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System Technique

EMEAI Valspar bv Zuiveringweg 89 8243 PE Lelystad The Netherlands Tel. +31 (0) 320292200 www.valsparindustrialmix.com

Select the system and click on the corresponding box. Information / UK

Date of issue: 6/2011 - Version: 1.0 These products are for Professional use only

Applications

Garage doors

Metal frames

Metal sheets

Metal Furniture

Small metal items

Agricultural machinery / equipment

Cranes & Construction equipment

Mining equipment

Trains/Trams/Metros

Railings

Trailers/Chassis

Pumps & Pumping equipment

Boxes, Caskets & Covers

Bridges & Structures

Industrialparts for high quality system

Sea freight containers

Machinery

Mineral Substrate Garden outdoor

Substrates Iron/Steel

Stainless steel

Cast iron

Galvanized steel

Aluminum

Plastic

Fibre re-enforced objects

Hardened old coating

System Technique


Select the system and click on the corresponding box. Information / UK

Date of issue: 6/2011 - Version: 1.0 These products are for Professional use only

Systems

3-1

33-1

34-1

4-1

44-1

44-2

5-1

5-2

5-3

5-4

54-1

54-2

54-3

54-4

54-5

55-1

55-2

55-3

544-1

544-2

544-3

754-1

754-2

System Technique


Explanation Information / UK

Date of issue: 1/2012 - Version: 1.0 These products are for Professional use only Page 1

System Primer Primer/Surfacer Topcoat Clearcoat Additive Legenda

3-1 TB300 IM Industrial Mix

3-2 TB300 + AD309 E Europe

33-1 FP300/PB300 TB300 + U US

33-2 FP300/PB300 TB300 AD309 CT Color Toner

34-1 FP400/FP401 TB300 PB Primer Binder

34-2 FP400/FP401 TB300 AD309 FP Factory Pack

333-1 FP300/PB300 TB300 CC300 TB Topcoat Binder

344-1 FP402 FP400/FP401 TB300 CC Clear coat

4-1 TB400 AT Activator Topcoat

44-1 FP400/FP401 TB400 AU Activator Polyurethane

44-2 FP402 TB400 AP Activator Primer

5-1 TB510 AA Accelerator

5-2 TB511 RS Reducer Solvent

5-3 TB512 AD Additional Products

5-4 TB510 + AD600 1 COLORS

5-5 TB510 + AD602 2 ACRYLIC

54-1 FP400/FP401 TB500 3 SYNTETHIC

54-2 FP402 TB500 4 EPOXY

54-3 FP400/FP401 TB520 5 POLYURETHANE

54-4 FP402 TB520 6 MISC

54-5 FP400/FP401 TB510 7 Clear coat

55-1 FP500 TB500

55-2 FP500 TB520

55-3 FP500 TB510

System Technique




544-1 FP402 FP400/FP401 TB500

544-2 FP402 FP400/FP401 TB520

544-3 FP402 FP400/FP401 TB510

544-4 FP402 FP400/FP401 TB540

754-1 FP400/FP401 TB500 CC700

754-2 FP402 TB500 CC700

754-3 FP400/FP401 TB520 CC700

754-4 FP402 TB520 CC700

System Technique




Only one product Two products Three products 3-1, 4-1, 5-1 …. 33-1, 44-1, 54-1, 55-1 …. 544-1, 754-1, 754-2, ….

In this case is only one product on the substrate 5-1 = TB510 oder TB511 or TB512 4-1 = TB400

Two products one the substrate 54-1 = TB5xx FP40x

Three products on the substrate 754-1 = CC700 TB5xx FP40x

Topcoat TB300 Synthetic Topcoat High Gloss TDS–Nr.: TB300/UK

Preparation and Pre-treatment Characteristics

Iron, steel, cast iron, aluminum, glass fiber reinforced plastic, for plastic substrates – after suitability and adhesion test, use FP600 Plastic Primer. Hardened, solvent resistant surfaces, sanded original- and old paintwork.

Note: Only for inside – Coating without corrosion protection.

The durability of the coating system largely depends on the thoroughness of the preparation of the surface (for more detailed information about preparing, see the Technical Information “Preparation and Pre-treatment”).

1K Synthetic Topcoat

Total layer thickness: 40-60µm

Application

Convertional gun, Brush, Roll

Airless, Airmix

For more Information see our Technical Data Sheets.

Topcoat

Product Mixing ratio

(Volume) Layers Dry times

TB300 Synthetic Topcoat High Gloss 100

15-30%

2 40-60µm

Dust dry: 20-30 min./20°C Dry to assembly: 5-7 hours/20°C Dry: 24 hours/20°C Force-dry: 30‘/60°C

RS300 Synthetic Reducer

For a higher chemical resistance and faster drying, use AS300 Synthetic Activator (max.25% + 0-10% RS300 Synthetic Reducer can be added), instead of the Synthetic Reducer.

In case a Semi Gloss or Matt finish is required, it is possible to add max. 30% of AD300 Synthetic Matting Agent to the Topcoat. By adjusting the added % of Synthetic Matting Agent the gloss level can be reduced from High Gloss to Semi Gloss or Matt. In case of over 25% until 30% of Matting Agent add ½-1% AA300 Dryer extra. The Mixing ratio is the same, with Synthetic Reducer or Synthetic Activator.

For a higher thickness use AD309 Synthetic High Build Additive without Activator 50-100% and 15-30% Synthetic Reducer. With Activator: TB300 - 100 parts, Synthetic Activator – 25 parts, + 40-80% Synthetic High Build Additive, + 0-10% Reducer. Only for air-drying! Please, see the TDS for more information.

Information:

If you want to weigh the components by balance, please use our VIM-CRS software. For airless or air mix processing, follow the instructions on our technical data sheet. Further Information about the products mentioned can be found in our technical data sheets.

System Technique

Nº 3-1

Topcoat TB400 Epoxy Topcoat DTM High Gloss TDS–Nr.: IME.TB400/UK

Preparation and Pre-treatment Characteristics Iron, steel, cast iron, aluminum, glass fiber reinforced plastic, for plastic substrates – after suitability and adhesion test, use FP600 Plastic Primer. Hardened, solvent resistant surfaces, sanded original- and old paintwork.

Coating with higher chemical resistant. Note: Only for Indoor – not use outside!


2K Epoxy Topcoat DTM


Application

Convertional gun,

Airless, Airmix


Topcoat

Product Mixing ratio (Volumen)

Layers Dry times

TB400 Epoxy Topcoat DTM High Gloss 3

2 40-60µm

Dust dry: 40 min./20°C Dry to assembly: 5-7 hours/20°C Dry: 24 hours/20°C Force-dry: 30‘/60°C

AT400 Epoxy Activator 1

RS605 Universal Reducer + 25-30%

For a faster process of drying use AA600 Accelerator (max.5%).

Information:


System Technique

Nº 4-1

Topcoat TB510 PU Topcoat DTM High Gloss TDS–Nr.: TB510/UK


Iron, steel, stainless steel (blasted), cast iron, galvanized steel, aluminum, glass fiber reinforced plastic. For plastic substrates – after suitability and adhesion test, use FP600 Plastic Primer. The durability of the coating system largely depends on the thoroughness of the preparation of the surface (for more detailed information about preparing, see the Technical Information “Preparation and Pre-treatment”).

2K Topcoat DTM High Gloss


Application

Convertional gun,

Airless, Airmix

For more Information see our Technical Information- and Data Sheets.

Topcoat



TB510 PU Topcoat DTM High Gloss 5

2 50-80µm

Dust dry: 25-30 min./20°C Dry to assembly: 3-5 hours/20°C Dry: 8-10 hours/20°C Force-dry: 30 min./60°C

AU500 Polyurethane Activator 1


For a faster process of drying use AA600 Accelerator (max.5%) For a higher thickness use AD600 High Build Additive (Mixing ratio is 5:1 + 40-80% Additive + 10-20% Reducer, please see the TDS for more information).

Information:

If you want to weigh the components by balance, please use our VIM-CRS software. For airless or air mix processing, follow the instructions on our technical data sheet. Further Information about the products mentioned can be found in our technical data sheets. For recommended layer thickness, as per ISO 12944, see the information sheet TI-G9.

System Technique

Nº 5-1

ISO 12944

C4 > 15 years

C5 I/M 5 – 15 years

Topcoat TB511 PU Topcoat DTM Semi Gloss TDS–Nr.: TB511/UK


Iron, steel, stainless steel (blasted), galvanized steel, cast iron, aluminum, glass fiber reinforced plastic. For plastic substrates – after suitability and adhesion test, use FP600 Plastic Primer. The durability of the coating system largely depends on the thoroughness of the preparation of the surface (for more detailed information about preparing, see the Technical Information “Preparation and Pre-treatment”).

2K Topcoat DTM Semi Gloss

Glosslevel 60GU/60°


Application

Convertional gun,

Airless, Airmix


Topcoat



TB511 PU Topcoat DTM Semi Gloss 5

2 40-80µm

Dust dry: 30 min./20°C Dry to assembly: 3-5 hours/20°C Dry: 8-10 hours/20°C Force-dry: 30-40 min./60°C



For a faster process of drying use AA600 Accelerator (max.5%). For a higher thickness use AD600 High Build Additive (Mixing ratio is 5:1 + 40-80% Additive + 10-20% Reducer, please see the TDS for more information).

Information:


System Technique

Nº 5-2

ISO 12944

C4 > 15 years


Topcoat TB512 PU Topcoat DTM Matt TDS–Nr.: TB512/UK


Iron, steel, stainless steel (blasted), galvanized steel, cast iron, aluminum, glass fiber reinforced plastic. For plastic substrates – after suitability and adhesion test, use FP600 Plastic Primer. The durability of the coating system largely depends on the thoroughness of the preparation of the surface (for more detailed information about preparing, see the Technical Information “Preparation and Pre-treatment”).

2K Topcoat DTM Matt

Glosslevel 25GU/60°


Application

Convertional gun,

Airless, Airmix


Topcoat



TB512 PU Topcoat DTM Matt 5

2 40-80µm




For a faster process of drying use AA600 Accelerator (max.5%). For a higher thickness use AD600 High Build Additive (Mixing ratio is 5:1 + 40-80% Additive + 10-20% Reducer, please see the TDS for more information).

Information:


System Technique

Nº 5-3

ISO 12944

C4 > 15 years


Topcoat TB510 + AD600

PU Topcoat DTM High Gloss High Build Additive

TDS–Nr.: AD600/UK


Iron, steel, stainless steel (blasted), cast iron, galvanized steel, aluminum, glass fiber reinforced plastic. For plastic substrates – after suitability and adhesion test, use FP600 Plastic Primer. The durability of the coating system largely depends on the thoroughness of the preparation of the surface (for more detailed information about preparing, see the Technical Information “Preparation and Pre-treatment”).

2K Topcoat DTM High Gloss


Application

Convertional gun,

Airless, Airmix


Topcoat




2-3 80-200µm

Dust dry: 1-2 hours/20°C Dry to assembly: 5-7 hours/20°C Dry: 12-16 hours/20°C Force-dry: not recommended


AD600 High Build Additive + 40-80%


For a faster process of drying use AA600 Accelerator (max.5%) It is also possible to use instead of TB510, TB511 PU Topcoat DTM Semi Gloss or TB512 PU Topcoat Matt.

Information:


System Technique

Nº 5-4

ISO 12944

C4 > 15 years

C5 I/M > 15 years

Primer FP300 Synthetic Primer DTM Grey TDS–Nr.: FP300/UK

Topcoat TB300 Synthetic Topcoat High Gloss TDS-Nr.: TB300/UK


Iron, steel, cast iron, aluminum, glass fiber reinforced plastic, for plastic substrates – after suitability and adhesion test, use FP600 Plastic Primer. Hardened, solvent resistant surfaces, sanded original- and old paintwork. The durability of the coating system largely depends on the thoroughness of the preparation of the surface (for more detailed information about preparing, see the Technical Information “Preparation and Pre-treatment”).

1K Synthetic Primer DTM

1K Synthetic Topcoat


Application

Convertional gun, Brush, Roll

Airless, Airmix


Primer



FP300 Synthetic Primer DTM Grey 100 1-2

40-60µm

Dust dry: 20 min./20°C Recoatable: 30-45 min./20°C Dry: 6-8 hours/20°C Force-dry: 20-30 min./60°C RS300 Synthetic Reducer 15-30


Topcoat



TB300 Synthetic Topcoat High Gloss 100 2

40-60µm

Dust dry: 20‘-30‘/20°C Dry to assembly: 5-7 Std./20°C Dry: 24 Std./20°C Force-Dry: 30‘/60°C RS300 Synthetic Reducer 15-30




Information:


System Technique

Nº 33-1

Primer FP400 Epoxy Primer DTM Grey TDS–Nr.: FP400/UK

Topcoat TB300 Synthetic Topcoat High Gloss TDS–Nr.: TB300/UK


Iron, steel, stainless steel (substrate blasted), cast iron, galvanized steel, aluminum, glass fiber reinforced plastic. Hardened, solvent resistant surfaces, sanded original- and old paintwork. For plastic substrates – after suitability and adhesion test, use FP600 Plastic Primer.


2K Epoxy Primer DTM

1K / 2K Synthetic Topcoat


Application

Convertional gun,

Airless, Airmix


Primer



FP400 Epoxy Primer DTM Grey 3

1-2 40-80µm

Dust dry: 20 min./20°C Recoatable: 1-24 hours/20°C Dry: 10-16 hours/20°C Force-dry: 30-40 min./60°C

AP401 Epoxy Activator 1

RS405 Epoxy Reducer + 10-50%

As Sanding Primer use 10-30% Epoxy Reducer. Wet on wet application use 35-50% Epoxy Reducer / 1 layer 30-40µm. After 24 hours please, sand again. FP401 Epoxy Primer DTM is the same product only the color is white.

Topcoat



TB300 Synthetic Topcoat High Gloss 100

15-30%

2 40-60µm

Dust dry: 20-30 min./20°C Dry to assembly: 5-7 hours/20°C Dry: 24 hours/20°C Force-dry: 30‘/60°C

RS300 Synthetic Reducer




Information:

If you want to weigh the components by balance, please use our VIM-CRS software. For airless or air mix processing, follow the instructions on our technical data sheet. For recommended layer thickness, as per ISO 12944, see the information sheet TI-G9.

System Technique

Nº 34-1


Topcoat TB400 Epoxy Topcoat High Gloss TDS–Nr.: TB400/UK


Iron, steel, stainless steel (blasted), galvanized steel, cast iron, aluminum, glass fiber reinforced plastic. For plastic substrates – after suitability and adhesion test, use FP600 Plastic Primer. Only for Indoor! Outside will the color pale after some weeks.


2K Epoxy Primer DTM

2K Epoxy Topcoat


Application

Convertional gun,

Airless, Airmix


Primer



FP400 Epoxy Primer Grey 3

1-2 40-80µm

Dust Dry: 20 min./20°C Recoatable: 60‘ min.20°C W/W Dry: 10-16 hours/20°C Force-dry: 30-40 min./60°C




Topcoat



TB400 Epoxy Topcoat High Gloss 3

2 40-60µm

Dust dry: 40 min./20°C Dry to assembly: 5-7 hours/20°C Dry: 24 hours/20°C Force-dry: 30-40 min./60°C




Information:


System Technique

Nº 44-1

ISO 12944

C4 > 15 years


Primer FP402 Epoxy Primer Zinc Rich DTM Grey TDS–Nr.: FP402/UK

Topcoat TB400 Epoxy Topcoat High Gloss TDS–Nr.: TB400/UK


Iron, steel – only blasted metal surfaces (SA 2½). Only for Indoor! Outside will the color pale after some weeks. The durability of the coating system largely depends on the thoroughness of the preparation of the surface (for more detailed information about preparing, see the Technical Information “Preparation and Pre-treatment”).

2K Epoxy Primer DTM

2K Epoxy Topcoat


Application

Convertional gun,

Airless, Airmix


Primer


(Weight) Layers Dry times

FP402 Epoxy Primer Zinc Rich DTM Grey 1000 g

1-2 40-80µm

Dust dry: 20 min./20°C Recoatable: 60 min./20°C Dry: 10-16 hours/20°C Force-dry: 30-40 min./60°C

AP402 Epoxy Activator 84 g

RS405 Epoxy Reducer 25-60 g

As Sanding Primer use 25-40 g Epoxy Reducer. Wet on wet application use 40-60 g Epoxy Reducer / 1 layer 30-40µm. After 24 hours please, sand again.

Topcoat



TB400 Epoxy Topcoat High Gloss 3

2 40-60µm





Information:


System Technique

Nº 44-2

ISO 12944

C4 > 15 years

C5 I/M > 15 years


Topcoat TB500 PU Topcoat Performance High Gloss TDS–Nr.: TB500/UK




2K Epoxy Primer DTM

2K PU Topcoat


Application

Convertional gun,

Airless, Airmix


Primer




1-2 40-80µm





Topcoat



TB500 PU Topcoat Performance High Gloss (VOC <420g/l)

4

2 40-65µm

Dust dry: 60-90 min./20°C Dry to assembly: 5-7 hours/20°C Dry: 24 hours/20°C Force-dry: 30-40 min./60°C



For a faster process of drying use AA600 Accelerator instead of IME.RS605 Universal Reducer.

Information:


System Technique

Nº 54-1

ISO 12944

C4 > 15 years

C5 I/M 5 - 15 years

Primer FP402 Epoxy Primer Zinc Rich TDS–Nr.: FP402/UK



Iron, steel – only blasted metal surfaces (SA 2½). The durability of the coating system largely depends on the thoroughness of the preparation of the surface (for more detailed information about preparing, see the Technical Information “Preparation and Pre-treatment”).

2K Epoxy Primer

2K PU Topcoat


Application

Convertional gun,

Airless, Airmix


Primer



FP402 Epoxy Primer Zinc Rich Grey 1000 g

1-2 40-80µm

Dust dry: 20 min./20°C Recoatable: 60 min./20°C w/w Dry: 10-16 hours/20°C Force-dry: 30-40 min./60°C




Topcoat




4

2 40-65µm

Dust dry: 60-90 min./20°C Dry to assembly: 5-7 hours/20°C Dry: 24 hours/20°C Force-dry: 30-40 min./60°C



For a faster process of drying use AA600 Accelerator instead of IME.RS605 Universal Reducer.

Information:


System Technique

Nº 54-2

ISO 12944

C4 > 15 years

C5 I/M > 15 years


Topcoat TB520 PU Topcoat Basic High Gloss TDS–Nr.: TB520/UK




2K Epoxy Primer

2K PU Topcoat


Application

Convertional gun,

Airless, Airmix


Primer




1-2 40-80µm





Topcoat



TB520 PU Topcoat Basic High Gloss 6

2 40-60µm




For a very fast process of drying use AA600 Accelerator (max.5%) For a higher thickness use AD600 High Build Additive Mixing ratio is 6:1 + 40-80% Additive and + 20-35% Reducer. Please, see the TDS for more information.

Information:


System Technique

Nº 54-3

ISO 12944

C4 > 15 years

C5 I/M 5 - 15 years

Primer FP402 Epoxy Primer Zinc Rich DTM TDS-Nr.: FP402/UK




2K Epoxy Primer

2K PU Topcoat


Application

Convertional gun,

Airless, Airmix


Primer




1-2 40-80µm





Topcoat




2 40-60µm

Dust dry: 20-30 min./20°C Dry to assembly: 2-4 hours/20°C Dry: 8-10 hours/20°C Force-dry: 20-30 min./60°C



For a very fast process of drying use AA600 Accelerator (max.5%). For a higher thickness use AD600 High Build Additive Mixing ratio is 6:1 + 40-80% Additive and + 20-35% Reducer. Please, see the TDS for more information.

Information:


System Technique

Nº 54-4

ISO 12944

C4 > 15 years

C5 I/M > 15 years






2K Epoxy Primer DTM

2K PU Topcoat DTM


Application

Convertional gun,

Airless, Airmix


Primer




1-2 40-80µm





Topcoat




2 50-80µm


AU500 PU Activator 1


For a faster process of drying use AA600 Accelerator (max.5%) For a higher thickness use AD600 High Build Additive (Mixing ratio is 5:1 + 40-80% Additive and + 10-20% Reducer. Please, see the TDS for more information. It is also possible to use: TB511 PU Topcoat DTM Semi Gloss or TB512 PU Topcoat DTM Matt instead of TB510 PU Topcoat DTM High Gloss (mixing ratio is the same).

Information:

If you want to weigh the components by balance, please use our CRS software. For airless or air mix processing, follow the instructions on our technical data sheet. Further Information about the products mentioned can be found in our technical data sheets. For recommended layer thickness, as per ISO 12944, see the information sheet TI-G9.

System Technique

Nº 54-5

ISO 12944

C4 > 15 years

C5 I/M 5 - 15 years

Primer FP500 PU Primer DTM Grey TDS–Nr.: FP500/UK



Iron, steel, cast iron, galvanized steel, aluminum, glass fiber reinforced plastic. Hardened, solvent resistant surfaces, sanded original- and old paintwork. For plastic substrates – after suitability and adhesion test, use FP600 Plastic Primer.


2K PU Primer DTM

2K PU Topcoat (VOC <420g/l)


Application

Convertional gun,

Airless, Airmix


Primer



FP500 PU Primer DTM Grey 8

1-2 40-80µm




For a very fast process of drying use AA600 Accelerator (max. 3-5%). After 24 hours please, sanding again. PB500 PU Primer Binder DTM is the same product with the possibility to add. 20% Color Toner (see CRS), which color the user like.

Topcoat




4

2 40-65µm




For a faster process of drying use AA600 Accelerator instead of RS605 Universal Reducer.

Information:


System Technique

Nº 55-1

ISO 12944

C4 > 15 years

C5 I/M 5 - 15 years






2K PU Primer DTM

2K PU Topcoat


Application

Convertional gun,

Airless, Airmix


Primer




1-2 40-80µm




For a very fast process of drying use AA600 Accelerator (max. 3-5%). After 24 hours please, sanding again. PB500 PU Primer Binder DTM is the same product with the possibility to add. 20% Color Toner (see CRS), which color the user like.

Topcoat




2 40-60µm




For a very fast process of drying use AA600 Accelerator (max.5%). For a higher thickness use AD600 High Build Additive (Mixing ratio is 6:1 + 40-80% Additive and + 20-35% Reducer. Please, see the TDS for more information).

Information:


System Technique

Nº 55-2

ISO 12944

C4 > 15 years

C5 I/M 5 - 15 years






2K PU Primer DTM

2K PU Topcoat DTM


Application

Convertional gun,

Airless, Airmix


Primer




1-2 40-80µm




For a very fast process of drying use AA600 Accelerator (max. 3-5%). After 24 hours please, sanding again. PB500 PU Primer Binder DTM is the same product with the possibility to add 20% Color Toner (see CRS).

Topcoat




2 50-80µm




For a faster process of drying use AA600 Accelerator (max.5%) For a higher thickness use AD600 High Build Additive (Mixing ratio is 5:1 + 40-80% Additive and + 10-20% Reducer. Please, see the TDS for more information). It is also possible to use: TB511 PU Topcoat DTM Semi Gloss or TB512 PU Topcoat DTM Matt instead of TB510 PU Topcoat DTM High Gloss (mixing ratio is the same).

Information:

If you want to weigh the components by balance, please use our CRS software. For airless or air mix processing, follow the instructions on our technical data sheet. Further Information about the products mentioned can be found in our technical data sheets. For recommended layer thickness, as per ISO 12944, see the information sheet TI-G9.

System Technique

Nº 55-3

ISO 12944

C4 > 15 years

C5 I/M 5 - 15 years

Primer FP402 Epoxy Primer Zinc Rich DTM TDS–Nr.: FP402/UK





2K Epoxy Primer Zinc rich

2K Epoxy Primer

2K PU Topcoat (VOC <420g/l)


Application

Convertional gun,

Airless, Airmix


Primer

Product Mixing ratio (Weight)

Layers Dry times


1-2 40-80µm

Dust Dry: 20 min./20°C Recoatable: 60‘/20°C Dry: 10-16 hours/20°C Force-dry: 30-40 min./60°C



As Sanding Primer use 25-40 g Epoxy Reducer. Wet on wet application use 40 g Epoxy Reducer / 1 layer 30-40µm. After 24 hours please, sand again.

Primer




1-2 40-80µm

Dust Dry: 20 min./20°C Recoatable: 60 min./20°C Dry: 10-16 hours/20°C Force-dry: 30-40 min./60°C



As Sanding Primer use 10-30% Epoxy Reducer. Wet on wet application use 35-50% Epoxy Reducer / 1 layer 30-40µm. After 24 hours please, sand again. FP401 Epoxy Primer DTM is the same product only the color is white. For the best Quality and a smooth surface – sand after the drying time with Excenter machine P320-P400.

Topcoat




4

2 40-65µm

Dust dry: 60 min./20°C Dry to assembly: 12 hours/20°C Dry: 16-24 hours/20°C Force-dry: 30-40 min./60°C



For a faster process of drying use AA600 Accelerator instead of RS605 Universal Reducer.

Information:

If you want to weigh the components by balance, please use our VIM-CRS software. For airless or air mix processing, follow the instructions on our technical data sheet, Further Information about the products mentioned can be found in our technical data sheets. For recommended layer thickness, as per ISO 12944, see the information sheet TI-G9.

System Technique

Nº 544-1

ISO 12944

C4 > 15 years

C5 I/M > 15 years







2K Epoxy Primer

2K PU Topcoat


Application

Convertional gun,

Airless, Airmix


Primer


Layers Dry times


1-2 40-80µm





Primer




1-2 40-80µm





Topcoat




2 40-60µm




For a faster process of drying use AA600 Accelerator, max. 5%.

Information:


System Technique

Nº 544-2

ISO 12944

C4 > 15 years

C5 I/M > 15 years







2K Epoxy Primer

2K PU Topcoat


Application

Convertional gun,

Airless, Airmix


Primer


Layers Dry times


1-2 40-80µm





Primer

Product

Mixing ratio (Volume)

Layers Dry times


1-2 40-80µm





Topcoat

Product Mixing ratio (Volume)

Layers Dry times


2 50-80µm




For a faster process of drying use AA600 Accelerator (max.5%) For a higher thickness use AD600 High Build Additive (Mixing ratio is 5:1 + 40-80% Additive and + 10-20% Reducer. Please, see the TDS for more information. It is also possible to use: TB511 PU Topcoat DTM Semi Gloss or TB512 PU Topcoat DTM Matt instead of TB510 PU Topcoat DTM High Gloss (mixing ratio is the same).

Information:


System Technique

Nº 544-3

ISO 12944

C4 > 15 years

C5 I/M > 15 years

Primer FP400 Epoxy Primer DTM TDS–Nr.: FP400/UK


Clear coat CC700 Clear coat Anti Graffiti TDS–Nr.: CC700/UK


Iron, steel, stainless steel (blasted), cast iron, galvanized steel, aluminum, glass fiber reinforced plastic. Hardened, solvent resistant surfaces, sanded original- and old paintwork. For plastic substrates – after suitability and adhesion test, use FP600 Plastic Primer.


2K Epoxy Primer DTM

2K Topcoat (VOC <420g/l)

2K Clear coat


Application

Convertional gun,

Airless, Airmix


Primer


Layers Dry times


1-2 40-80µm

Dust dry: 20 min./20°C Recoatable: 60 min./20°C Dry: 10-16 hours/20°C Force-dry: 30-40 min./60°C



As Sanding Primer use 10-30% Epoxy Reducer. Wet on wet application use 35-50% Epoxy Reducer / 1 layer 30-40µm. After 24 hours please, sanding again. FP401 Epoxy Primer DTM is the same product only the color is white.

Topcoat


Layers Dry times

TB500 PU Topcoat Performance High Gloss 4

2 40-65µm




For a faster process of drying use AA600 Accelerator instead of IME.RS605 Universal Reducer. For a very good finish apply the CC700 Clear Coat after drying time (till 24 hours without sanding, after 24 hours sand again – Scotch-brite very fine/ultra fine).

Clear coat


Layers Dry times

CC700 Clear coat Anti Graffiti 2

2 40-60µm


AU570 Clear coat Activator 1



Information:


System Technique

Nº 754-1

ISO 12944

C4 > 15 years

C5 I/M 5 - 15 years

Primer FP402 Epoxy Primer Zinc rich DTM TDS–Nr.: FP402/UK


Clear coat CC700 Clear coat Anti Graffiti TDS–Nr.: CC700/UK


Iron, steel, stainless steel (blasted), cast iron, galvanized steel, aluminum, glass fiber reinforced plastic. Hardened, solvent resistant surfaces, sanded original- and old paintwork. For plastic substrates – after suitability and adhesion test, use FP600 Plastic Primer.


2K Epoxy Primer DTM

2K Topcoat (VOC420g/l)

2K Clear coat


Application

Convertional gun,

Airless, Airmix


Primer


Layers Dry times

FP402 Epoxy Primer Zinc rich DTM Grey 1000 g 1-2

40-80µm

Dust dry: 20 min./20°C Recoatable: 60’/20°C Dry: 10-16 hours/20°C Force-dry: 30-40 min./60°C

AP402 Activator 84 g


As Sanding Primer use 25-40 g Epoxy Reducer. Wet on wet application use 40-60 g Epoxy Reducer / 1 layer 30-40µm. After 24 hours please, sanding again.

Topcoat



TB500 PU Topcoat Performance High Gloss 4

2 40-65µm




For a faster process of drying use AA600 Accelerator instead of IME.RS605 Universal Reducer. For a very good finish apply the CC700 Clear Coat after drying time (till 24 hours without sanding, after 24 hours sand again – Scotch-brite very fine/ultra fine).

Clear coat


Layers Dry times

CC700 Clear coat Anti Graffiti 2

2 40-60µm


AU570 Clear coat Activator 1



Information:


System Technique

Nº 754-2

ISO 12944

C4 > 15 years

C5 I/M > 15 years

Technical Information Sheet


General Information: Corrosion TI – G 1 / UK

Date of issue: 01/2013 - Version: 1.0 These products are for professional use only! Page 1 of 3

Corrosion (from Latin ‘corrodere’ = to rot away)

Corrosion is the gradual destruction of material, usually metals, by chemical reaction with its environment. In the most common use of the word, this means electrochemical oxidization of metals in reaction with an oxidant such as oxygen. Rusting, the formation of iron oxides, is a well-known example of electrochemical corrosion. This type of damage typically produces oxide(s) or salt(s) of the original metal. Corrosion can also occur in materials other than metals, such as ceramics or polymers, although in this context, the term degradation is more common. Corrosion degrades the useful properties of materials and structures including strength, appearance and permeability to liquids and gases Fixed scale of corrosion in:

• Chemical corrosion

• Electrochemical corrosion Degree of Corrosion

1. Chemical corrosion Corrosion is a process that occurs when oxygen, water, acids and salts mix together. The temperature must be above 0°C. When the relative humidity is below 40% almost no corrosion, from 40-60% increases the risk of corrosion proportionately and above 60% (relative humidity) significant corrosion is to be expected. In connecting with air pollution, hygroscopic salts, depending on the construction and the position of the component, the corrosion stress loads are considerably increased. Redox (reduction-oxidation-reaction) is a chemical reaction. This happens when one electron is transferred to the other. In such an electron transfer reaction the electron cuts (oxidation) through a material on an electron uptake (reduction).

Humidity

In our case: By the action of oxygen, water, salts, acids, it depends on the steel surface for a chemical reaction – corrosion takes space. The steel surface is reduced and the surface corrosion increases.

2. Electrochemical corrosion / Contact corrosion

Contact corrosion arises when two metals with different solution potential are connected through an electrolyte (water, moist air, salts…). The non-noble material (to be sacrificed) becomes the anode and the nobler material acts as the cathode, e.g. Zinc and Copper form with an electrolyte, a galvanic element (galvanic cell). This creates a voltage between the two materials. The negative terminal is non-noble and will corrode, and at the same time, corrosion of the other noble metal will be prevented.





Reasons for the development of electrochemical corrosion / contact corrosion

• Different types of metals rubbing together due to (false) construction results in what is called electrolysis Corrosion

• Different structural components from the manufacturing process in alloys form a galvanic cell Intergranular corrosion, e.g. Chrome in steel alloys combines on heating (welding) with the carbon, effect is - chrome loose the anticorrosive properties.

• Different surface tension through deformities and stress increase the corrosion-tendency Stress corrosion cracking

Standard electrode potential of metals (At 298.15 K / 25°C) Non-noble negative ( - ) positive ( + ) Noble

2,37 V Magnesium

1.66 V Aluminium

0.76 V Zinc

0.76 V Chrome

0.49 V Nickel

0.41 V Iron

0.40 V Cadmium

0.14 V Tin

0.13 V Lead

0 V Hydrogen

Copper +0.52 V

Silver +0.8 V

Platinum +1.2 V

Gold +1.4 V

-2.5 -2.0 -1.5 -1.0 -0.5 0 +0.5 +1.0 +1.5

This chart above show the Standard electrode potential of metals. If you measure the metals with an electro voltage device the result is the value in the column. If you join Aluminium (-) 1,66 V with Iron (-) 0,41 V in a construction, and the local environment has more than 60% of humidity or if it is raining, an electronic cell will be created, and the electrons are moving from the noble to the non noble metal. More negative electrons will gather on the contact area, and the metal will corroded more – contact corrosion will develop.





• The composition of the electrolyte

Outdoor in connection with weathering (rain, fog), this type of corrosion depends on the duration of exposure to moisture. Very adverse conditions prevail when the metal has been left out in the moisture and electrolytes occur with a high conductivity e.g. in areas with high levels of industrial pollution, salt air, in contact with sea water or on salted roads.

• The size of the contact surfaces and the surfaces of the components (surface area ratio)

If metal pieces e.g. hot-dip galvanized steel (- charge) are greater in terms of surface area, the pairing with other materials is (-/+ charge) usually is a minor a problem. If the surface of the hot-dip galvanized steel is smaller than the other pairing area then take precautions, e.g., clamps in galvanized steel to copper pipes.

• Oxidation products on the surface of the metals

When metal surfaces are heavily oxidised, the voltage potential will chance, which in turn will have a considerable effect on the extent of the.

If metals which are widely spaced in the voltage spread of the chemical elements must be paired, the metals should be separated by insulation media (e.g. plastic disc or rubber mat). Note: Zinc, negative charge ( - ) can be corroded by noble metals, positive charge ( + ). Small galvanized parts in contact with larger metal areas are more vulnerable. Liability for content: The contents of our information sheets were prepared with great care. For the accuracy, completeness and timeliness, we can not take any responsibility. Upon notification of errors or of such violations, we will change the content accordingly. Basically, working with machines, hand tools and chemical products can be very dangerous. Therefore our examples and information are intended for professional customers only (experienced and skilled craftsmen). An assurance for the success and liability for consequential damages, we can not accept, because that depends on the skill of the user, the personal protective clothing, the materials used and the processing conditions.



General Information: Rust Grades TI – G 2 / UK


Rust grades on steel

Steel is classified according to the corrosion attack in rust degree. Coated surfaces

You can compare the degree of corrosion to the painted area. For example, when the measured result is below 1% (1 in 100), the rust degree is R1.

Degree of rust Pictures of rust – DIN EN ISO 4628-3 and DIN 53210 Covered rust area

Ri 0

Without rust

Ri 1

C. 1%

Ri 2

C. 3%

Ri 3

C. 10%

Ri 4

C. 30%

Ri 5

C. 50%



General Information: Rust Grades TI – G 2 / UK


Uncoated (Bare) steel surfaces

The rust grade is also compared visually. It is given as A-B-C and D graduation, this determines the coverage of areas with rust, mill scale and scale. Degree of

rust Pictures from rust ISO 8501-1+2 and DIN 55928 Condition

A

The whole surface is covered with mill scale and scale – no rust

B

Beginning to rust – Mill scale and scale is starting to show

C

Mill scale and scale from corrosion process – degraded or removable. – barely visible pitting corrosion

D

Completely rusted – Extreme pitting corrosion visible

Liability for contents: Our information sheets were prepared with great care. Nevertheless, we can not assume any responsibility for the accuracy, completeness and timeliness. Upon notification of errors or of any possible violations of legal issues, we shall change the contents accordingly. Basically, working with machines, hand tools and chemical products can be very dangerous. Therefore our examples and information are intended for professional customers only (experienced and skilled craftsmen). Yet, we can not give assurance for the success, and we shall not accept any liability for any follow-on damages, as either case depends on the skill of the user, the personal protective clothing, the materials used and the processing conditions.



General Information: Gloss Measurement TI – G 3 / UK


Information about Gloss measurement

Gloss is the most obvious optical property of a surface. This occurs when directed light reflects from a surface. Paints and varnishes are measured by gloss units (GU). Gloss measurement shall me made at least at three areas of the test object. In doing so the maximum unit or the low 5 GU value should not be exceeded, otherwise measure at two additional locations. The measurement results are calculated as the average of the individual measurements and they are recorded in gloss units (GU). Areas of application

Car paints and coatings (Car refinish), plastics as well as manufacturing industry (General Industry). Measurement Geometry: 20° High gloss / 60° Semi gloss / 85° Matt gloss This gloss measurement meets the standards of ASTM D 523, ASTM D 2457, BS 3900, DIN EN ISO 2813 and DIN 67530. When you measure the matt surface, they have to measure 3 times on one part/object. Example: Result of the 1st measure 24.1 / 2nd measure 27.4 / 3rd measure 25.7 ; the smallest and the largest values are is 24.1 and 27.4 ; the max. difference is 3.3 which is within the 5 GU limit. Now, add the three allowable values 24.1 + 27.4 + 25.7 = 77.2 and divide by 3 (number of measurements) for the result 25.7 This is the gloss level.

Is the 1st measure 24.1 / 2nd 30.2 / 3rd 28.4 – the smallest and the largest is 24.1 – 30.2 = 6.1 out of the tolerance of 5 GU, the customer shall measure at 2 additional locations on that part/object - 4th measure 29.4 / 5th measure 27.4 …. Is 24.1 + 30.2 + 28.4 + 29.4 + 27.4 = 139.5 / 5 = 27.9 GU

Procedure to follow: A lacquered surface is measured at 60° angle of light. If the measured value is between 10 GU and 70 GU (e.g. 45 GU), the measuring geometry is correct. If the measured value is above 79 GU, you should select a 20° angle. If the measured value is below 10 GU, you should select 85° for the angle of light.

Selection geometry GU

Degree of gloss (Notation) 100

High-gloss 20° 90 100-70 GU downwards from high-gloss until glossy 80 surfaces 70

Semi-gloss 60°

60 70-10 GU downwards from glossy – semi-gloss - 50 until matt surfaces 40 30 20 10

Low-gloss 85° 0 10-0 GU matt until dull-matt surfaces



General Information: Gloss Measurement TI – G 3 / UK





General Information: Blasting Technology TI – G 4 / UK


Basics of beam technology Blasting technology is general term for the surface treatment by abrasive blasting. The adhesion and the quality of old coatings can be improved by blasting different substrates. The abrasive medium, in most applications a granular medium, is accelerated by means of compressed air, liquids, or blasting wheels, and adjustable nozzles are used to direct the high energy blasting jet onto the workpiece surfaces. The result is heavily dependent on the beam method and the selected parameter settings - and the abrasive medium used. Owing to the silicosis risk (pneumoconiosis) for personnel, “sandblasting” (blasting with quartz sand), for many years by now, is permitted only when comprehensive precautionary measures are taken. The beam system requires regular maintenance and the blasting medium must be monitored depending on the type and degree of contamination on re-use and condition of the granularity. Safety measures

Hazardous substances such as e.g. antimony, tin, arsenic, lead, and cadmium may are permitted only be present in the abrasive medium within the legally fixed limits Self-contained breathing apparatus for blasting work as well as special protective clothing e.g. clothes, safety shoes and personal hearing protection should be used. Deposits or suspended dust can be ignited by ignition sources. The alternating or simultaneous blasting of light metals and ferrous parts increases the risk of fire and explosions, particularly with the presence of aluminium and rust. The relevant statutory provisions and regulations must be observed. How Blasting works By using blasting technology outstanding results can be achieved; see pictures below. As you will see, the process achieves de-scaling, rust removal, paint stripping, sand removal, cleaning, deburring, shot blasting, matting, roughing and other surface finishes.

Steel girder - before Steel girder - after



General Information: Blasting Technology TI – G 4 / UK


Blasting materials The state of the present and the desired surface condition determine which type of blasting medium should be used. Factors to consider for the choice of blasting medium are: price, object material, material thickness and the required blast profile, viz. surface roughness. On thin material “softer” beam techniques are recommended to preclude deformation or other damage to the material. On structural steel the surface roughness normally is between 25-60µm, rarely up to 80 µm. Different blasting materials:

Aluminium oxide

Granulate

Steel grit

Steel shot

Plastic

Other types may include: Glass beads, ceramic, dry ice, corundum, steel ball, cut wire, emery, blast furnace slag, bronze shot. Common methods are:

Air blasting Dry abrasive

Dry ice blasting CO2-pellets, temperature at least -78°C, embrittlement of coatings by cold to roughen the surface

Wet abrasive blasting Moisturized blasting, dust control

Wet blasting Abrasive with the addition of water, dust control

Slurry blasting Water with slurry abrasive, damped mechanical particle impact

Hot water and stream jet Hot water or superheated stream at 50 -160 bar

Pressure liquid jets Water using granular abrasives pressure by 50 – 2000 bar

Centrifugal wheel blasting (dry) High speed wheels with dry abrasive medium

Centrifugal wheel blasting (wet) High speed wheels with water and dry blasting agents

Ultrasonic cleaning Balls, acceleration caused by mechanical vibrations and electrical shock




General Information: Degree of Purity TI – G 5 / UK


Degree of purity (steel)

The degree of purity describes the purity of mill scale, scale and rust from steel surfaces. Different standards define the degree of purity and are usually required by the paint manufacturer or customer of a project. A steel surface to be painted normally requires the purity of SA 2.5 or better SA 3. In the cleaning process the surface must be cleaned of all ferrous and non-ferrous components. If residues are left on the surface it will warp and affect the adhesion of later coating and the corrosion resistance. These residues can be:

• Mill scale and scale

• Oil, grease and waxes

• Corrosion/rust

• Soluble salts

• Soiling like e.g. dust Classification and definition according Swedish Standard (SIS 05 5900 / ISO 8501-1+2):

SA =

Blasting of coated and uncoated steel surfaces

SA 1

Brush-off Blast Cleaning

The surfaces are free of non-ferrous components such as oil, grease, dirt and lose paint. Lose ferrous layers from the producing process as mill scale, scale and rust are removed. The remaining scale, rust and paint are adherent and the surface may be roughened sufficiently to achieve a good adhesion of the following coating.

SA 2

Commercial Blast Cleaning

SA 1 process and extra processes: Rust/scale or adherent coating residues are almost removed. 70% (⅔) of every square inch should be free of visible residues. Depressions in the surface may hold traces of residue.

SA 2.5

Near White Blast Cleaning

As with SA 2. Only traces or shades of type layers may be visible. 95% of every square inch should be free of visible residues.

SA 3

White Metal Blast Cleaning

SA 2.5 process and extra process: The workpieces have a uniform grey-white metal surface. All ferrous and non-ferrous residues are removed by 100%.

P SA 2.5

Partial removal of damaged areas (existing coatings)

Spotty removal of rust, scale, loose coating and contaminants. Remaining exposed areas show light shading corresponding to SA 2.5. Remaining coating must be intact, it is recommended to carry out an adhesion test.





ST = Hand- or machine tool de-rusting

ST 2

Loose Coatings and loose mill scale and scale are removed; rust is removed to the extent that after the cleaning has a faint metallic luster.

ST 3

Like ST 2, furthermore the metal has a higher metal shine.

Fl

Flame blasting

Mill scale, scale, rust, paint coatings and foreign matter are removed. Residues may show only as discoloration and shades.

Be

Pickling with acids (chemical rust removal)

All ferrous and non-ferrous components are removed. Before coating the surface must be re-treated with neutral detergents.

Examples of untreated to treated steel surfaces

Rust Grade A

Untreated SA 1 SA 2 SA 2½ SA 3

Rust Grade B

Rust Grade C

Rust Grade D





Blasted steel surfaces prepared to at least SA 2.5 and processed with the recommended coating materials and coating systems according to the technical data sheets provide up to four times longer protection! The finish of the blasted steel surface is mainly dependent on the blasting technique as such, the abrasives used and the eventual surface roughness. The blast profile or surface roughness may be up to 100µm. For structural steel the value normally lies between 25-60µm, and less common 80µm. Excellent results are achieved through the use of sharp corundum. Ferrous and non-ferrous components and other types of contaminates are ideally removed and the blasted surface provides good adhesion with the following corrosion protecting coating. Standards

The table below gives an overview of internationally recognised standards of surface preparation. The mostly used standards are: NACE (National Association of Corrosion Engineers) the Swedish standard – for Europe (SIS 05 5900), SSPC (Steel Structures and Paint Council) and the British Standard (BS 4232). The German standard DIN 55928 and the ISO 8501-1+2 are identical to the Swedish standard. Degree of purity - Standard – comparison

Sweden Standard

SIS 055900 ISO 8501-1 BS7079 / A1

England (UK)

BS 4232

USA SSPC SP

USA NACE

Canada CGSB

China GB 8923

Japan SPSS

SA1 Light blast to brush off

SSPC SP 7 NACE 4 31 GP 404

Type 3 Sd1 / Sh2

SA2 Third

Quality SSPC SP 6 NACE 3

31 GP 404 Type 2

SA2 Sd1 / Sh2

SA2.5 Second Quality

SSPC SP 10 NACE 3 SA2½ Sd3

SA3 First

Quality SSPC SP 5 NACE 1

31 GP 404 Type 1

SA3

ST2 SSPC SP 2 ST2

ST3 SSPC SP 3 ST3




General Information: Pictogram TI – G 6 / UK


Pictogram Information

If you want attention for something important without using words, usually a pictogram is used. A pictogram is a visual indication and more concrete and clearer than a spoken or written information. There are no language barriers, and pertinent information is communicated to the professional user without saying a word. The three basic rules for a pictogram are:

1. Concrete and clear 2. Uni-vocal (Globally recognised) 3. Simple/easy

In the Industrial and Automotive markets we are confronted daily with pictograms as pictorial representational character, as instructions or statistical diagrams. Due to their graphical nature and fairly realistic style, they are widely used in public areas such as toilets, airports, train stations, emergency exits, etc. Valspar uses pictograms for:

• Safety purposes

• Application information

• Product information Overview of processing pictograms Technical information:

Information Attention point

Storage:

Store in a Frost free Duration of Protect from Close container cool place store storage humidity tightly





Cleaning:

Degreasing Cleaning Spray equipment

Sanding:

With eccentric With eccentric Sanding by Sanding by sander/grinder keying with Polishing by tappet dry tappet wet hand dry hand wet machine dry Scotch-brite machine

Mixing:

Use Valspar Add catalyst Add Valspar Ready to use Mixing ratio of Mixing ratio of Mixing ratio of Mixing stick Mixing toner 2 components 2 components 3 components almost even Viscosity:

Material viscosity Construction parts

Metal Metal plates Profile





Coloring:

Stirr by hand Stirr on the Topple Shake before Check Variant Low Mixing machine use colour available usage

Total re-spray Panel repair Spot repair Fade out Roof colour Bumper colour Paint work

Trailer and Truck/Lorry Cabin Wheel colour Engine bay Interior cabin colour colour

2 Tone Colour Lead Texture paint 3 Layer Poor Immiscible Contact Colour Combination containing paint system coverage dept

Personal protection

Use a fresh Use a dust Use charcoal Gloves Air hood mask respirator





Processing

Polyester Gravity feed Suction feed Undercoating Airless/ Application Application Putty Spraygun Spraygun Spraygun Airmix Gravity feed Suction feed Spraygun Spraygun

Application Application Aerosol Aerosol Shake well Application After use invert by brush with a roller Application Application before use distance the aerosol Drying:

Flash off Dry time Infa Red Bake Liability for contents: Our information sheets were prepared with great care. Nevertheless, we can not assume any responsibility for the accuracy, completeness and timeliness. Upon notification of errors or of any possible violations of legal issues, we shall change the contents accordingly. Basically, working with machines, hand tools and chemical products can be very dangerous. Therefore our examples and information are intended for professional customers only (experienced and skilled craftsmen). Yet, we can not give assurance for the success, and we shall not accept any liability for any follow-on damages, as either case depends on the skill of the user, the personal protective clothing, the materials used and the processing conditions.



General Information: Spray Procedure TI – G 7 / UK


The choice of the application system depends on several points:

• Object The size and the shape of the component Quality requirements

• Legislation VOC or other local rules

• Paint system Material e.g. Primer or Topcoat. Material e.g. Structure, Texture, highly fluid, viscous.

• Sprayer (Painter) Speed of work Work habits

Overview of the “normal“ spray application tools

Procedure

Pressure

Atomisation

Extreme pressure (Without air support)

Material pressure 100-250 bar

(<550 bar)

Hydraulic atomization through material pressure

Extreme pressure (With air support)

Material pressure

20-150 bar

Hydraulic atomization through material pressure and air suppport

Electrostatic (Extreme and high pressure)

Material pressure

~ 3-50 bar

Hydraulic atomization and/or pneumatic air support

High pressure

Material pressure

3-10 bar

pneumatic atomization through air support

Optimizes high pressure

Material pressure

2-2,5 bar


Low pressure („HVLP“ „LVLP“)

Material pressure

max. 0,7 bar


Other Manufacturer designation for:

Extreme pressure without air support: Airless Extreme pressure with air support: Airmix, Air-Coat, Spraymix, Air-Combi, Airless-Plus….





Low pressure application:

In the HVLP air spray process (High Volume Low Pressure, i.e. high air volume at low pressure), the coating material is sprayed with low air pressure (anywhere from 0.2 bar to 0.7 bar) and a high air volume. The HVLP requires an air flow of about 400-800 l/min (in some cases up to 2000 l/min), which is produced by a compressor or a turbine. The LVLP air spraying process (Low Volume Low Pressure), a further development of the HVLP process, requires significantly smaller airflow volumes. In relation to the HVLP process, the air volume with LVPL can be reduced by nearly 40%.

High pressure application:

The high-pressure spraying - The coating/paint material is sprayed with an air pressure of 2-10 bar depending on the method. The required amount of air is between 300-500 l/min, and the air is usually generated by a compressor. The transfer rate is set at 35-65% according to the application The adjustable spray gun is perfect for the use of low-viscosity media. The use of high-viscosity media, however, is rather limited. Another feature is the fine atomization and excellent surface quality. High Pressure application is available as:

• Gravity flow cup or suction spray gun

• Pressure-fed spray gun with pressure tank as material feeding (air/paint material via hoses)

• Pressure-fed spray gun with pneumatic pump as material feeding (air/paintmaterial via hoses)

• Automatic spray devices with pressure tank or pneumatic pump

Extreme pressure application:

Airless spray comprises "high pressure and low pressure spraying." The fluid pressure is usually between 100 to 250 bar but also up to 550 bar is possible. The coating medium with the use of spray pressure and spray apparatus is pressed through a die measuring 0.18 to 1.65 mm and producing a finely atomized spray pattern. The benefits are: lower media consumption as compared to compressed air spraying, high working rates, fast finishes in large areas and less overspray across from other spraying. Viscosity materials can be easily processed and can be applied in thick layers with a single layer. With Spraymix or Airmix spraying (air-supported airless spraying) the coating medium is atomized at a lower bar pressure of 20-150 bar. The airless spray pattern is supported with air from 0.5 till 2.0 bar pressure and is thereby "softer". The risk of edge banding is reduced. Both systems are designed for the use with large objects. Small objects can be processed to a limited extent only.

Electrostatic application:

The electrostatic coating method uses a use of high voltage field of 20 - 150kV. This requires a pump or a pressure vessel plus a control unit converting the alternating current into direct current and low voltage via a cable from 3V to 12V to the high voltage generator in the electrostatic spray gun. The integrated electronic system in the control unit clears the electrical voltage to the gun only when the trigger is pulled to release the atomizing air to the gun. Conditions to be considered are the electrical surface resistance of the component itself and the electrical conductivity of the paint. The paint’s electrical resistance shall be at least 5MΩ.cm. Non-conductive coating materials can be applied, however the transfer efficiency is significantly lower. The paint droplets are negatively charged by the high voltage electrostatic spray gun and they move along the electrostatic field lines to the positively charged or grounded component surface.





Where possible, the workpiece is moved to create a generally uniform coating surface. Advantages of this method is the low loss of paint material and no overspray, time savings as well as the briefer cleaning intervals of the spraying tools. The uniform coating has a thickness between 60-80μm. Special precautions must be taken with the electrostatic application of waterborne paints.

Usual application facts: For more detailed information refer to the manufacturer’s instructions!

Spray distance Input pressure Atomisation

pressure Transmission

rate

HVLP/LVLP

10-15 cm / 4“– 6“ max. 2 bar / 29 psi 0,7 bar / 10 psi > 65%

Optimizes high pressure

18-23 cm / 6“– 8“ 2,2 bar / 32 psi 1,8 bar / 26 psi > 65%

High pressure

25 cm / 10“ max. 5 bar / 72 psi 4,5 bar / 65 psi ~ 35-40%

Extreme pressure with air support

10-23 cm / 4“- 8“ max.8 bar / 116 psi

Air support 0,5 -2,5 bar

Material pressure 20 – 150 bar

~ 70-75%

Extreme pressure without air support

20-30 cm / 7“– 12“ -- Material pressure

100 – 250 bar ~ 60-70%

Electrostatic (depending on the system)

20-50 cm / 7“– 18“ Depending oft he

procedure Depending oft he

procedure ~ 80-90%

Furthermore consider the Manufactor information and instructions to avoid application mistakes. Liability for contents: Our information sheets were prepared with great care. Nevertheless, we can not assume any responsibility for the accuracy, completeness and timeliness. Upon notification of errors or of any possible violations of legal issues, we shall change the contents accordingly. Basically, working with machines, hand tools and chemical products can be very dangerous. Therefore our examples and information are intended for professional customers only (experienced and skilled craftsmen). Yet, we can not give assurance for the success, and we shall not accept any liability for any follow-on damages, as either case depends on the skill of the user, the personal protective clothing, the materials used and the processing conditions.



General Information: Mixing Stick TI – G 8 / UK


Handling und usage: (Paint) mixing sticks are used for metering of single or multi-component materials with hardener, thinner and other additives to mix by volume in a conical container. It is important that the required mixing ratio is maintained according to the technical data sheet. To avoid mistakes and poor coating results, the recommended mixing stick from the paint manufacturer should be used. If mixing sticks from other paint suppliers are used ensure that the volume indicators on the stick are in parts and/or percent as shown in the example. If a metric (cm) mixing stick is used, make sure to use the correct conversion factors.

1. Example: Mixing stick 5 : 1 : 1

100 5

= 20 First component Second component Third component

5 parts 1 part 1 part

x 20 = x 20 = x 20 =

100 20 20

This example (:) shows the first component in its entirety (100). All other components will be added at this volume.

2. Example: Mixing stick 5 : 1 + 20% or 5 : 1 : 20%

100 5

= 20 First component Second component Third component

5 parts 1 part

6 100

= 0,06 X 20 = 1,2 = First component Second component Third component

5 parts 1 part 1,2 parts

In that example (: +) the first number is divided by 100 to determine the proportion of the second component. In the second step the first and second components are added, and the result is considered as a whole (100). Now, the 20% can be calculated from the sum. If there is a percentage, the earlier parts shall be added.

3. Example: Mixing stick 4 : 1 : 1 + 10% or 4 : 1 :1 : 10% (see the picture below)

100 4

= 25

First component Second component Third component Fourth component

4 parts 1 part 1 part

6 100

= 0,06 X 10 = 0,6 =

First component Second component Third component Fourth component

4 parts 1 part 1 part 0,6 parts

In this example ( : : +) the first component is divided by 100 to obtain the remaining shares. In the next step all components are added together without the without the percentage and considered as a whole (100), Now, the 10% can be calculated from the sum. If percentage figures area used, the figures before have to be added. When a customer uses a metric (cm) mixing stick, calculation must be as shown above (conversion factors). See also the example on the next page.



General Information: Mixing Stick TI – G 8 / UK


4.

The fourth and last component is finally added to it.

3. The third component is also added up to the same figure.

2.

The second component is also added up to the same figure as for the first component.

1.

The first component is added up to the respective mark, depending on the requested volume.

As can be seen on the cm-stick we have a mixing ratio of 8: 2: 2: 1.2 which corresponds to a mixing ratio of 4: 1: 1: 10% (+ or 10%).




General Information: ISO 12944 TI – G 9 / UK

Date of issue: 6/2013 - Version: 1.0 For professional users only! Page 1 of 6

Introduction: Unprotected steel will corrode in contact with air (atmosphere), in water or earth. Therefore, a number of techniques have been developed to protect steel parts from the effects of corrosion, thereby precluding long-term damage. ISO (International Organisation for Standardisation) is a world-wide association with headquarters in Geneva, Switzerland. The ISO mission is to prepare standards for materials, directives and processes. Test results and empiric data are recorded and made available to users, viz. planners, designing engineers, instructors, students, trades and technicians. All persons concerned shall take reference to applicable standards and procedures and they shall become familiar with the basics of corrosion protection for steel structures and steel objects through the application of surface treatment and coating systems. The standard for corrosion protection DIN EN ISO 12944 was introduced in 1998 as a European and International standard for the protection of steel surfaces, and this standard has become the basis for a number of directives and specifications. Steel is widely used and highly versatile material. It is priceworthy and available world-wide with a host of design possibilities. However, steel also has its handicap: When steel is in contact with oxygen and humidity, iron oxide will develop – or more commonly ‘rust’. Aside from the poor appearance of unprotected steel structures, this oxidation jeopardises these structures as the steel components will deteriorate by up to 200 µm per year. Therefore and right from the planning stage, special care should be addressed when welding, joining with other components to optimally design and position the various components. Extensive pre-treatment of the steel components and appropriate coating systems will prevent corrosion damage, and long useful service lives and high retention of the original value for many years are added rewards. For the selection of the best suitable coating system, the following important issues should be clarified :

• What is the physical location of the structure? In a rural area, within a city, in an industrial environment, at the shoreline; is the structure fully or partially under water or is it in contact with the ground?

• What are normal / additional stress loads at/for the structure? Industrial gases, high humidity, rain, salt, mechanical stress loads, long-term presence of condensated water, etc.

• What is the planned service life for the structure? 5, 10, 15 or 25 years?

• What shall be the designed appearance of the building? Shall the visual impression be secondary or shall there be special colour effects?

• Will the project include regular cleaning and maintenance work? Will road salt on bridges and railing be cleared off at the end of the winter season?

Scope of application:

Type of structure:

Structures made from alloyed or low-alloyed steel, wall thickness 3 mm and more, designed in compliance with a safety certification.

Type of surfaces to be coated and surface treatment:

Uncoated steel surfaces, hot sprayed zinc coating, hot-dip zinc coating and galvanised zinc coating, other surface coatings.





Environmental conditions:

Six corrosivity categories (C1 – C5 I/M) for atmospheric conditions. Three categories for structures in water or ground.

Type of coating system:

Coating materials which dry/cure/harden in the surrounding atmosphere. What is the desired coat thickness and which materials?

Type of measure:

Initial protection and/or repair

Service life of coating:

Three time periods for the expected endurance.

DIN EN ISO 12944 comprises eight parts which include the following parts:

Anticipated duration of protection endurance for coating systems acc. to DIN EN ISO 12944-1 and -5

Duration of protection The indicated duration of the protection until the first repair work depends on the corrosion stress or environmental conditions, respectively, and on the selected type of coating. The first partial repair phase for reasons of corrosion is due when the coating system shows rust grade Ri 3 acc. to ISO 4628-3, unless contractual provision dictate specific time periods. The duration of protection does not constitute a warranty period. It is a technical recommendation to assist the ordering party when defining periodic service and maintenance.

Time frame Years

Short L (Low)

2 – 5

Medium M

5 - 15

High H

more than 15

DIN EN ISO 12944-1 General introduction

DIN EN ISO 12944-2 Environmental conditions DIN EN ISO 12944-3

Corrosion-relevant design

DIN EN ISO 12944-6 Suitability certificate for coating systems

DIN EN ISO 12944-5 Coating systems and thickness

DIN EN ISO 12944-7 Monitoring

of coating work

DIN EN ISO 12944-8 Specification for

initial protection / repair

DIN EN ISO 12944-4 Surface preparation





Classification of environmental conditions acc. to DIN EN ISO 12944-2

Climate category

Application area

Recommended total coating thickness

outdoors indoors

C1 negligible

Heated rooms, e.g. offices, shops, schools, hotels

80µm

C2 low

Low pollution, mostly rural areas Unheated buildings where condensation may occur, e.g. storage facilities, sports centres

120-160µm

C3 medium

Urban and industrial areas, moderate pollution, coastal regions with low salt concentration

High humidity rooms with some air pollution, e.g. breweries, dairies, food production facilities

160-200µm

C4 severe

Industrial areas, coastal regions with moderate salt concentration

Chemical plants, swimming pool, boat houses above sea water

200-240µm

C5 – I extreme (industrial)

Industrial areas with high humidity and aggressive atmospheres

Buildings and areas with ever present condensation and heavy pollution

240-320µm

C5 - M extreme (maritime)

Coastal and offshore regions with high salt concentration

Buildings and areas with ever present condensation and heavy pollution

240-320µm

This information does not consider stress categories in water and soil. Im1 = Fresh water – Im2 = Salt water or brackish water – Im3 = Soil (Steel decomposition – unprotected 250-1000µm/year) Pre-treatment of surface: Proper pre-treatment of surfaces is prerequisite for a durable coating system. The best coating system will fail when it was applied to poorly cleaned and insufficiently treated surfaces. For steel surfaces, we recommend blasting with a suitable blasting medium (minimum SA 2.5) for a roughness of 25 – 50µm. The primer coat should measure 80 – 160µm. At higher roughness grades the primer coat should be increased 3-fold. For further information please refer to the technical information provided with the product or contact us via our service hotline. Steel surfaces always show ‘ferrous‘ deposits, such as rust, rolling skin and mill scale, and ‘non-ferrous‘ deposits such as oils, grease, salts, dust, condensation, etc., any of which reduce the desired bonding of a coating system and support corrosion. These deposits and impurities must be totally removed (refer to the table below).





Hot-dip galvanised steel surfaces do not show rolling skin and mill scale, however, zinc corrosion products, zinc salts and remains of flux must be removed. Users must always be aware that there is a oily layer on freshly zinc coated surfaces. Surface pollutions and removal/cleaning methods acc. to DIN EN ISO 12944-4:

Pollution Cleaning processes Remarks

Water-soluble pollution, salts, mineral matters

Cleaning with water or steam jet

Clean water with or without cleaning agents, afterwards rinsing with clean water

Oils, greases

Cleaning with alkaline solutions Cleaning with solvents

Possible aggressive action at metallic coatings, therefore rinsing with clean water. Cleaning and dry rubbing, using several pieces of cloths.

Rolling skin and mill scale

Pickling with acidic solution Dry blasting Wet blasting Flame blasting

Always followed by rinsing with clean water. Use suitable blasting medium, remove any dust. Always followed by rinsing with clean water. Remove any residue.

Rust

Process as with rolling skin and mill scale Mechanical tools Selective/spot blasting High-pressure water jet

Mechanical brushing or grinding Local removal of rust Removal of loose rust

Existing coatings

Pickling Dry blasting High pressure water jet Mechanical tools Sweep blasting

Alkaline or solvent-containing products, afterwards rinsing with ample clean water Use suitable blasting medium, remove any dust. Pressure 100 . 250 bar, depending on coating. Grinding – roughing of bonded coating or removal of coating. Roughing of coating, remove any dust.

Zinc corrosion products

Sweep blasting Alkaline cleaning

(smooth blasting) for zinc use corundum, silicates must not destroy zinc coating. Use alkaline cleaning agents, rinse with clean water.





Corrosion through coating systems: Coating materials are applied in liquid form onto the steel surface/galvanised steel surface where they create a homogenous, coherent lacquer coat. This is a film-forming process which is decisive for the overall quality of the protective coating. Film-forming can be the result of either physical drying or chemical drying/curing/hardening. This depends on the type of binding agent / resin. Chemical curing/hardening is effected through a second component, and in most cases, this medium is added in a precise proportion to the base material. The coating is dried in the surrounding atmosphere, at 20°C or by furnace drying in closed cabins at up to 80°C or by means of IR radiation. Powder lacquers or baking enamels are normally baked at 80°C to 250°C. Not every paint shop or lacquering service has the facilities for powder lacquers and the necessary processes. Classical laquer structure:

1. Zinc dust epoxy primer is mostly used as the adhesion or basic layer, serving as a sound ‘foundation‘ on the blasted steel surfaces. Other corrosion protecting pigments are zinc phosphate and zinc oxide.

2. An intermediate coating layer increases the anti-corrosion properties, it smoothes possible unevenness, supports a uniform distribution and enhances the gloss of the top coat. If required, this intermediate layer – mostly made from epoxy-based primer (EP) – can be ground to create a smoother surface.

3. The top coat essentially produces the optical effects, such as colour hue and surface texture, i.e. high

gloss, matt, structured, effect lacquers, etc. By the same token, they shall be abrasion resistant, of satisfying UV resistance and they shall prevent the effect from aggressive media in the atmosphere.

The term “Duplex Systems“ hot-dip galvanising + coating: A coating system is applied onto the hot-dip galvanised steel surface. This provides for substantially longer protection (extension factor 1.5 to 2.5 x) than the sum of the protection times of zinc plating and coating system. Laboratory tests for the assessment of coating systems: DIN EN ISO 12944-6 describes laboratory tests for assessment purposes. Using a salt spraying device, ageing of the object is accelerated owing to the increased corrosion stress. These tests serve as reference data for a safe forecast regarding the corrosion protection properties of a given surface coating system.





Execution and monitoring of coating work (DIN EN ISO 12944-7): The following conditions must be met before a steel object will enjoy a long enduring corrosion protection:

• Surface preparation in compliance with approved standards

• Preparation and coating executed by professionals of the trade

• Certified coating media suitable for the specific demands, proper storage and use of the coating media

• Coating application for the desired minimum dry coat thickness

The contracted party can best achieve these conditions by prior development of a quality management scheme certified to DIN EN ISO 9000 which define and monitor the various processing and application phases. The contracted party shall perform all work details and ensure continuous own quality monitoring. If so required, the producer of the coating media should be contacted for competent professional consulting on specific jobs. Preparing of specifications for initial protection systems and for regular maintenance: The last part of DIN EN ISO 12944-8 holds: Procedures for the preparation of specifications for initial protection and maintenance, details for coating system specifications, form sheets for final reports and test reports. For the initial corrosion protection of a structure, users should select a coating system ensuring long protection endurance. Planning for maintenance and for applicable repair is facilitated when users can refer to a professionally prepared documentation or to records of previous maintenance or repair work. Before preparing a specification, user should identify the situation and status as to the need for a complete renewal or for spot or isolated corrective measures at the coating system. An exact description of the expected performance for the desired coating system on steel surfaces should be the basis for any contractual agreement between the ordering party and the executing contractor. The specification shall describe the object in full detail and define the extent of the work details and of the coating media to be used. The contractual agreement shall also include the issues of monitoring and control, quality control and planned warranty times. (Source: Bundesverband Korrosionsschutz e.V. und Verband der deutschen Lack- und Druckfarbenindustrie e.V. ) [Federal Association for Corrosion Protection and Association of German Paint, Lacquer and Printing Ink Industries] Liability for contents: Our information sheets were prepared with great care. Nevertheless, we can not assume any responsibility for the accuracy, completeness and timeliness. Upon notification of errors or of any possible violations of legal issues, we shall change the contents accordingly. Basically, working with machines, hand tools and chemical products can be very dangerous. Therefore our examples and information are intended for professional customers only (experienced and skilled craftsmen). Yet, we can not give assurance for the success, and we shall not accept any liability for any follow-on damages, as either case depends on the skill of the user, the personal protective clothing, the materials used and the processing conditions.



Pre-treatment: Metal Substrates TI – P 1 / UK


General Information:

The pre-treatment of metal substrates is an important requirement for the adhesion and durability of the coatings. The term cleaning includes removal or treating of all “inherent residues” and “foreign inherent residues” which could cause contamination to the coating, prevent positive adhesion or support corrosion. The condition of welds, joints, especially corners and edges should be rounded with a minimum radius of 2mm. (responsibility of the steel worker). Requirements of ISO 12944 Part 3-4 and ISO 8501 Part 1-3 should be observed. The inherent residues on the surface are:

• Mill scale and scale

• Corrosion / rust

• Metal-specific salts The foreign inherent residues on the surface are:

• Oil / grease

• Dust

• Salts

• Alkali

• Soling any kind

• Existing coatings

For the cleaning method we differentiate between “Technically possible/normal procedures” and “Industrial or commercial processes”.

1. Cleaning:

Workpieces must be degreased before any preparation is started. The type of cleaning agent depends on the material, the present impurities, “inherent residues” and “foreign inherent residues”, on the requested degree of purity and on pertinent legal regulations applicable for chemicals used in such processes. Normally, degreasing is executed with solvent-based media or watery solutions. On some surfaces, e.g. structural surfaces which cannot be sanded, it is recommended to use pickling for the cleaning process.

2. Technically possible/normal procedures for surface treatment:

Impurities, such as e.g. rust, loose/seized weld spatter, mill scale and scale should be mechanically removed. These include: grinding, brushing, and blasting (with metal- or mineral abrasives). The mechanical pre-treatment can also be used to remove the old coating. The degree of surface roughness increases the effective adhesion. Bare metal surfaces should not be touched with bare fingers or hands. Always wear gloves! Surfaces must be coated very soon after cleaning and preparation depending on the weather otherwise there is the risk of renewed corrosion.

3. Industrial or commercially process:

For industrial cleaning the workpieces are usually put in immersion tanks rather than using spray jets for cleaning. The use of ultrasonic or electrolysis immersion tanks will further improve cleaning processes. For “inherent residues” the best cleaning process is the use of e.g. pickling, acids and bases. Depending on the process, the components are subsequently cleaned with a rinse and/or coated with a conversion layer. This very thin non-ferrous layer increases the surface profile (roughness), providing excellent adhesion for following coatings, - and there is it has an added anti-corrosive effect.



Pre-treatment: Metal Substrates TI – P 1 / UK


As a rule, the conversion layer to be coated may be:

• Phosphate on steel

• Pickling or phosphate on aluminium

• Pickling by alkalis on galvanized steel Painting: Before application of coating materials the substrates must be absolutely dry. There should also be a minimum temperature of about 10°C. 20-30°C would be perfect this also means the sprayer can handle the materials very well. Furthermore the humidity should not be too high, the parts must have reached ambient temperature otherwise there is a risk of condensation. The instructions of the paint manufactures should be followed. Liability for contents: Our information sheets were prepared with great care. Nevertheless, we can not assume any responsibility for the accuracy, completeness and timeliness. Upon notification of errors or of any possible violations of legal issues, we shall change the contents accordingly. Basically, working with machines, hand tools and chemical products can be very dangerous. Therefore our examples and information are intended for professional customers only (experienced and skilled craftsmen). Yet, we can not give assurance for the success, and we shall not accept any liability for any follow-on damages, as either case depends on the skill of the user, the personal protective clothing, the materials used and the processing conditions.



Pre-treatment: Cleaning TI – P 2 / UK


General information:

Almost every surface that needs to be painted is likely to have contamination of some kind. This contamination can be “inherent residues” on a surface such as corrosion deposits like mill scale and scale or “foreign inherent residues” or abnormalities on the surface, such as waxes, oil, grease, silicones, soiling and so on. The cleaning process to select depends on the paint system on the users shop facilities. The removal of inherent residues layers was described in detail in “TDS TI-P1 Pre-treatment: Metal Substrates”. This TDS discusses in more detail the cleaning processes and the available cleaners and options for removal of the “inherent residues” and “foreign inherent residues” residues on different substrates. Correct use of personal protective equipment “PPE” such as gloves, respirators, safety glasses, etc. is mandatory when executing any cleaning work details. Information provided by employers’ liability insurances, regulations on accident prevention and pertinent laws and directives must be observed. Coated Surfaces: (Also see TDS TI-P3 Pre-treatment: Sanding)

Old paint – Damaged substrate, restoration, repainting and corrosion etc. Existing paint surfaces generally have residues of some kind. This, among others, could be oils, bitumen, tree resin, bird droppings, conservation media, salts, etc. To remove mineral residues such as salts use aqueous cleaners or clean water. Solvent-based cleaners such as silicone remover (Degreaser) which evaporate slowly should be used on the stubborn residues such as bitumen, oil, etc. Note! Water-soluble salts can not be removed with silicone removers.

• Surfaces to be painted must be thoroughly cleaned before starting with a grinding process. If the dust is not automatically extracted and filtered, the ground surface must first be cleaned with compressed air.

• Thereafter, use silicone remover (Degreaser), apply this degreaser onto a cloth and wipe the surface. Use a second (clean) cloth to wipe the surface dry.

• It is Important that the silicone remover must always be wiped until it is dry – do not let it simply evaporate!

• The surface is now fully prepared and ready for painting; apply primer or topcoat. Iron/Steel surfaces: (Also refer to – TDS S1 Substrate: Steel)

“Inherent residues” on the surface such as rust, mill scale and scale must be removed.

• To clean the “foreign inherent residues” such as oils, grease, etc on the substrates with solvent-based cleaners such as universal thinners or silicone remover it is also possible to use slow evaporating products to achieve longer open cleaning durations.

• The solvent-based cleaners are applied by means of a spray bottle, high pressure sprayer, brush, cloth or other similar application tools.

• After a certain reaction time, the steel surface has to be cleaned. To further improve the adhesion properties, use sanding pads or steel wool to prepare a better surface texture.

• After the first cleaning step and the drying processes are completed the substrates may be ground to increase the surface area for better adhesion properties.

• Clean the surface from dust and wipe again with a solvent-based cleaner.

• Important: If the parts are very dirty and contaminated, repeat the cleaning steps until the cloth appears clean.





Industrial cleaners such as pickling, degreasing, rust removal agents and special detergents may also be used. These are usually water-based and can be applied undiluted or diluted with spray tools or in tanks using steam jets. After an appropriate reaction time, the surface shall be cleaned with plenty of clean/pure water. Water quality varies from area to area. Therefore, purified water should be used for further cleaning and rinsing (fully de-mineralised). Untreated Aluminium Surfaces: (Also see – TDS TI S3 Substrate: Aluminium)

Aluminium surfaces are very sensitive to finger or hand prints, It is imperative to wear gloves. New aluminium substrates always have an oily coat. Older components form a very thin protective layer on the surface. This is called patina.

• Solvent agents like universal thinners with long evaporation rates can be used for cleaning, or use silicone remover (Degreaser).

• To improve the adhesion sanding the surface can be roughened using an abrasive pad.

• After the first cleaning step and drying then the substrate may also be sanded with a sanding machine to increase the surface area. This will achieve excellent adhesion.

• Finally the surface shall be cleaned from dust and wiped again with a solvent-based cleaner with a cloth until all of the black residue is removed from the aluminium.

Warning: Sanded aluminium is highly explosive. Use specially designated electric sanding devices with dust extraction. Industrial cleaners such as pickling, degreasing, rust removal and special detergents may also be used. These are usually water-based and can be applied undiluted or diluted with spray tools or in tanks with steam cleaners. After an appropriate reaction time, the surface is to be cleaned with plenty of clean/pure water. Water quality varies from area to area. Therefore, fully demineralised water should be used for final rinsing. The application of a a coating should be executed without any undue delay (within 60-90 minutes). Otherwise, humidity in the air will support the formation of a non-adhesive layer on the aluminium surface. Galvanised Steel: (Also see – TDS TI S2 Substrate: Zinc- galv. Steel)

Galvanized steel substrates have oily surfaces. Older substrates are usually covered by white corrosion which forms on the surface. This must be removed.

• To clean the zinc surface use solvent agents such as universal thinners with long evaporation rates in combination with a plastic abrasive pad. Silicone removers are not suitable.

• For the preparation of zinc surfaces the use of an ammonia alkaline wetting agent is recommended. Mix 10 liters of water add 0.5 liters of ammonia (25% ammonium hydroxide) and add 1 tablespoon dishwater detergent. This liquid is applied with a plastic abrasive pad (not steel wool) until a foam is formed.

• Clean with clean/pure water. Water quality varies from area to area. Therefore, purified water should be used for further cleaning and rinsing (fully de-mineralised).

Industrial cleaners such as pickling, degreasing, rust removal and special detergents may also be used. These are usually water-based and can be applied undiluted or diluted with spray tools or in tanks with steam cleaners. After an appropriate reaction time, the surface is to be cleaned with plenty of clean/pure water.





Water quality varies from area to area. Therefore, purified water should be used for further cleaning and rinsing (fully de-mineralised). Important! For all substrates: If substrates are going to be coated with water-based technology clean the surface with solvent products such as slow reducer or degreaser, but final cleaning should be with aqueous cleaners. Liability for contents: Our information sheets were prepared with great care. Nevertheless, we can not assume any responsibility for the accuracy, completeness and timeliness. Upon notification of errors or of any possible violations of legal issues, we shall change the contents accordingly. Basically, working with machines, hand tools and chemical products can be very dangerous. Therefore our examples and information are intended for professional customers only (experienced and skilled craftsmen). Yet, we can not give assurance for the success, and we shall not accept any liability for any follow-on damages, as either case depends on the skill of the user, the personal protective clothing, the materials used and the processing conditions.



Pre-treatment: Sanding TI – P 3 / UK


Sanding/Pretreatment basics:

When a substrate is to be coated the surface pre-treatment is crucial. The better and more precise the preparation e.g. cleaning, sanding of the surface and the final cleaning process, the better adhesion properties can be expected. There is a well-known saying in our industry: "A painted surface is only as good as the underlying prepared ground!” Grinding/Sanding is a method for surface pretreatment which can be performed manually or mechanically. The process is used to create a desired shape and/or surface roughness through removal of material, rust removal, deburring, smoothing, coarse / fine sanding, roughing, polishing, etc. of metal workpieces, coated components, wood and mineral objects. Proper grinding/sanding will effectively increase the contact area for optimum adhesion of the coatings. Overview of the most common abrasives:

Sandpaper, grinding wheels, sanding fleeces, abrasive cloth (fabric), abrasive belts (endless) and sanding discs. For the particular grinding job the abrasive or the grain must meet various requirements, such as grain hardness criteria and cutting ability, long service life, no or low heat development, uniform distribution of the grains on the sanding paper, etc.

• The abrasives are divided into natural and synthetic materials. Natural grain materials e.g. Garnet, quartz and natural corundum are of little use, primarily due to their insufficient strength properties (except for the natural diamond)!

• Synthetic abrasive such as corundum, silicon carbide, boron nitride, boron carbide and diamond are used because of their excellent properties for almost all grinding operations.

• Corundum is the most commonly used medium due to its excellent hardness and toughness Depending on the composition of the properties, Corundum is almost 100% white aluminum oxide (9.4 Mohs), and with its remarkable hardness, it can attack virtually any material right from the start. The grain shape is blocky with straight cutting edges.

• Silicon carbide (9.6 Mohs) is next to diamond and boron carbide the hardest abrasive grain. It features long and free-cutting edges, ideal shapes for an abrasive grain. With a lower toughness, the wear resistance is somewhat lower than that of aluminum oxide (Corundum). It is an excellent medium for use with soft materials.

We recommended:

• Aluminum oxide (noble corundum white) for hard materials

• Silicon carbide for soft materials In the production of the grinding material, an electro-static process is applied to bond the abrasive grains with the glued pad. This technique provides for a perfect orientation of the abrasive grains. This ensures excellent grinding/cutting performance from the very start. Depending on the grain size and density and on the hardness of the workpiece to be processed, a high wear resistance can be achieved. Continuous extraction of grinding waste will enhance the durability and service life.





For this purpose, the term "hardness" is mentioned: If a substance can scratch or damage another it is harder than the other. Under this principle the Mohs scale of hardness (Mohs) has been established. The Mohs scale is from 1 to 10 Mohs (diamond) hardness level. To test the hardness we use a number of different tests: Abrasive hardness test device, pencil hardness device and pendulum hardness device. Roughness:

One of the main surface parameter of a substrate is the roughness (R). This provides information the condition of the surface. The most common roughness definitions are:

Roughness depth Rt Arithmetic mean deviation Ra Average roughness (depth) Rz

Working speed and the grinding tool strongly affect the resultant surface roughness of the workpiece. For example, a grinding disk with P320 grains will leave marks when used by hand. These marks will show also after the application of thin lacquers. The same abrasive medium on a rotating sander and with a minute vertical stroke will produce faster material removal and a fine uniform finish. Sanding paper is standardized (DIN / ISO) according to "grain" size and bears the letter P.

• The series starts at P16 (very coarse) to P1200 (very fine) and to Super Fine (sf). Some manufacturers also use the ‘P’ standard for products above P1200 up to P4000.

• Likewise, there is a division into wet and dry abrasive paper. Wet sanding is used less and less.

• When sanding is necessary, the information by paint manufacturers should be followed.

Important! When sanding dry old coatings, fillers, etc. it is recommended to initially use grinding disks of less than P100 sanding paper.

Example:

• Putty is sanded with an eccentric grinding machine and P80 paper.

• The preparation paper grade for application of a filler medium should be P220/P240. Changing from P80 to P220 is a difference of 140 (i.e. 40 more than 100) - This step is too large! There should have another sanding step in-between.

• The correct procedure is to prepare 80% of the surface using a P80 grinding disk.

• Continue with P150 to finish the surface for 90%.

• Thereafter use P220 / P240 to complete the surface for 100%.





Sanding chart with eccentric machine (dry):

Substrate Cleaning Sanding Note

Steel Thinner / Degreaser P80 – P180

Surface must be free from oil, grease also rust, mill scale and scale

Galvanized steel Thinner / alkaline cleaner P180 – P240 Scotch-brite

Remove oxidations products and other contamination products

Hot dipped galvanized steel

Thinner / alkaline cleaner P150– P220 Scotch-brite


Aluminum Thinner / alkaline cleaner P180 – P240 Scotch-brite


Glass fibre (GFK) Degreaser

P220 – P280 Scotch-brite

Putty Remove dust / Degreaser P80 – P240

Intermediate sanding step with P150/P180

Surfacer/Primer Degreaser P320 – P400 Must be well cured.

Oldcoating Degreaser P320 – P400 Must be well cured.




Substrate: Steel TI – S 1 / UK


General Information

All steel grades are a mixture of iron, with a maximum of 2% carbon. By addition of chemical elements such as phosphorus, sulphur, manganese, nickel and chromium to the raw steel will change the properties of the new steel, and as such, its behaviour during subsequent processing steps. Steels are the most commonly used material as they feature good ductibility, stress resistance, excellent heat transfer and high tensile strengths. The melting point of steel depending on the alloy contents can be up to 1536°C. Distinction in ferrous metals:

• Cor-Ten steel

• Quality steel and stainless steel – higher purity than structural steel and alloyed.

• Structural steel – mostly non alloy or low alloy steel / grade steel.

• Cast iron – The carbon content of cast iron is at 2.06 till 6.64%. It will not deform, neither cold or hot.

Steels according to EN 10025 and DIN 17100 are organized by letters and numbers, for example. Example:

S For structural steel, the follow-on number represents the tensile strength/yield strength in N/mm² (e.g. S355 = structural steel with 355 N/mm²).

C Is used for carbon contents and the number of the mass percentage, e.g. C45 = non-alloy grade steel with a carbon contents of 0.45 mass percent

K (low) phosphorus- and sulfur content

The letters and numbers also give information about quality, manufacturing process, the addition of chemical elements, etc.

Cor-Ten steel (with patina)

Low alloy steel with small quantities of copper, chromium, nickel and phosphorus. Through weathering, these steels form a patina layer (rust), on the surface, but below this layer there is an especially tight barrier which inhibits further corrosion. This insensitivity to weather commends its use in art and architectural (e.g. facades, monuments, statues, sculptures, etc..

Stainless steel and grade steel (alloyed / non-alloy)

For quality steel/grade steels there are specific requirements regarding ductibility, toughness and welding properties. High quality steel grades have better purity and more uniform structuring than structural steel grades. For stainless steel the requirements are even higher than for quality steels. Stainless steel contains at least 10.5% chromium and not more than 1.2% carbon. Other alloy components are manganese, nickel, molybdenum and niobium. The results feature better corrosion resistance and some favorable mechanical properties. A dense, protective passive layer of chromium oxide is formed on the material surface. However, the smooth surface provides some problems for painting, mostly adhesion problems. With suitable blasting systems or abrasives there is a possibility to increase the effective contact surface for improved adhesion of coatings.





Structural steel - Construction steel - Tool steel

Usually non-alloyed steel; minute additions of chemical elements yield the desired properties. The cold steel ingots are heated again until reaching the yellow-red-hot condition at about 1000°C till 1200°C and then they rolled into the desired profile shape. The spontaneous oxygen consumption at temperatures above 570°C causes mill scale and scales. This hard and brittle layer forms a galvanic voltage difference and expands at a rate other than that of the steel. Therefore, mill scale and scale are always removed before coating. Structural steel corrodes by numerous environmental effects, and for that matter, it should be coated. Unalloyed steel/structural steel (grade steel) have a carbon contents of 0.2 to 0.65%.

Corrosion is a reaction of metal material with its environment.

Corrosion is a process that occurs when oxygen, water, acids and salts act directly. The temperature must be above 0°C. When the relative humidity is below 40% almost no corrosion occurs, from 40-60% the risk of corrosion increases proportional, and above 60% relative humidity significant corrosion is to be expected. Corrosion stress loads are considerably increased through the exposure to polluted atmospheres, hygroscopic salts, by the type of use and by the position of the components.

Degree of corrosion

Humidity

The Corrosion rate of steel layers (EN ISO 12944-2) with the criteria of the ambient atmospheric conditions each year:

Corrosivity category

Typical Environments Average Steel mining Exterior Interior

C1 Negligible

Heated buildings with clean atmospheres; Offices, schools, shops, hotels

Around 1.3µm/year

C2 Slightly

Low level of pollution, mostly rural areas

Unheated buildings, where condensation may occur; depots, warehouses, sports hall

1.3 till 25µm/year

C3 Moderately

City and industrial atmospheres, moderate sulfur dioxide pollution. Coastal areas with low salinity.

Production rooms with high humidity and some air pollution; breweries, dairies, food processing plants

25 till 50µm/year





C4 Strong

Industrial areas and coastal areas with moderate salinity.

Chemical plants, swimming pools, coastal shipyards over sea level

50 till 80µm/year

C5 – I Very strong (Industrial)

Industrial areas with high humidity and aggressive atmosphere.

Buildings or areas with almost permanent condensation and high pollution.

80 till 200µm/year

C5 - M Very strong (Sea)

Coastal and offshore areas with high salinity.


80 till 200µm/year

Surface preparation of steel parts

Components have to be checked to ensure their suitability for coating. Depending on the condition of the surface, user need to decide which cleaning system, blasting system, grinding system and so on should be applied. Possibilities for the steel surface preparation are:

Contamination / Residues Possible common method

Grease and Oil Grease and oil / water-soluble contaminants e.g. salt

Cleaning with thinners Cleaning with water, steam cleaning Cleaning with emulsions or alkalis

Mill scale and scale Acid pickling, dry blasting, wet blasting, flame descaling

Corrosion / Rust (depends of the rust level)

Same procedure as for mill scale and scale, In addition, clean/grind with mechanically driven devices, pressure water jet cleaning, spot beams

Old/existing coatings Grid cutting, layer thickness measurement performance DIN Pickling, dry blasting, wet blasting, pressure water jet cleaning, sweep blasting, spot blasting, grindling

For detailed information and recommendations contained on our preparation information page. Liability for contents: Our information sheets were prepared with great care. Nevertheless, we can not assume any responsibility for the accuracy, completeness and timeliness. Upon notification of errors or of any possible violations of legal issues, we shall change the contents accordingly. Basically, working with machines, hand tools and chemical products can be very dangerous. Therefore our examples and information are intended for professional customers only (experienced and skilled craftsmen). Yet, we can not give assurance for the success, and we shall not accept any liability for any follow-on damages, as either case depends on the skill of the user, the personal protective clothing, the materials used and the processing conditions.



Substrate: Zinc - Galvanized Steel TI – S 2 / UK


General Information

Zinc is produced as sheet metal for further processing or it is used as an anti-corrosion metal coating which can be applied to steel in different ways. Following appropriate cleaning, zinc can be coated with paints and lacquers according to the manufacturer’s instructions. Zinc is not magnetic, and as such, when measuring any (paint) coating thickness on galvanised steel surfaces through the use of electromagnetic or magnetic measuring instruments, the thicknesses of the zinc layer and the coating layer are added. According to the electrochemical series (see information electrochemical series) the steel is protected by the less noble zinc. Zinc corrodes like all common metals, however, a form of limited protective topcoat is created. Zinc and zinc coatings are not stable below acidic pH=5 and at alkaline effects over pH=12,5. Likewise the atmosphere has a great influence on the stability. Depending on local circumstances larger amounts of aggressive air pollutants, such as sulphuric dioxide, carbon monoxide may be present. The combined effect of moisture creates acids which react to form water-soluble zinc salts, which in turn, accelerate the degradation of the zinc (see the ISO12944 chart below). The appearance of zinc surfaces can be silver metallic shiny, and dull grey go to matt. Depending on the steel material and the type of galvanising, zinc flowers are visible on the surface. Zinc surfaces corrode – forming white/transparent corrosion products. White rust can develop when freshly galvanised surfaces come in contact with moisture, such as rain, fog and condensation formation. White rust is not a quality defect; it is only due to improper wet storage. Fresh hot dipped components should be stored in dry well ventilated area, because after a few days a protective topcoat develops, the so-called zinc patina, which prevents white rust. The galvanized workpieces are passivated, oiled or delivered without surface treatment so this should be performed in duplex system, carefully cleaned and prepared. Duplex systems are composed of zinc or a zinc coating on steel and organic coating. The selection of the coating system is based on the stress and subsequent use of the component. Coating materials must not become brittle or lose adhesion by reactions with the zinc. Corrosion rate of zinc layers (EN ISO 12944):

Corrosivity category

Typical Environments Average Zinc mining Exterior Interior

C1 negligible

Heated buildings with clean atmospheres; Offices, schools, shops, hotels

under 0.1µm/year

C2 slightly

Low level of pollution, mostly rural areas

Unheated buildings, where condensation may occur; depots, warehouses, sports hall

0.1 till 0.7µm/year

C3 moderately

City and industrial atmospheres, moderate sulphur dioxide pollution. Coastal areas with low salinity.

Production rooms with high humidity and some air pollution; breweries, dairies, food processing plants






C4 strong

Industrial areas and coastal areas with moderate salinity.

Chemical plants, swimming pools, coastal shipyards above sea level


C5 – I very strong (Industrial)

Industrial areas with high humidity and aggressive atmosphere.



C5 - M very strong (Sea)

Coastal and offshore areas with high salinity.



Popular types of zinc galvanizing steel 1.1 Hot-dip zinc coat – batch galvanizing:

Batch galvanizing is the hot galvanizing of steel parts and larger structural components. Following a pre-treatment, blanks or finished components are immersed in a hot zinc bath. This full immersion technique ensures that hard-to-reach areas, too, are fully coated, such as internal pipe surfaces and unique profile sections. Edges and corners should be rounded, hollow sections have to be in place drilled ø10 mm and more so that the liquid media can drain away completely during processing. Procedure for the parts for batch galvanizing:

Attachment:

Parts to be galvanised are aligned at the optimum angle on devices attached to allow for a perfect galvanization.

Cleaning:

Components are cleaned in a degreasing bath. Normal degreasing agents usually are aqueous alkaline or acidic products.

Pickling bath:

To create a clean surface for the steel components a pickling bath is used. As rule, the bath is charged with diluted hydrochloric acid. Rust, mill scale and scale are effectively removed.

Rinse: After pickling the workpieces are cleaned with plain water in two rinsing processes

Fluxing:

A flux bath is used to create a thin salt film on the surface. When the workpiece is immersed in the zinc bath the flux layer promotes the reaction between the steel surface and molten zinc.

Drying: Galvanised steel parts are dried.

Galvanising:

The pre-treating steel parts are immersed in a 450°C hot, liquid zinc melt. Their zinc contents is accordance with DIN EN ISO 1461 at least 98.5%. During the hot-dip process and as a result of mutual diffusion, various iron-zinc layers form on the surface. When pulling the workpiece out from the molten bath a glossy, pure zinc layer has formed on the components.

Cooling:

The hot-dip galvanised components for cooling is usually air-cooled, this helps to treat defects such as: zinc runs, zinc splash.

.





The Iron-Zinc-Layer has a thickness of 40-55µm, and the pure zinc coating is 30-40µm. The total zinc protective layer is about 70-86µm (DIN 50 976 at least 50-86µm).

1.2 Galvanising a steel strip – Senzimir process:

A cold-rolled steel strip (0.4 till 4.0 mm thick – 400 to 1800 mm wide) is wound into a coil. The length of a steel strip coils can be up to 3,000 m. The steel strip process consists of the continuous furnace – holding zone – cooling zone – melt bath – zinc order/distribution – cooling. In the continuous furnace in the first stage the strip is heated at 450-650°C. Here, the oxidative purification of the material takes place, and other residues from the cold rolling process are also removed. In the reduction zone and holding, the steel strip is continuously annealed at 800°C. This process defines and adjusts the desired mechanical properties of the material. The strip is than cooled and dipped into the molten bath at a zinc temperature of 450-480°and reversed on a pulley for the return motion. A direct air jet strips excessl liquid zinc from the strip surface. The zinc coating is determined by the belt speed, and the blow-off nozzle width. After cooling, the strip is rolled into a coil for further processing. About 0.2 – 0.5% aluminium are added to the zinc bath, thus the bright glossy coating, creating a “spangle”. Bbelt speeds are up to 220 m/minutes, depending on the bandwidth. The usual layer thicknesses of zinc coatings in this process are between 5 till 20µm. This is specified in the rule for basic weight in g/m (usually 100 to 275 g/m² on both sides, 100 g/m² correspond to approximately 7µm on one side). Further processing of the galvanised steel strip materials will come later (punching, drilling, sawing, welding, etc.) It must therefore be expected that processing surfaces which are attached after the galvanising process, are not-galvanised. Possible corrosion of such spots must be expected. Appropriate use us of primer before the coating will prevent corrosion.

2.1 Electrolytic zinc coating / galvanising:

The components to be treated are immersed in a zinc electrolyte, whereby the component functions as a cathode in a solution. Pure zinc parts are used for the anodes. With this type of zinc coating, the zinc coat develops acc. to strength and duration of the electric current. Zinc is deposited as a film on the whole workpiece. Normally a zinc coating measures 10-20µm. Stronger film thicknesses up to 50µm are possible. Workpieces which are uniformly galvanised keep their original hardness, they can be bent easier because they have no inter-metallic alloy coatings such as hot dip galvanised materials. Passive layers are formed up to 120°C. As with galvanised components any contact with acids and alkaline conditions should be avoided as they promote corrosion. After cleaning, yellow and blue passivated substrates can easily be (spray) painted. In the automotive industry among other zinc coatings from 2,0 till 7,5µm can be applied for the protection of corrosion on steel sheets. The metal surface is then contacted with several lacquer coats with thicknesses ranging from 60 to 130µm.

3.1 Zinc spraying – electric arc (mechanical zinc plating).

In the zinc spraying process, a zinc wire is melted by flame or electric arc. Here, the liquid zinc is applied onto the blasted / cleaned surface by compressed air. The still liquid zinc forms a porous layer on the surface, providing similar corrosion protection as a galvanised object. In contrast to hot-dip galvanising the material is subjected to low thermal stress and is not deformed in the process. However it should be noted that folds, hollow sections and hard-to-reach areas are not fully zinc coated or even not at all. If the zinc coating reaches a thickness of about 100µm, the zinc coating it will absorb an unusually large amount of primer or paint material. Users should calculate for a greater amount of primer or paint.





4.1 Zinc laminated coating.

In a spray or dip-spin method, small zinc and partially aluminium flakes are applied to the workpiece and baked at 250-350°C, commensurate with the specific use of the final product. The layer thickness is in a coating operation only 4-5µm and the protective layer is porous. For this reason, the process is normally carried out twice. Preparation of a zinc surface

Careful preparation by removing dirt, grease, oil deposits, corrosion products and old coatings will contribute to improve the adhesion.

For cleaning surfaces the zinc ammonia alkaline wetting agent can be used. Prepare 10 litres of water with 0.5 litres of aqueous ammonia (ammonium hydroxide 25%) and 1 capr dishwashing liquid as a wetting agent in a container. The cleaning liquid is to be used with a cleaning pad/abrasive pad as Scotchbrite (not steel wool) applied to the zinc surface to be cleaned and sanded thoroughly forming a wet foam. After a short exposure the surface is thoroughly cleaned with water. Similarly, appropriate cleaning fluids can be used. Observe the manufacturer’s instructions. Steam cleaning with special conditioning agents is also suitable for cleaning. After rinsing the surface with water, it should be well dried, with special attention to tight spaces, gaps and voids. Otherwise is there a danger of renewed corrosion and damage to the coating.

One type of jet blasting is “sweeping”. This technique will prepare the zinc surface to be treated in a smooth and careful manner. Caution when using this beam blasting technique: Use of a non-metal abrasive, a blasting pressure of 3-4 bar, a beam angle of 30-45°, in a distance of 0.3 – 0.5 meters.

Warning: Sweep blasting may damage the zinc surface! Liability for contents: Our information sheets were prepared with great care. Nevertheless, we can not assume any responsibility for the accuracy, completeness and timeliness. Upon notification of errors or of any possible violations of legal issues, we shall change the contents accordingly. Basically, working with machines, hand tools and chemical products can be very dangerous. Therefore our examples and information are intended for professional customers only (experienced and skilled craftsmen). Yet, we can not give assurance for the success, and we shall not accept any liability for any follow-on damages, as either case depends on the skill of the user, the personal protective clothing, the materials used and the processing conditions.



Substrate: Aluminium TI – S 3 / UK


General Information

Aluminium is the general term for ultrapure and pure aluminium. Aluminium corrosion resistance can be excellent due to a thin surface layer of aluminium oxide that forms when the metal is exposed to air, effectively preventing further oxidation, thickness of 0.05µm, which looks dull, silvery gray. At a pH=4 until pH=9, this protective oxide layer is highly corrosion resistant. Aluminium is the most abundant metal in the earth’s crust, the melting point of 660.4°C. Aluminium it is a relatively light, soft and stringy material which is increasingly used in the manufacturing industry to make lighter vehicles to help with fuel savings. The production of aluminium is very energy-intensive. 13 to 17.8 kWh of electrical energy are required in the electrolysis to produce one kilogram of aluminium. When alloyed with magnesium, silicon and other metals, the properties of aluminium alloy are comparable to steel. Aluminium should not be in direct contact with other metal parts such as steel, otherwise it will form contact corrosion. Caution is advised when condensation is present! This is a result from a temperature difference between ambient air and the component to be coated. Before the application of coatings or other materials, the workpiece should be at room temperature. For example, if a component in the open air at low temperatures is brought into the heated zone/spray booth, a film of moisture is formed on the metal surface which is barely visible to the eyes. However, this thin layer will jeopardise the adhesion of any coating. Remedy: Store or place components in a heated building at max. 70°C relative air humidity overnight 12-16 hours. Another possibility is to bring the cold workpieces into the spray booth before painting and heat them at 40-50°C for 2-3 hours, depending of the material thickness. Aluminium surfaces are treated partly it distinguishes:

Pure Aluminium: Surface is not treated; however, a thin oil coat is always to be expected.

Anodised Aluminium:

Anodising (electrolytic oxidation of aluminium) is an artificial enhancement of the anodic oxide layer. Suitable solutions are treated (e.g. Sulphuric or chromic acid) are electrolytically treated and decomposed by electric current. A 5-25µm layer of oxide is formed on the anode surface. This produces a hardness of between 200-400 HV (Vickers-hardness). After anodizing the aluminium can be dried, it is immersed in a hot coloured solvent and then purged.

Chromated Aluminium:

In this chemical method the aluminium surfaces are formed by the action of chromic acid complex chromium, hydrochloric acid, which will etch the base material. The dissolved metal ions move into the chromate layer. Chromate coatings have a thickness from 0.05 to 1.5µm and they rank among passivated protective layers. Depending of the kind of chromate process different colours are used.

Coated Aluminium: Varnish, paint coat or be powder coated.





When aluminium is to be coated an assessment of the surface, substrate and testing for the further processing and treatment of the substrate is of great importance:

Testing of Method Distinguishing marks

Oily surface Press on absorbent paper (Time about 1-2 minutes)

Paper becomes transparent by oil

Metal blank aluminium Scratch test with a coin or knife back

Coin runs at low pressure leaves scratches

Anodised aluminium (anodic oxidised aluminium)

Scratch test with a coin or knife back

Coin runs at low pressure leaves no scratches

Chemically treated aluminium Scratch test with a coin or knife back

Coin runs at low pressure leaves scratches

Chromated aluminium Visible Transparent coloured layer

Lacquered aluminium Visible Test with solvent

Transparent or colour coating swells and can be peeled off.

Pre-treatment before coating of aluminium

When grinding aluminium workpieces, highly explosive dust is created. Therefore, only appropriate tools and equipment with anti-static properties shall be used in compliance with EU directives. At the same time make sure that there is adequate ventilation and personal protective equipment is worn. To avoid contact corrosion and possible later claims by customers, use only proper and certified grinding media and grinding tools when processing any aluminium workpieces. The appearance of the coating and the smoothness of the film surface are closely related to the state of the substrate. No direct lacquer or primer can effectively cover up poor surface conditions (e.g. deep sanding marks, coarse blasting structure). In this case and if a smoother finish is desired, the primer coating must be ground to the desired surface finish.

Mechanical:

Caution: Wear gloves when working with aluminium!

Cleaning: Degrease with IME.RS607 Universal Reducer slow, wipe dry!

Sanding - hard aluminium: (sanding Filler back)

Sand areas with P150 grinding machine, alternative Scotch-brite red (fine)

Sanding - hard aluminium: (paint DTM or Primer wet/wet)

Sand areas with P240 grinding machine, alternative Scotch-brite grey (extra fine)

Sanding - soft aluminium: (sanding Filler back)

Sand areas with P240 grinding machine, alternative Scotch-brite grey (extra fine)





Sanding - soft aluminium: (paint DTM or Primer wet/wet)

Sand areas with P240 grinding machine, alternative Scotch-brite grey (extra fine

Anodized aluminium

Primer on anodized coating is no solution. - This hard coating must be completely removed by suitable blasting or grinding systems.

Corroded aluminium

White rust is visible and must be removed by suitable blasting or sanding system (P150 – P240).

Aluminium profiles

Joins, rivets and corrugations can be worked with rotary grinders. These are suitable for stainless steel brushes, brass brushes and korflex brushes. Rivets shall not be damaged during grinding (tensile strength).

Blasting

Select suitable abrasive blasting systems for aluminium, e.g. Glass bead, dry ice blasting etc. (do not use iron-containing abrasives).

Sanding dust to aspirate or to blow down

After the grinding/sanding work, the grinding residue must be thoroughly extracted with a vacuum cleaner (observe explosion protection) or removed by compressed air.

Cleaning:

Thorough cleaning with IME.RS607 Universal thinner, until the cloth is no longer turns black.

Painting:

Recoating must be executed without any undue delay (within 60-90 minutes), otherwise the aluminium surface through exposure to the atmosphere will develop a non-contacting surface layer with poor adhesive properties. Depending on the requirements and demands on the coating, direct lacquers or primers with topcoat can be applied (Epoxy, Polyurethane or wash-primers).

Note:

Coating work shall not be executed below 8°C, e.g. paint work at the open air. Ideal conditions for adhesion and high quality coatings are room temperatures of 18°C and up. Do not apply any paint to objects which are subject the influence of moisture, rain, fog and condensation. Before applying paint to old coatings, perform an adhesion test by cross-cutting and test the possibility of applying another coating by performing a solvent test. Liability for contents: Our information sheets were prepared with great care. Nevertheless, we can not assume any responsibility for the accuracy, completeness and timeliness. Upon notification of errors or of any possible violations of legal issues, we shall change the contents accordingly. Basically, working with machines, hand tools and chemical products can be very dangerous. Therefore our examples and information are intended for professional customers only (experienced and skilled craftsmen). Yet, we can not give assurance for the success, and we shall not accept any liability for any follow-on damages, as either case depends on the skill of the user, the personal protective clothing, the materials used and the processing conditions.

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