
surface preparation (ISO 12944-4:1998)
3; 3-c-1; 3-c-2; 4-a-2;

4-a-3
EN ISO
12944-5
2007

by protective paint systems - Part 5: Protective paint systems
(ISO 12944-5:2007)
4.1; 7
EN ISO
12944-6
1998

by protective paint systems - Part 6: Laboratory performance
test methods (ISO 12944-6:1998)
2.3.6; 2.3.7; 2-b-6
EN ISO
12944-7
1998

by protective paint systems - Part 7: Execution and supervision
of paint work (ISO 12944-7:1998)
5-a
EN ISO
12944-8
1998

by protective paint systems - Part 8: Development of
specifications for new work and maintenance
(ISO 12944-8:1998)
86/87
2-a-7
2-b-8

January 2012
YEAR
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)
EN ISO/IEC
17025
2005
General requirements for the competence of testing and

calibration laboratories (ISO/IEC 17025:2005)
EN ISO/IEC
17025:2005/
AC
ISO 105-AO2
2006
General requirements for the competence of testing and

calibration laboratories (ISO/IEC 17025:2005/Cor.1:2006)
1993
Textiles - Tests for colour fastness - Part A02: Grey scale for
assessing change in colour (ISO 105-A02:1993)
ISO 7724-3
1984
Paints and varnishes - Colorimetry - Part 3: Calculation of

colour differences
ISO 9223
1992
Corrosion of metals and alloys - Corrosivity of atmospheres Classification
ISO 15184
1998
Paints and varnishes - Determination of film hardness by

pencil test
87/87
TITLE
SPECIFICATIONS
2.2.1; 2-a-1; 6-c-2.1;
6-d-2.1
2-b-10
2-b-8; 2-b-9
a-1
2.2.5; 2-a-5

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QUALISTEELCOAT version 2.

QUALISTEELCOAT version 2.0

Chapter 1 General information!.................................................................................................!3!

QUALISTEELCOAT version 2.0

Chapter 1 General information

Permission for a coating applicator to use the

Confirmation that a specific coating system meets the

General Licensee (GL):

National association holding the QUALISTEELCOAT Master

Independent quality testing laboratories duly approved by the

The technical specifications are based on atmospheric corrosivity categories in accordance

The specifications laid down in this document concern:

the different processes used for steel protection;

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

the performance of applied coating systems in relation to Corrosivity 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

QUALISTEELCOAT version 2.0

QUALISTEELCOAT version 2.0

Chapter 2 Test methods

2.1 Test panels

2.2 Mechanical tests (appendix 2-a)

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

EN ISO 2409 Cross-cut test equipment and results

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

QUALISTEELCOAT version 2.0

2.2.3 Impact resistance test (2-a-3)

QUALISTEELCOAT version 2.0

2.3 Chemical and environment tests (appendix 2-b)

QUALISTEELCOAT version 2.0

2.3.10 Colour difference (2-b-10)

QUALISTEELCOAT version 2.0

Chapter 3 Surface preparation (EN ISO 12944-4)

3.2 Storage of parts to be treated

3.3 Removal of contamination

3.4 Pre-treatment for powder and liquid coating systems

QUALISTEELCOAT version 2.0

Chapter 4 Coating systems

The temperature of the cleaning water at the moment of impact must be

QUALISTEELCOAT version 2.0

Chapter 5 Application of coatings

5.2 Powder coating

QUALISTEELCOAT version 2.0

5.2.2.Oven drying (5-b-2)

QUALISTEELCOAT version 2.0

Chapter 6 Applicators in-house control

6.1 In-house control pre-treatment and application

QUALISTEELCOAT version 2.0

Chapter 7 Approval of coating systems

type of surface pre-treatment;

minimal dry film thickness per layer;

coating products for primer, midcoat and topcoat;

In appendix 4-b, examples of powder coating systems are given.

QUALISTEELCOAT version 2.0

Chapter 8 Licence for coating applicators

QUALISTEELCOAT version 2.0

Appendix 1-a Corrosivity category

Examples of typical environments

Heated buildings with

> 0,1 to 0,7

> 0,7 to 2,1

Production rooms with

> 2,1 to 4,2

Industrial areas and