Testing procedures - Senze-Instruments Benelux

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Process & Quality Control

Testing procedures

Qualicoat > Qualicoat
2. Test Methods and Requirements

2.2. Gloss
2.4. Adhesion
2.6. Cupping test (only for the approval of organic coatings)
2.7. Bend test   Model 266 S
2.9. Resistance to humid atmospheres containing sulphur dioxide  
2.10. Acetic acid salt spray resistance  Refractometer      Analyse    Tools
2.12. Accelerated weathering test
2.12.1 Accelerated weathering test for classes 1, 1.5 and 2  Cycle 1 (102 min dry/18 min wet))   (SOLARBOX  E RH offers also immersion system).
After 1000 hours exposure the test panels shall be rinsed with demineralised water and  checked for:
- Gloss variation: ISO 2813 - angle of incidence 60°      &  SPEKTROMASTER 565-D
- Colour change: CIELAB Delta E*ab using the formula in ISO 11664-4, measurement  including specular reflection.   SPEKTROMASTER 565-D
2.12.2 Accelerated weathering test for class 3  (Florida exposure test of 3  years) (corrocutter)
2.13. Natural weathering test  (Exposure in Florida according to ISO 2810)     SPEKTROMASTER 565-D
2.14. Polymerisation test (Prescribed solvent for liquid coatings: MEK

2.16. Resistance to boiling water
2.18. Sawing, milling and drilling (corrocutter)
2.19. Filiform corrosion test (Corrosion is produced by dripping hydrochloric acid)   Model 463
2.21. Scratch and mar resistance test (Martindale)  (gloss)

3. WORK SPECIFICATIONS
3.1. Storage of the products to be treated and layout of equipment  
3.1.1  Storage
3.1.1  Layout of equipment
3.2. Surface preparation  
3.2.1 Etching stage
Different types of etching are possible:
▪ Type A : acid etching
• Type A1: simple acid etching
• Type A2: acid etching + acid etching
▪ Type AA : dual etching
• Type AA1: alkaline etching and acid etching
• Type AA2: acid etching + alkaline etching + acid etching
The etching degree is measured by taking the weight of a test sample before and after  etching.
Two preliminary pretreatments are defined:
a) Standard pretreatment (compulsory) The total etching degree shall be at least 1.0 g/m2 .
b) Enhanced pretreatment (for SEASIDE endorsement) This pretreatment includes degreasing either in an independent step or in a combined  degreasing/etching step.
The total etching degree shall be at least 2.0 g/m2 . For type AA (dual etching) the two final steps shall be at least 0.5 g/m2.
3.3. Chemical conversion coatings  
3.3.1 Chromate conversion coatings
Demineralised water shall be used for the final rinse after chemical chromate conversion before drying.  (Beakers)
The conductivity of the dripping water shall not exceed a maximum of  30 µS/cm at 20°C. The conductivity should only be measured for open sections and not  for hollow sections. The weight of the chromate conversion coating shall be between 0.6 and 1.2 g/m² for  chemical chromate conversion (yellow coating)
and between 0.6 and 1.5 g/m² for  chemical chromate-phosphate conversion (green coating).
3.3.2 Chemical pretreatments  
The conductivity of the dripping water of all chemical pretreatment systems with a final  rinse shall not exceed a maximum of 30 μS/cm at 20°C. (Beakers)
3.4. Anodic pretreatment (automatic SEASIDE endorsement)  
The anodic pretreatment parameters can be as follows:
- Acid concentration (sulphuric acid): 180-220 g/l  (Beakers)
- Aluminium content: 5-15 g/l
- Temperature: 20-30°C (+/- 1°C of the temperature chosen by the coater)
- Current density: 0.8-2.0 A/dm² - Agitation of the electrolyte
Record of test results
Coating applicators using this type of anodic pretreatment shall perform and record the following additional tests:
• Anodising bath
- The acid concentration and aluminium content of the anodising bath shall be  analysed once per day.
- The temperature of the anodising bath shall be checked every 8 hours.
- The etching rate shall be checked once per day.
- The thickness of the anodic coating shall be checked (every load).
• Testing of the coated finished products
- Before application, each coating (of a system and/or a manufacturer) shall be  tested for resistance to boiling water, followed by an adhesion test (see § 2.4).  - During application, resistance to boiling water shall be tested, followed by an  adhesion test every 4 hours.
3.5. Electrophoretic coatings  
The cleaned surfaces shall be rinsed in demineralised water with a  maximum conductivity of 30 µS/cm at 20°C prior to coating.
3.6. Drying
After chemical pretreatment and before the application of organic coating, the products  shall be dried thoroughly in an oven. For this purpose, a drying oven shall be installed in  each plant.
For continuous treatment9 the maximum drying temperature allowed is 100°C.
For discontinuous treatment the products shall be dried at the following temperatures:
- chemical chromate conversion (yellow coating): maximum 65°C
- chemical chromate-phosphate conversion (green coating): maximum 85°C
3.7. Coating and stoving
3.7.1 Coating
3.7. 2 Stoving
The coating line shall have an oven for drying and one for curing; in cases where the  oven is combined (performing both functions), an efficient control system for temperature  and time shall be in place to ensure that suppliers’ recommended conditions can be  followed.
It should be possible to measure the temperature over the whole length of the oven.
3.8. Laboratory
The coating plant installation shall have laboratory facilities which are separate from the  production facilities.
The laboratory shall have the apparatus and chemicals necessary  for testing and controlling the process solutions and finished products.
The laboratory  shall at least be equipped with the following apparatus:
3) 1 analytical balance (precision 0.1 mg)
4) Cutting tools and instruments necessary for performing the adhesion test
6) Recorder for stoving temperature and time with four different measuring points,  three on the parts and one to measure the air temperature.
8) Apparatus for testing resistance to cracking on bending
9) Test solutions for the polymerisation test
11) Device prescribed for the analytical coating weight determination (only for chemical pretreatment according to § 3.3.2)
       The conductivity of the dripping water of all chemical pretreatment systems with a final  rinse shall not exceed a maximum of 30 μS/cm at 20°C.
Each piece of apparatus shall have a data sheet showing the apparatus identification  number and calibration records.
The oven temperature recorder shall be checked, and the results shall be registered at  least twice per yea
3.9. In-house control  
3.10. Operating Instructions  
3.11. Registers  

4. APPROVAL OF ORGANIC COATINGS  
4.1. Granting of an approval
Any modification of the chemical properties of the binder (resin(s) and/or hardening  agent(s) is tantamount to a new product and absolutely requires a new QUALICOAT  approval
4.1.1 Technical information  
4.1.2 Minimum laboratory equipment
2) Instruments for measuring coating thickness
3) Apparatus for testing resistance to cracking on bending
4) Cutting tools and instruments necessary for performing the adhesion test
5) Instrument for measuring indentation hardness
6) Apparatus for cupping test
8) Apparatus for controlling stoving temperature and time
9) System for checking polymerisation
11) Apparatus for accelerated weathering test12
13) RAL GL cards  (RAL-K5 Glossy or RAL 841-GL)
4.1.3 Tests for granting an approval
Tests for granting an approval
The following tests shall be made:
- Gloss (2. 2)
- Dry adhesion (2.4.1)
- Indentation (2.5)
- Cupping test (2.6)
- Bend test (2.7)   Model 266 S
- Impact test (2.8) 11
- Resistance to humid atmospheres (2.9)     
- Accelerated weathering test (2.12)    + Gloss variation: ISO 2813 (angle of incidence 60°)  & Colour change:
- Polymerisation test (2.14)
- Resistance to mortar (2.15)
- Wet adhesion (2.4.2)    Resistance to boiling water
        No blistering in excess of 2 (S2) according to ISO 4628-2.

- Condensation water test (2.17)
          No blistering in excess of 2 (S2) according to ISO 4628-2
TEST METHOD
The test shall be performed on one panel. The demineralised water shall be heated up to 60°C in a beaker of the proper size and  kept under stirring to uniform temperature. The test panel shall be immersed for a half in water. Care must be taken not to put the  panel in contact with the bottom of the beaker. The panel shall be immersed for 24  hours at 60 ± 1°C. The glass shall be properly covered to avoid water evaporation. At the end of the test, the panel shall be immediately cooled down in demineralised  water at a temperature of ≤ 5°C. It shall then be dried with paper towels without  rubbing.  Colour change: Delta E and Delta L CIELAB formula according to ISO 11664-4, measurement  including specular reflection.
- Scratch and mar resistance test Martindale (2.21)
REQUIREMENTS: Gloss retention
The gloss retention shall be at least
• 60% for organic coatings with a structured appearance in all classes
• 40% for class 1 and 1.5 smooth organic coatings
• 30% for class 2 and 3 smooth organic coatings
- Natural weathering (Florida) (2.13)
REQUIREMENTS:
4.1.4 Basic colours to be tested for standard approvals and metallic extension
Classes 1, 1.5 and 2  The following colours shall be tested (independently of gloss category or appearance):
- white RAL 9010
- blue RAL 5010
- red RAL 3005
Class 3 The following RAL colours shall be tested:
• Lightness category LIGHT - RAL 1015 - RAL 7035 - RAL 9010
• Lightness category MEDIUM - RAL 1011 - RAL 7040 - RAL 8024
• Lightness category DARK - RAL 7016  - RAL 8019 - RAL 9005
4.1.4.2 Metallic extension
For all classes; if a manufacturer wishes to have an approval extended for metallic colours, tests shall be carried out on RAL 9006.   RAL K5 glossy
4.1.5  Basic colours to be tested for special approvals
If a coating material is produced for a single colour, tests shall be carried out only on the  colour mentioned in the system name. The tests are the same as those specified in  § 4.1.3. No other colours may be produced under the same approval number.
4.1.5.1 Special approvals valid for single colours
The manufacturer shall send coating materials and coated samples to the laboratory in  charge, together with the relevant technical data sheet for each colour. The data sheet  shall include at least the following information: colour, gloss value and curing conditions  (including range of times and temperatures). The testing laboratory shall prepare the test samples on its premises using chromium VIfree chemical pretreatment and the coating materials supplied by the manufacturer. The  test samples may also be coated elsewhere provided that the inspector is present during  the whole time of treatment.  The testing laboratory shall always select the minimum stoving time and temperature  specified by the manufacturer. After checking the colour and gloss, the laboratory shall  perform the above-mentioned tests on the samples.
4.1.6 Assessment of test results
The testing laboratory shall submit the test report to the General Licensee or to  QUALICOAT in countries where there is no General Licensee.
4.1.8 Inspection of coating manufacturer’s plant
A visit shall be required for new applicants in order to check the laboratory equipment of  the coating manufacturer’s plant.
4.2. Renewal of an approval  
4.2.1 Laboratory tests and Florida exposure  
4.2.1.1 Renewal of class 1 and class 1.5 approvals  
4.2.1.2 Renewal of class 2 and class 3 approvals  
4.2.1.3 Renewal of special approvals  
4.2.2 Sampling
4.2.3 Assessment of laboratory test results
4.2.4 Assessment of the Florida test results  
4.2.5 Banned colours
QUALICOAT shall publish on www.qualicoat.net the colours currently banned according  to § 4.2.4, including colours suspended according to § 4.2.6, for every approved organic  coating P-No. by the end of August.  Banned colours shall not be used under QUALICOAT’s approval.
4.2.6 Suspended colours  
A colour shall have the status “suspended” in case of:
• an unsatisfactory accelerated weathering test, with samples sent to Florida for the  natural weathering test;
• satisfactory results of the laboratory tests on a banned colour, with samples sent to  Florida for the natural weathering test.
4.2.7 Withdrawal of an approval or extension
4.2.8 Procedure for unbanning colour families for class 2
4.3. Powder manufacturer’s right of appeal
4.4. Use of the logo by coating manufacturers

5. LICENSING OF COATING APPLICATORS
5.1. Granting of a licence (quality label)
5.1.1 Inspection of materials  
5.1.2 Inspection of laboratory equipment
5.1.3 nspection of production process and equipment  
5.1.4 Inspection of chemical pretreatment
5.1.5Inspection of finished products
The inspector shall perform the following tests on the finished products:
- Appearance (to test the uniformity of production) (2.1)
- Thickness (2.3)
- Dry adhesion (2.4.1) and wet adhesion (2.4.2)
- Acetic acid salt spray (2.10)    (corrocutter)
- Machu (2.11)
- Sawing (2.18)
5.1.6 Inspection of the test panels  
5.1.7Review of in-house control and registers  
5.1.8 Final assessment for granting the licence
5.1.9 “SEASIDE” endorsement
5.2. Routine inspections of licensees  
The inspectors shall take along the following equipment:
- Thickness meter
- Conductivity
- Calibration tools for the other tests stipulated
5.3. Coating applicator’s right of appeal
5.4. Confidentiality of information  
5.5. Deadlines for submission of inspection reports
5.6. Use of the logo by coating applicators

6. SPECIFICATIONS FOR IN-HOUSE CONTROL
The aim of in-house control is to give the coating plant a tool to keep control over its own  production process.
The number of shifts worked, the requirements, the results of the  analyses and corrective actions shall be entered in charts or some other  records/registration systems readily accessible to the inspector.
The staff responsible for managing in-house control shall follow the training programme  stipulated by QUALICOAT.
6.1 . Controlling the production process parameters
6.1.1Chemical pretreatment baths  
The chemical parameters defined by the manufacturer of the chemical pretreatment  materials shall be analysed at least once per bath in every working shift
6.1.2  Water quality
The conductivity of the final rinsing preceding chromate bath and of the demineralised  rinsing water shall be measured at least once per bath in every working shift (Beakers)
6.1.3  Measuring the temperature of chemical pretreatment and rinsing baths
The temperature of the pretreatment baths and the final rinse, if a hot water rinse, shall  be measured at least once per bath in every working shift,
6.1.4 Recording and measuring the drying temperature  
The drying temperature displayed shall be recorded at least once in every working shift. The temperature should be measured on parts at least once a week using a recording  instrument or some other means such as thermochromic pencils or tablets.
6.1.5 Measuring the stoving conditions
The stoving conditions according to § 3.7 shall be tested as follows:
• The displayed temperature shall be recorded at least once in every working shift.
• A stoving curve shall be made on profiles at least twice a week.
6.2. Quality control of the chemical pretreatment  
6.2.1 Testing the etching degree
The etching degree is measured by taking the weight of a test sample before and after  etching.
6.2.2Testing the weight of the conversion coating
The weight of chromate conversion coating shall be tested in accordance with ISO 10546 at least once in every working shift
6.3. Quality control of the finished products  
6.3.1 Gloss test (ISO 2813)  
6.3.2 Coating thickness test (ISO 2360)
6.3.3 Appearance test
6.3.4 Adhesion test
6.3.4.1 Dry adhesion (ISO 2409)  
The same panel to be chosen for dry adhesion test, bend test and impact test.
6.3.5 Polymerisation test
6.3.6 Bend test (ISO 1519)  Model 266 S
6.3.7 Impact test (ISO 6272 / ASTM D 2794)
6.4. Quality control registers  
6.4.1 Control register for the production process
6.4.2 Control register for test panels
This control register is either a bound register (not a spiral binding) with numbered pages,  or a computer listing. It shall show the following information:
- the production date
- the references of the organic coating material used: RAL or some other reference  for identification, lot number, manufacturer's name   
- the following results:
- gloss test
- thickness test
- adhesion test
- polymerisation test (optional for powder coatings)
- bend test   Model 266 S
- impact test
- colour shade inspection (visual inspection to compare the actual colour  with the colour shade required by the customer)  SPEKTROMASTER 565-D
6.4.3 Control register for finished products
It is either a bound register (not a spiral binding) with numbered pages, or a computer  listing.
It shall show the following information
- the customer's name and the order or lot identification data
- the production date
- the reference of the organic coating material used
- the following results:
- coating thickness test (minimum and maximum values)
- inspection of the colour shade and its gloss   SPEKTROMASTER 565-D
6.4.4 Control register for tests carried out by the chemical manufacturer
This is either a bound register (not a spiral binding) with numbered pages, or a computer  listing.
It shall show the following information
- sample reference
- date of sampling and dispatch/collect
- chemical manufacturer’s test report
- test results (see Appendix A6)
- remarks and/or corrective action.
6.5. Table summarising the specifications for In-House Control .

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