Qualisteelcoat: Version 3.0 January 2015

Qualisteelcoat
Technical Specifications V3.0
Version 3.0 January 2015

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Table of Contents
I. GENERAL INFORMATION ................................................................................... 4

1. SCOPE................................................................................................................. 4
2. DEFINITIONS ......................................................................................................... 4
3. LIABILITY DISCLAIMER .............................................................................................. 4
II. LICENSE FOR COATING APPLICATORS .............................................................. 5
1. APPLICATION FOR A QUALISTEELCOAT LICENSE ................................................................. 5
2. FIRST INSPECTION .................................................................................................. 5
3. FINAL ASSESSMENT FOR GRANTING THE LICENSE................................................................ 6
4. INSPECTIONS OF LICENSEES ....................................................................................... 6
5. CHANGE OF CHEMISTRY ............................................................................................. 6
6. USE OF THE LOGO BY COATING APPLICATORS .................................................................... 6
7. COMPANY STATUS CHANGE ......................................................................................... 7
III. QUALITY ASSURANCE BY THE COATING APPLICATOR ....................................... 7
1. IN-HOUSE CONTROL – PROCEDURES .............................................................................. 7
2. COMPANY LABORATORY ............................................................................................. 7
3. THE REGISTER........................................................................................................ 7
4. STORAGE ............................................................................................................. 8
IV. SURFACE PREPARATION .................................................................................... 9
1. SOME INFORMATION ON SUBSTRATES ............................................................................ 9
2. REMOVAL OF CONTAMINATION ..................................................................................... 9
3. PRETREATMENT FOR POWDER AND LIQUID COATING SYSTEMS ................................................ 9
A. QUALITY CONTROL FOR SURFACE PREPARATION BY BLASTING ........................................ 9

1. In-house control ................................................................................................................................................ 9
2. Laboratory and inspection equipment for Blasting Surface Preparation ................................... 10
B. QUALITY CONTROL FOR CHEMICAL PRETREATMENT ..................................................... 10

1. Procedures......................................................................................................................................................... 10
2. Laboratory and inspection equipment for chemical pretreatment ............................................... 11
V. FINISHED PRODUCTS QUALITY CONTROL ....................................................... 11
1. TEST PANELS ....................................................................................................... 11
2. PROCEDURES ....................................................................................................... 11
3. LABORATORY AND INSPECTION EQUIPMENT FOR FINISHED PRODUCTS ...................................... 12
VI. APPROVAL OF COATINGS ................................................................................ 13
1. SCOPE OF THE APPROVAL ......................................................................................... 13
2. EXAMPLES OF COATING SYSTEMS ................................................................................ 13
3. PROCEDURE ........................................................................................................ 13
A. APPROVAL OF POWDER COATING SYSTEMS ................................................................ 15

1. Powder coating systems (Quick Guide) ................................................................................................................. 15
2. Test panels ............................................................................................................................................................ 16
3. Required tests ........................................................................................................................................................ 17
B. APPROVAL OF LIQUID COATING SYSTEMS .................................................................. 17

1. Liquid coating systems .......................................................................................................................................... 17
2. Test panels ............................................................................................................................................................ 18
3. Required tests for the Initial approval ................................................................................................................... 18
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VII. ADDITIONAL DETAILS ON TESTING PROCEDURES .......................................... 19
1. COATABILITY OF PARTS ........................................................................................... 19
2. DETERMINATION OF PARTICLE SIZE DISTRIBUTION ............................................................ 19
3. DETERMINATION OF SURFACE ROUGHNESS .................................................................... 19
4. ASSESSMENT OF THE ZINC COATING AFTER SWEEP BLASTING ............................................... 19
5. INSPECTION OF SURFACE CLEANLINESS AFTER BLASTING ................................................... 20
6. DETERMINATION OF THE CONDUCTIVITY OF DRIPPING WATER .............................................. 20
7. EFFECTIVENESS OF THE PICKLING BATH ........................................................................ 20
8. ASSESSMENT OF THE CONVERSION COATING .................................................................. 20
9. THE DRYING TEMPERATURE FOR LIQUID COATINGS ............................................................ 20
10. ADHESION .......................................................................................................... 20
11. DIRECT IMPACT RESISTANCE TEST .............................................................................. 21
12. DETERMINATION OF DRY FILM THICKNESS..................................................................... 21
13. GLOSS .............................................................................................................. 21
14. DETERMINATION OF DEW POINT ................................................................................ 22
15. STOVING CONDITIONS ............................................................................................ 22
16. APPEARANCE TEST................................................................................................. 22
17. BOILING TEST...................................................................................................... 22
VIII. ENVIRONMENTAL TESTS ON FINISHED PRODUCTS ......................................... 23
1. RESISTANCE TO MORTAR ......................................................................................... 23
2. NEUTRAL SALT SPRAY TEST ...................................................................................... 23
3. RESISTANCE TO HUMIDITY ....................................................................................... 24
4. CHEMICAL RESISTANCE TEST .................................................................................... 25
5. RESISTANCE TO HUMID ATMOSPHERE CONTAINING SULFUR DIOXIDE ..................................... 26
6. ACCELERATED WEATHERING TEST .............................................................................. 27
7. NATURAL WEATHERING ........................................................................................... 27
List of Annexes
Annex 1 Admissible ∆E* for RAL numbers after Florida exposure

Annex 2 List of abbreviations used in the Tables
Annex 3 Powder Coatings – Interior Systems
Annex 4 Powder Coatings – Exterior Systems
Annex 5 Powder Coatings – Thermoplastic Systems
Annex 6 List of applicable standards
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I. General Information
1. Scope
a. Qualisteelcoat is an international quality label for coated steel, specifically
developed to sustain the quality of coating applications on new steel
constructions or equipment, erected or used in more or less corrosive
conditions as detailed in ISO 12944-2.
Both powder coatings and liquid coatings are feasible protective coating
systems. Powder coatings may be thermoset or thermoplastic in nature.
Liquid coatings may be one component, but generally will be two component
systems.
b. Qualisteelcoat considers as substrates carbon steel, low-alloy and non-alloy,
but also hot dip galvanized steel, continuous hot dip galvanized steel, electro-
galvanized steel, sherardized steel or steel covered with a thermal spray
coating, and finally steel covered with a primer coat or electrocoating.
These substrates, electrocoating excluded, are either chemically pretreated or
blasted.
c. The Qualisteelcoat specifications establish the quality level with which
pretreatments as well as coating systems must comply to obtain a
Qualisteelcoat label. They also determine the procedures imposed to the
coater committed to the Qualisteelcoat label.
d. The license attributed to a coater or an approval for a coating system is
related to the corrosivity of the environment as detailed in ISO 12944-2. Only
protective coatings presenting high durability properties will be considered. To
every corrosivity category corresponds a testing level, for example a number
of hours of corrosion tests. Both a coating system and a coater can obtain a
label for a certain corrosivity category. A label is also valid and may be used
for lower corrosivity categories. The inspected system is indicated on the
certificate.
The label is however not valid for higher corrosion categories.
2. Definitions
a. License: Quality Label Qualisteelcoat granted to a coating applicator fulfilling
the requirements of the present specifications.
b. Approval: Quality Label Qualisteelcoat granted to a coating system fulfilling
the requirements of the present specifications.
c. General Licensee: A National Association authorized to administrate the label
in its country. No General Licensee can be simultaneously a Testing
Laboratory, since an obvious conflict of interests will arise.
d. Testing Laboratory: An independent laboratory capable of and approved by
both the national General Licensee and Qualisteelcoat to carry out all the
assessments necessary for the Qualisteelcoat quality label, both for coating
systems and for coaters. The Laboratory has to be accredited according ISO/IEC
17025 General requirements for the competence of testing and calibration laboratories
3. Liability disclaimer
Qualisteelcoat stands for a quality label, and attributes its label based on a
annual report issued by a qualified laboratory. This report states on the quality
level of either a coating applicator or a coating product at the moment of testing.
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Qualisteelcoat cannot be liable for any consequences or damages whatsoever,
directly or indirectly imposed to persons or materials, companies, products or
organizations, nor can it be held responsible for any material or other damages
caused by a holder of the label in the execution of his coating activities, or by any
product detaining a Qualisteelcoat label.
II. License for Coating Applicators

1. Application for a Qualisteelcoat license
Any coater of steel constructions or steel equipment can apply for a Qualisteelcoat
license. A letter of intent expressing the company’s engagement to obtain a
Qualisteelcoat license must be addressed at the General Licensee responsible in the
country where the company is situated. If there is no General Licensee in the country
the coater is located in, the letter can be sent to Qualisteelcoat - c/o AC-Fiduciaire
SA, P.O. Box 1507, CH-8027 Zürich, Switzerland.
This letter of intent must also define the corrosion category the coater wishes to
apply for, and mention in detail the coating system the license will be applying to.
2. First Inspection
a. After reception of this letter of intent, the General Licensee will start up the
procedure and notify the Testing Laboratory, which will contact the coater for
an appointment.
During the first inspection the coater must be coating objects that are
intended for the corrosion category he is requesting the license for.
b. The inspector from the Testing Laboratory will check the following points.
(1) Coatings
The inspector will check that the coating applicator uses coatings
approved by Qualisteelcoat on the parts that will be tested.
(2) Laboratory equipment
The required testing equipment must be available and functional,
together with the relevant documents.
(3) The coating process
Both the pretreatment and the actual coating process will be monitored.
All the equipment used at the production lines should be properly
functioning and will be checked.
(4) Inspection of pretreated and coated products
Only parts and test panels that have been released by the quality control
of the coating applicator will be tested.
The tests are listed in Chapters IV A & B (surface preparation) and
Chapter V (Finished Products Quality Assurance).
(5) In-house control and registers
The inspector will check that in-house control has been carried out and
that the coating plant maintains the required registers. The results
recorded in the register must be coherent with the results obtained on
the test panels. Test panels must be kept and held at the inspector’s
disposal for one year, and the register must be conserved for five years.
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(6) Training
Personnel involved in pretreatment or coating operations shall be
qualified on the basis of proper education, training or experience.
Appropriate records of training shall be established and maintained.
Furthermore, training needs shall be identified and provided for, and shall
also be documented.
3. Final assessment for granting the license
The inspector submits the inspection report to the general licensee and a copy
must be send to Qualisteelcoat in Zürich where it will be stored.
If the result of the inspection meets the requirements, a license to use the
Qualisteelcoat label will be granted.
If the result of the inspection does not meet the requirements due to an
administrative matter, like a missing document, this must be resolved or the
document transmitted within 60 days, or the procedure is suspended.
If the result of the inspection does not meet the requirements but meets those for
a lower corrosivity class, then a license for this lower corrosivity class can be
attributed. Alternatively, the coater can ask for another inspection that must then
be made within 60 calendar days. If this second inspection does not lift the
unsatisfactory requirement, the coating applicator will be informed in a letter
explaining the grounds for the momentary refusal, and the license for the lower
corrosivity class is granted. He must wait at least three months before making a
new license application for the higher corrosivity class.
4. Inspections of licensees
After a plant has been granted a license to use the Qualisteelcoat label, it will be
inspected every year; on appointment to evaluate the level of the license, and the
same tests as for granting the license will be performed;.
The inspector submits the inspection report to the general licensee. If no general
licensee is available the report will be sent to Qualisteelcoat in Zürich.
If the result of the inspection meets the requirements, authorization to use the
quality label will continue.
If the result of the inspection does not meet the requirements, but meets those
for a lower corrosivity class, then a license for this lower corrosivity class can be
attributed. Alternatively, the coater can ask for another inspection that must then
be made within 60 calendar days. If this second inspection does not lift the
unsatisfactory requirement, the coating applicator will be informed in a letter
explaining the grounds for the momentary refusal, and the license for the lower
corrosivity class is granted. The coating plant must wait at least three months
before making a new license application for the higher corrosivity class.
5. Change of chemistry
When the coater modifies in an important way his pretreatment chemistry or
introduces a new pretreatment chemistry, he must notify the General Licensee,
and apply for a new Qualisteelcoat license.
6. Use of the logo by coating applicators
The use of the logo must comply with the Regulations for the use of the
QUALISTEELCOAT quality label (see www.qualisteelcoat.org ).
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7. Company status change
The Qualisteelcoat label is not transferable and not attachable. However, if a
company holding a Qualisteelcoat license is subject of a fusion or taken over by
another company, then the license is transferred to the new owner. If for
whatever reason the company stops its activities as a coating applicator, the
Qualisteelcoat label granted to this company will cease to be valid.
III. Quality Assurance by the coating applicator
The inspector from the Testing Laboratory will evaluate the quality assurance system
set up by the coater by assessing the following points.
1. In-house control – Procedures

The coating applicator shall have a quality control system set up, including a test
plan in accordance with the present Specifications. Both the production methods
and the coated products must be monitored and tested.
A test plan consists of the parameter or property that will be tested, the test
frequency, and where in the process it will be tested. A test plan also needs an
estimation of the duration of the test, and a statement on any required resources.
The suppliers’ instructions must be followed, both for pretreatment products and
for the coatings, and proof thereof must be recorded.
The in-house tests that must be executed are listed below, for a mechanical or
blasting surface preparation in Chapter IV.A and for chemical surface preparation
in Chapter IV.B. Assessment of finished products is described in Chapter V.
2. Company Laboratory
The applicator must dispose of a laboratory facility that is separated from the
production facilities. The laboratory must be equipped to assess the quality of both
the pretreatment and the coated parts.
Technical information and the instruction manuals of every testing device, showing
the identification number and proof of calibration, must be available.
The Technical Data Sheets (TDS) and the Material Safety Data Sheets (MSDS) of
all the products must be available to the laboratory responsible, as well as the
applicable standards or clear working instructions describing the test procedures.
3. The register
The results of the in-house control must be recorded and readily accessible to the
inspector. This control register with numbered pages or a computer record must
be maintained by the laboratory supervisor and must comprehend all the
measurement results and laboratory tests. The control register must show the
nominal values, maximum values not to be exceeded and the measured values.
Any corrective measures, when required or implemented, must be noted in the
register. The register must be kept for a period of five years.
The register must contain the following information:

 The customer's name and the order or lot identification
 Corrosivity category of the environment in which the product will be used
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 Gloss, Color or RAL number and visual reference of the color (color card or
model piece)
 References on the blasting media with dates of their exchange or addition
 The references of the used coating: product name and manufacturer; batch
numbers; for liquid coatings both of the base and the curing agent and
eventually the thinner
 The temperature difference between the part and the dew point in the coating
booth prior to coating application
 The application date of the different coating layers
 Thickness of the different layers of the coating system
 Results of all the performed tests
4. Storage
a. Storage of Coating Materials
The storage of coating materials must comply with the applicable safety
requirements. Only the coating used during the application, and in case of
liquid coating the additional thinner, may be present in the coating application
area.
All coating materials must be stored in a dry room, protected against freezing
or too hot conditions (see Technical Data Sheet for temperature range),
isolated from the production facilities and protected from any contamination.
b. Every lot of parts must be labeled.
c. Storage of pretreated parts
Pretreated parts should preferably be coated immediately after pretreatment.
They must not be stored for more time than mentioned in the table below, and
never in a dusty or otherwise detrimental atmosphere. The storage conditions
must not allow condensation onto the parts. All workers handling pretreated
parts must wear clean textile gloves to avoid contamination of the surface.
C4-C5 ≤ 8 hours
C1-C3 ≤ 24 hours
Blasted hot dip galvanized steel ≤ 4 hours
d. Storage of Coated Materials

The coated products must be stored in a suitable area. The parts must be
packed for transport as soon as possible.
Parts not accepted by quality control must be clearly labeled and kept
separated from the accepted parts.
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IV. Surface Preparation
1. Some information on Substrates
For surface preparation, a coater is equipped with either a blasting booth or a
chemical pretreatment or both. Detailed information on types of surfaces and
surface preparation can be found in ISO 12944-4.
Some substrates will however require a supplementary treatment.
a. Laser cut steel
Unless nitrogen gas or alike is used during the cutting, the cutting edge will be
oxidized. This oxide must be removed, either mechanically by brushing or
sanding or any other suitable method, or by pickling with an acid.
b. Various metal combinations
Preliminary testing of such combinations is mandatory.
2. Removal of Contamination
A surface can be contaminated with oil and grease, marks with chalk or paint or
other, dirt or oxidation. Stickers may be present.
Prior to the surface preparation and the application of a coating system, any such
surface contamination must be removed by suitable means.
3. Pretreatment for Powder and Liquid coating systems
The purpose of the pretreatment is to prepare the substrate for the application of
the protective coating system, and consists in sandblasting or in a chemical
treatment, or both.
Every surface treatment must be done in the plant. Only hot dip galvanizing,
continuous hot dip galvanizing or electro-galvanizing, and also the application of
an electrophoretic coating can be subcontracted.
A. Quality Control for Surface Preparation by Blasting

1. In-house control
The coating applicator must check his production methods and products according
to the following methods and frequency.
C3 – C4
Evaluated Property C1 – C2
C5(M) – C5(I)
Coatability of parts Every lot
Particle distribution of Twice per year by supplier
N/A
abrasives
Blast cleanliness and dust Random testing twice per day
removal
Surface roughness Once per day
Assessment of the zinc coating N/A Once per shift
after blasting
Twice per day – morning & late afternoon
Difference between dew point
Every lot of parts suspected of too low
and surface temperature
temperature
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If the blasting is followed by a conversion treatment, the following is also checked
when it applies.
C3 – C4
C5(M) – C5(I)
Visual inspection
Assessment of the conversion
Chemical assessment 4 times a
coating
year by supplier
The temperature of conversion Once per day
N/A
and rinsing baths
Conductivity of rinsing water 1) Once per shift
Drying temperature after Once per week if applicable
conversion
1) One measurement in the bath before conversion and one in the drippings after final rinse
The results of the tests in the table must be entered in the register.
2. Laboratory and inspection equipment for Blasting Surface Preparation

Instruments
 Roughness measurement device
 Thermometer & Dew Point device
 Equipment and chemicals for testing the conversion coating (if applicable)
 Conductivity meter for the conversion bath and the rinsing
 Temperature pads for the drying oven (if applicable)
 Thickness measurement gauge
3. Additional explanations of the test procedures and test results can be found in
Chapter VII (normative) and Chapter VIII (normative).
B. Quality Control for Chemical pretreatment

1. Procedures
The coating applicator must check his production methods and products according
to the following frequency.
C3 – C4
C5(M) – C5(I)
Coatability of Parts Every lot

Concentration of pretreatment baths 1)
N/A Once per day
Once per Once per shift
Assessment of pH value of baths 1)
day
Conductivity of rinsing water 1) 3)
N/A Once per shift
Temperature of baths 1)
Once per day
Zn and Al content 1) 2)
Once per shift
N/A
Drying temperature Once per day
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C3 – C4
C5(M) – C5(I)
Assessment of the loss of zinc by Once per shift

pickling
N/A Visual once per shift, and
Assessment of conversion coating 1)
chrome free once per month
Weight of the conversion layer 1)
Once per month
N/A
Surface preparation Visual
1) According to the chemicals supplier’s instructions.
2) If using a combined zinc and aluminum bath.
3) One measure in the bath before conversion and one measure in the drippings after final rinse
2. Laboratory and inspection equipment for chemical pretreatment

For Corrosivity Category C1 & C2, only the pH meter and the thermometer are
needed.
Laboratory Instruments for C3-C5 (if applicable)
 Thickness measurement gauge
 Conductivity meter
 pH meter and thermometer
 Chemicals to determine the bath concentrations
 Test solutions for Zn and Al content, when such bath is used
 Test solutions and equipment to test the chemical conversion coating
according to the chemicals supplier’s instructions
 Temperature pads for drying oven
V. Finished Products Quality Control

1. Test panels
Whenever possible, tests should be conducted on Parts from the production. This
may eventually require a supplementary number of parts from the client. When
test panels are used, these shall match the production parts and be covered with
a corresponding metallic layer or primer, and the coating system (See Approval of
Coatings – Panels for Powder Coatings – Liquid Coatings).
2. Procedures
The coating applicator must check his production methods and coated products
according to the following methods and frequency.
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Coating C3 – C4
Tested Property C1 – C2 C5(M) – C5(I)
(*)
All Every order according to Every order according to
Film Thickness
the sampling plan the sampling plan
TSP Once per shift on test Once per shift on test panel
panel
Cross-cut Adhesion 1)
TPP N/A X-cut on parts or test panel
or Pull-off test
LC Thickness < 250 µm: cross-cut
Thickness > 250 µm: pull-off test
TSP N/A Once per day
Direct Impact test 2)
TPP N/A By supplier
LC N/A N/A
TSP Twice per shift and per Twice per shift and per
color color
Gloss measurement
TPP N/A N/A
LC N/A N/A
TSP N/A If applicable, before
Difference between starting the application
dew point and surface TPP N/A Not for fluidized bed
temperature LC Twice per day: morning & late afternoon
Every lot of parts suspected of too low temperature
TSP & Actual oven temperature Actual oven temperature
Measurement of TPP once per day. twice per day.
curing (P & TPP) or Once per month a 4 Once per week a 4 point
forced drying (L) point measurement measurement
temperature LC Surface temperature Surface temperature twice
twice per day per day
Appearance All Every order Every order
assessment
TSP N/A Every order
Pressure cooker test 1)
3) LC N/A N/A
TPP N/A N/A
1) On test panels
(*) TSP = Thermosetting Powder
Coatings
TPP = Thermoplastic Powder Coatings 2)On thin test panels 0.6 to 0.8 mm
LC = Liquid Coatings 3)Not on a thermal sprayed coating nor on
hot dip galvanized steel
3. Laboratory and inspection equipment for finished products
Laboratory Instruments (if applicable)
 Cross-cut tester or Pull-off tester for adhesion
 Impact tester
 Film Thickness gauge
 Gloss meter 60º
 Thermometer & dew point device and a device for substrate temperature
 Recording instrument for object temperature and curing time with 4
measuring points
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 Equipment to conduct the boiling test
VI. APPROVAL OF COATINGS
1. Scope of the approval

A coating applicator can only use approved coating systems for those applications
where the Qualisteelcoat label is involved. Therefore an approval procedure for such
coating systems is necessary. A list of approved coating systems can be found on the
website www.qualisteelcoat.net .
However, since for the moment there are no approved liquid coating systems
available, the coating supplier shall perform a salt spray test on steel test panels
prepared by the coater, to demonstrate the coating systems’ ability to withstand the
imposed hours of salt spray. For a metallic zinc coating, the coating supplier shall
perform a condensation test. Both tests must be performed by a Qualisteelcoat
approved laboratory. These obligations for liquid coating suppliers end on January 1st,
2016, and from that moment on, only approved coatings systems shall be used.
A request for a Qualisteelcoat approval of a coating system includes:

 The Corrosivity Category it is intended for;
 The eventual presence and type of metallic layer;
 The type of surface pretreatment: mechanical or chemical or both – the applied
chemical product must be mentioned;
 The number and type of organic coating layers;
 For powder coatings also the nature of the finish (gloss, satin, matt or texture).
2. Examples of coating systems

Examples of thermoset powder coating systems are given in Annex 3 & 4.
Examples of thermoplastic powder coating systems are given in Annex 5.
Examples of liquid coating systems can be found in ISO 12944-5.
3. Procedure
a. Any company may submit a coating system for approval. In general however, a
Qualisteelcoat approval for a coating system will be attributed to a coating
manufacturer, or to any company that defines, partially or completely, the
composition of the coating, but relies for the manufacturing on a third party.
b. The company addresses a letter of intent expressing its engagement to obtain a
Qualisteelcoat approval to the General Licensee responsible for the country the
company is located in. If there is no General Licensee in the country the applicant
is located in, the letter can be sent to Qualisteelcoat - c/o AC-Fiduciaire SA, P.O.
Box 1507, CH-8027 Zürich, Switzerland.
This letter of intent must describe in detail the coating system the license will be
applying to, and also define the corrosion category the coating system is intended
for.
c. After reception of this letter of intent, the General Licensee will start up the
procedure and notify the Testing Laboratory. The coating manufacturer from a
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country without a General Licensee may submit his products to be tested to one of
the approved Qualisteelcoat Testing Laboratories. The Laboratory will contact the
manufacturer and the necessary quantities of coating products and/or test panels
will be handed over to the Laboratory. If possible, the laboratory will prepare the
test panels, but for an eventual zinc layer or chemical pretreatment, relying on a
subcontractor may be necessary and is therefore allowed. Hot Dip Galvanized
panels may also be purchased.
d. The submitting company provides all the necessary information on his coating
system to the Laboratory, including details on the successive coating layers to
apply and the film thickness of every layer. All the concerned product data sheets
must also be transmitted.
e. All the tests will be executed on a complete system as defined above, unless
otherwise specified. The Testing Laboratory will allow the coating system to cure
properly according to the manufacturers instructions before starting the tests.
f. Final assessment for granting the initial approval
The Testing Laboratory submits the inspection report to the General Licensee or
directly to Qualisteelcoat in countries where there is no General Licensee.
If the test results meet the requirements, a Qualisteelcoat approval for the coating
system will be granted.
If the test results do not meet the requirements, the applicant will be informed
with a letter explaining the grounds for the momentary refusal. The applicant
must wait at least three months before making a new application for an approval.
g. The Qualisteelcoat approval for a coating system is of course valid for the licensed
company, but indeed also for all its production sites where the approved coating is
manufactured. For every production site however, an individual document must be
established by the coating manufacturer, stating that the composition of the
produced coating is identical to the approved coating.
h. Procedure of renewal
(1) The Qualisteelcoat approval for a coating system remains valid for 2 years.
The coating manufacturer supplies the laboratory with the necessary coating
products and test panels for the renewal application. The tests requested for
the renewal application are the same as for the initial application.
(2) Every two years, the Technical Committee defines the color that shall be
submitted to the testing for the next two years. A rotation between RAL 9005
– RAL 7016 – RAL 6005 will be effective.
Applicants which have Qualicoat approvals for their final coats, identified by a
Qualicoat P-number, shall make a rotation of the different P-numbers.
(3) The test report must be submitted through the General Licensee to the
Technical Committee. The Committee decides on renewal or withdrawal of
the approval. If the test results meet the requirements, the approval is
renewed. In case of noncompliance, the tests that failed are repeated on
samples taken from another batch. If this second series of tests does not
lead to satisfactory results, but corresponds to a lower corrosivity category,
the approval is decreased to this lower category. The supplier of the tested
product can submit a new application for approval for the higher level.
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i. Any change in the formula of the coating product implies however that it must be
considered a new product, which consequently requires a new Qualisteelcoat
approval.
j. For powder coating systems, the Qualicoat approval of a final coat remains valid,
and it must not be retested as part of a Qualisteelcoat coating system.
Also test results for artificial weathering and outdoor exposure tests from
approved laboratories, collected to obtain other quality labels, may be used as
test results for the Qualisteelcoat approval, provided that the conducted tests
comply with these specifications and the test report is approved by the Technical
Committee.
A. Approval of powder coating systems
1. Powder coating systems (Quick Guide)

The powder coating supplier can only request an approval for a Coating System
Type of High Durability, defined in the table below (yellow fields).
Corrosivity
System Coating
Substrate Pretreatment Category
Number Layers
C2 C3 C4 C5
Mechanical
ST1 1
Chemical
Mechanical
Steel ST2 2
Chemical
Mechanical
ST3 3
Chemical
Mechanical
SZ1 1
Chemical
Continuous hot dip Mechanical
SZ2 2
galvanizing Chemical
Mechanical
SZ3 3
Chemical
Mechanical
HD1 1
Chemical
Hot Dip Mechanical
HD2 2
Galvanized Chemical
Mechanical
HD3 3
Chemical
MS1 1
Thermal Spray
MS2 2
Electrophoretic EC1 1
primer EC2 2
The applicant shall define his coating system, he shall transmit for each approval
his unique system name, which includes the Coating System Number (examples:
ST2, HD1, MS2,…), the manufacturer, for multi-layer systems the primer, and
describe in detail the process to be used to coat the test panels.
15
2. Test panels
a. Different Types
Type Purpose Substrate Application Dimensions

A Mechanical Test panels + Applied by the laboratory (*) 105 x 190 x 0,75 mm³
tests Coating Systems (ref. GB26S/W/OC
Etalon)
Bare steel + zinc
phosphate
B Corrosion Substrate + Applied by the powder 140 x 70 mm²
tests Surface Preparation supplier or by the laboratory Type 12-03
+ Coating Systems 1-2 mm thick
C Florida EN AW5005 + Applied by the laboratory (*) 300 x 100 mm²
Coating Systems 1 mm thick
(*) at lowest curing conditions (lowest temperature, shortest corresponding time according to the TDS)
b. Number of test panels Type B for the laboratory

Adhesion 3
Direct impact 1 (substrate thickness < 0.5 mm)
Resistance to boiling water 3 (not for thermal sprayed or hot
(Pressure Cooker Test) dip galvanized panels)
Resistance to mortar 3 (not for Qualicoat approved
topcoat)
Neutral Salt Spray test 6 for C5H, 5 for C4H, 4 for C3H
Resistance to continuous 3 (for all categories)
condensation
Resistance to humid atmosphere 3 (only for C5I)
containing sulfur dioxide
Resistance to liquids 9 (only for C5I)
Thickness of metallic layer 1 (with metallic layer only)
c. Total number of necessary test panels
System Substrate + Coating Corrosivity Category

Number Metallic Layers
coating C2 C3 C4 C5M C5I
ST1 1 Layer 16
Steel
ST2 & ST3 Multi-layer 16 17 18
SZ1 Continuous hot 1 Layer 16 17
SZ2 & SZ3 dip galvanizing Multi-layer 16 17 18
HD1 1 Layer 16 17 18
HD2 & HDG Multi-layer 16 17 18 19 31
HD3
MS1 1 Layer 11 14 15
Thermal spray
MS2 Multi-layer 11 14 15 16 28
EC1 1 Layer 16 17 18
Electrophoretic
EC2 Multi-layer 16 17 18 19 31
16
3. Required tests
a. Initial approval
For the initial approval the following color will be tested: RAL 9010 white.
Additional explanations of the test procedures and test results can be found in
Test Panel Standard

Adhesion B ISO 16276-2 0–1
ISO 2409
Direct Impact Test A, B ISO 6272-1 ≥ 2.5 Nm
Film Thickness A, B, C ISO 2808 According to system
ISO 19840 description
ISO 12944-5
Gloss A ISO 2813
Resistance to boiling water B EN 13438
(Pressure Cooker Test)
Resistance to mortar (*) B EN 12206-1
Neutral Salt Spray Test 1) B ISO 9227
Resistance to Continuous B ISO 6270
Condensation 2)
Resistance to Liquids B ISO 2812-1 Only for C5 I
Kesternich B ISO 3231 Only for C5 I – 30 cycles
Accelerated Weathering (*) A ISO 16474-2
Natural Weathering (*) C ISO 2810
1) Only for steel substrates without a metallic zinc coating – a scribe is made
2) For substrates both with and without metallic zinc coating – no scribe is made
*) See VI A 3 b Additional extensions (3)
b. Additional extensions
(1) For systems with one organic layer, the Qualisteelcoat approval is only
valid for the gloss category and the textured or smooth finish that was
tested.
(2) For multiple organic layers, the Qualisteelcoat approval can be valid for
different topcoats of the same supplier, but these topcoats must all be
Qualicoat approved.
(3) (*) These tests must not be executed for topcoats with Qualicoat
approval or for interior approval. For the topcoats without Qualicoat-
approval, the tests with (*) shall be executed on RAL 9010, RAL 7016
and RAL 6005 for the initial approval. The powder supplier provide the
necessary coating material and data..
B. Approval of liquid coating systems
1. Liquid coating systems

Any liquid coating system can be submitted for an approval for the corrosion class
and substrate it corresponds to in ISO 12944-5. A deviation from the proposed
coating systems in ISO 12944-5 for a particular Corrosivity Category, either in
number of coats or in layer thicknesses, must be based on strong field evidence.
17
Such a system will only be allowed with an authorization from the Technical
Committee.
2. Test panels
The Testing Laboratory will prepare test panels with the dimensions the laboratory
is used to work with, or alternatively use panels of approximately 150x70 mm²,
with a thickness between 0.5 and 2 mm. For every coating system entered for
qualification, fifteen panels shall be handed over to the Testing Laboratory.
− Steel panels of cold rolled steel are prepared to a degree of cleanliness
Sa 2 ½ or Sa 3, according to ISO 8501-1. The roughness Rz must be
between 50 µm and 100 µm. Blasted panels are dedusted prior to the
application of the primer coat.
− Hot dip galvanized or continuous hot dip galvanized panels of the same
dimensions may be bought or prepared by a subcontractor. The former
panels are sweep blasted prior to the application of the primer coat; the
latter panels may be sweep blasted prior to the application of the primer
coat, according to the instructions of the coating manufacturer. The panels
can eventually also be chemically pretreated.
− Thermal sprayed or electrogalvanized panels of the same dimensions may
be prepared by a subcontractor. Only the latter are eventually sweep
blasted prior to the application of the primer coat, according to the
instructions of the coating manufacturer.
3. Required tests for the Initial approval

The following tests will be conducted by the Testing Laboratory:
Test Standard Requirement

Film Thickness ISO 2808 In agreement with the
ISO 19840 system description
ISO 12944-5
Adhesion ISO 16276-2 0–1
Cross-cut or X-cut test ISO 2409
Pull-off test ISO 16276-1 > 3 MPa
ISO 4624
Neutral Salt Spray Test 1) ISO 9227
Resistance to Continuous ISO 6270
Condensation 2)
Resistance to Liquids ISO 2812-1 Only for C5 I
Kesternich ISO 3231 Only for C5 I – 30 cycles
Accelerated Weathering ISO 16474-2
Natural Weathering ISO 2810
1) Only for steel substrates without a metallic zinc coating – a scribe is made
2) For substrates both with and without metallic zinc coating – no scribe is made
18
VII. Additional details on testing procedures
1. Coatability of parts
The following questions should be considered to evaluate the suitability of an object
for the application of a coating system:
(1) Is the pretreatment adapted to the piece ?
(2) Can the coating system be applied to this substrate ?
(3) Is the paint system suitable for the corrosivity category ?
Doubts about the suitability of the object for the application of the considered
coating system must be discussed with the client. A written agreement must then be
available.
Sharp edges must be rounded – see EN 1090 p180 §F.6.1 and ISO 12944-3 Annex
D/Fig D5.
Structures with an expected life of the corrosion protection above 5 years with a C3H
and higher corrosivity category shall have rounded or chamfered edges in
accordance with EN ISO 12944-3.
For a liquid coating system, the edges shall be protected by a stripe coat extending
across approximately 25 mm on both sides of the edge and applied to a nominal
thickness appropriate to the coating system.
2. Determination of particle size distribution

The particle size distribution test is conducted according to ISO 11125-2 for metallic
blast-cleaning abrasives and ISO 11127-2 for nonmetallic blast-cleaning abrasives.
Determine the mean mass value of two tests and report the result to the nearest 1%.
The particle size distribution must correspond to the distribution necessary to achieve
the required surface roughness.
3. Determination of Surface Roughness

The roughness of the substrate after blasting must be assessed. As a parameter, the
maximum height is considered, which is the distance between the highest and lowest
points in the evaluation length/area. The coater has the choice of the method. The
assessment of the roughness is conducted in accordance with ISO 8503-2 for ISO
surface profile comparators, 8503-4 for the use of a stylus instrument, and 8503-5
for replica tape.
The surface roughness must be equal or higher than the value stated by the coating
manufacturer in the Technical Data Sheet.
4. Assessment of the zinc coating after sweep blasting

A zinc coating must be made ready to be coated, and dross particles, droplets and
sharp points, zinc ashes, zinc flakes, flux residues, and the like must be removed.
Additional sweeping may be necessary. This must be done with a fine grade non-
metallic abrasive at low pressure at an angle 30-35° to the surface. The remaining
film thickness of the zinc coating after sweep blasting must comply with ISO 1461 –
Table 3, and is function of the steel thickness. Thickness measurements must be
done for each project involving hot dip galvanized surfaces.
19
5. Inspection of Surface Cleanliness after Blasting
The surface must be very thoroughly blast cleaned (Sa 2 ½) according to
ISO 8501-1. Prior to an eventual chemical pretreatment and prior to the primer
application, the surface must be dedusted. The remaining dust quantity and size
must be evaluated according to ISO 8502-3. Both dust quantity and dust size must
not exceed Class 1.
6. Determination of the conductivity of Dripping Water

The final rinse preceding the conversion bath must be done with deionized water. The
conductivity must comply with the supplier’s instructions. If not otherwise prescribed
by the chemicals supplier, the conductivity of dripping water shall not exceed
30 μS/cm at 20°C.
7. Effectiveness of the pickling bath

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

The quality of the conversion coating can be visually assessed for traditional
conversion coatings. However, for chrome free conversion coatings, visual
assessment proves to be difficult or impossible. The chemical supplier's
recommendations about the test method must be applied.
The weight of the conversion layer must be determined according to the instructions
of the chemicals supplier, and may even be executed by the chemicals supplier.
9. The drying temperature for liquid coatings

The substrate must be heated to the maximum temperature allowed by the coating
manufacturer. If such a value is not available, it shall be heated to (60±5)°C.
10. Adhesion
The adhesion of the coating system onto the substrate is measured according to
ISO 16276-2 (Cross-cut testing and X-cut testing). Alternatively and certainly for film
thicknesses exceeding 250 µm, ISO 16276-1 (Pull-off testing) will be used.
The expected results shall be:
DFT (µm) Results

C1 – C2 C3 – C5
< 60 0-1 -
< 120 0-1 0–1
< 250 - 0–1
> 250 - > 3 MPa
For each color shade, gloss category and supplier, the adhesion properties must be
tested on sample panels.
20
11. Direct Impact Resistance Test
The direct impact resistance is determined according to ISO 6272-1 using a
20 mm diameter spherical indenter dropped under standard conditions. For powder
coatings, the test panels must have the thickness of the parts they are linked to.
For powder coatings with a thickness d≥60 µm, a mass of one kilo that falls from a
height of 25 cm must be used.
Coating systems should not show any cracking or any detachment of the coating from
the substrate.
12. Determination of Dry Film Thickness

The dry film thickness of the individual layers in the system and the total dry film
thickness shall be measured according to ISO 19840 with a method specified in
ISO 2808. The measurements must be representative of the inspected area.
According to ISO 19840, the total coated surface can be used to determine the
number of necessary measurements. The sampling plan consists of this number of
measurements to be taken in an inspection area, and is as follows:
Area/length of Maximum number of

Minimum number of
the inspected area measurements
measurements
(m2 or m) allowed to be repeated
up to 1 5 1
above 1 to 3 10 2
above 3 to 10 15 3
above 10 to 30 20 4
above 30 to 100 30 6
above 100 add 10 for every additional 20 % of the minimum
100 m2 or 100 m or part number of measurements
thereof
Areas above 1000 m2 or m should be divided into smaller inspection areas.
According to ISO 19840, the dry film thickness is accepted when:
(1) The arithmetic mean of all the individual dry film thicknesses is equal to or
greater than the nominal dry film thickness (NDFT);
(2) All individual dry film thicknesses are equal to or above 80 % of the NDFT;
(3) Individual dry film thicknesses between 80 % of the NDFT and the NDFT are
acceptable provided that the number of these measurements is less than 20
% of the total number of individual measurements taken
The NDFT is the dry film thickness specified for each layer or for the whole paint
system.
The dry film thickness cannot exceed the maximum imposed by the coating
manufacturer, or in absence of such a value may be three times the nominal dry film
thickness.
13. Gloss
Gloss is measured according to ISO 2813, using incident light at an angle of 60°.
21
Note: if the significant surface is too small or unsuitable for gloss to be
measured with the gloss meter, the gloss should be compared visually with
a reference sample, both observed under the same viewing angle.
RESULT:
Low Gloss : (0 – 30) ± 5 units
Semi-gloss : (31 – 70) ± 7 units
High Gloss : (71 – 100) ± 10 units
14. Determination of Dew Point

The substrate temperature must be at least 3°C above the dew point.
15. Stoving Conditions

The temperature in the curing oven and also the object temperature must be
measured with a 4-point measuring device. Three detectors must be attached to the
top, middle and lower parts of the oven and one to a reference panel mounted on the
traverse amidst the parts.
For forced drying, the temperature of the substrate in the drying oven must be
measured. This may be done by means of a 4-point measuring device, using
temperature probes attached to the substrate. The thickest part of the steel must
reach the maximum temperature allowed by the coating manufacturer.
16. Appearance Test

Any visual inspection of coated parts should be done at a distance of 3 m for an
interior setting and 5 m for an exterior setting, and with a normal unaided vision.
At these distances and in diffuse daylight, the coating must not show any wrinkles,
runs, sags, craters, blisters and other surface irregularities. Irregularities that are an
image of the steel surface or the hot dip galvanized zinc, visible through the coating,
must be disregarded.
Color and gloss may be measured if agreed upon between customer and coater.
17. Boiling Test

The objective of this test is to determine the resistance of the coating system to
cracking and loss of adhesion, or both, after accelerated aging by boiling water. The
test must be performed according to EN 13438, A.4.11.
Procedure
Fill a pressure cooker with (25 ± 3) mm de-ionized water with a maximum
conductivity of 30 µS/cm at 20°C. Partially immerse the coated test panel in the
water so that a minimum length of 25 mm is immersed and secure the lid of the
pressure cooker. Apply heat to the pressure cooker until steam is emitted from the
valve. Insert a weighted needle valve to give a pressure of 100kPa and continue
heating for two hours from the time the steam was first emitted. Cool the
apparatus with care. Remove the sample and allow it to cool down to room
temperature.
Examine the test piece for signs of blistering. Apply an 18 mm wide strip of Scotch
610, Permacel 99 or equivalent adhesive tape to the surface, ensuring that no air
is trapped. After one minute, remove the tape at an angle of 45° with a sharp and
even pull.
22
There shall be neither defects nor any loss of adhesion. Some color change is
however acceptable.
VIII. Environmental tests on Finished Products
1. Resistance to Mortar
This test is only applicable to powder coatings, and must be performed according
to EN 12206-1.
Procedure
The mortar is a mixture of sand, lime and water. The mortar must be
prepared by mixing 15 g of hydrated lime, 41 g of cement and 224 g of
sand with sufficient tap water to make a soft paste. Apply four portions of
the mortar, approximately 15 mm in diameter and 6 mm thick, to the test
panel.
Place the test panel horizontally at 38 ± 3ºC and 95 ± 5% relative humidity
for 24 hours.
Then manually remove the mortar from the coated surface and remove any
residue with a damp cloth. Allow the panel to dry, and examine the coating
with normal or corrected vision.
The mortar must be easily removable without leaving any residue. Any mechanical
damage to the coating caused by grains of sand must be disregarded.
The panel should not show any change in appearance or in color after the test.
2. Neutral Salt Spray Test
The objective of this test is to evaluate the corrosion resistance of the coating
system, and the test results will give an indication of the durability of the coating
system.
All coating systems, powder coatings and liquid coatings, will be tested according
to ISO 9227.
The exposure times are:
Corrosivity High
Category durability
1 N/A
2 240 h
3 480 h
4 720 h
5I 1440 h
5M 1440 h
Test Panel Preparation
Three test panels shall be prepared, type B (Chapter VI – A. 2) according to the
technical specifications of chemical and coating suppliers.. Liquid coatings must
be allowed to cure for 21 days in an environment 23/50 or 20/65 according to
ISO 554 before being submitted to the NSS. Test panels without a metallic zinc
layer must be scratched; panels with a metallic zinc layer shall not be scratched.
The scratch shall expose the substrate. According to ISO 17872, the form of the
scribe shall be a cross and shall have a length of at least 50 mm. Intersection will
23
be located in the middle of the panel. Diagonals will cross at an angle between
50 and 70°. The scribe shall not be within 20 mm of the edge of the panel or of
any eventual holes in the panel.
Assessment of the coated panels

i. Calculate M according to:
C−W C= mean overall width of the zone of corrosion (mm)

M=
2 W= width of the scribe (mm)
Assessment: M ≤ 1 mm
ii. Asses blistering, cracking and flaking immediately after the test
Standard Coating Assessment

defect
EN ISO 4628-2 Blistering 0 (S0)
EN ISO 4628-3 Rusting Ri 0
EN ISO 4628-4 Cracking 0 (S0)
EN ISO 4628-5 Flaking 0 (S0)
iii. Determine the ranking of the coating system:
Category # Panels OK # Panels NOK

A 3 0
B 2 1
C 1 2
D 0 3
iv. Determine the status of the license
Category Approval License

A OK Granted or continued
Granted or continued but results will be
B OK
submitted to the coating company
Momentarily not granted.
C NOK Salt spray test must be repeated – license granted
only if the second test results in A or B
Not granted, the whole qualification procedure must be
D NOK restarted. The corrosivity category must eventually be
verified with the coating company
3. Resistance to Humidity
This resistance of paint films to conditions of high humidity is evaluated according
to ISO 6270-2. The test is not applicable to corrosivity category C1. The exposure
time for the other corrosivity categories can be found in
ISO 12944-6, but is different for steel substrates and steel with a metallic zinc
layer.
24
Corrosivity Steel Metallic
Category substrate Zinc layer
2 120 h 240 h
3 240 h 240 h
4 480 h 480 h
5I 720 h 720 h
5M 720 h 720 h
Assessment is done immediately after the test and with the unaided eye.
i. Asses blistering, cracking and flaking

defect
ii. Determine the ranking of the coating system:

A 3 0
B 2 1
C 1 2
D 0 3
iii. Determine the status of the license

B OK
C NOK Continuous condensation test must be redone
– license granted only if the second test results in A or B
D NOK restarted. The corrosivity category must eventually be
verified with the coating company
4. Chemical Resistance Test

The chemical resistance of the coating system, corresponding to highly industrial
environments is determined according to ISO 2812-1, Method 1 – Procedure A for
168 hours and only for the Corrosivity Category C5I. The following chemicals of
analytical quality shall be used:
a. NaOH 10 % (m/m) aqueous solution
b. H2SO4 10 % (m/m) aqueous solution
c. Mineral Spirits, containing 18% of aromatic compounds
The samples are placed in a container holding the described test liquid.
25
i. Asses blistering, rusting, cracking and flaking

defect

A 3 0
B 2 1
C 1 2
D 0 3

B OK
C NOK Chemical resistance test must be redone
Not granted, the whole qualification procedure
D NOK must be restarted. The corrosivity category must eventually
be verified with the coating company
5. Resistance to Humid Atmosphere Containing Sulfur Dioxide

The objective of this test is to determine the resistance of coating systems to
heavily polluted atmospheres, and therefore only applicable to the corrosion
category C5I. The coated surface is exposed to 0.2 liter of SO2 in a test cabinet for
720 hours according tot ISO 3231.
i. Asses blistering, rusting, cracking and flaking

defect
No surface defects or discoloration shall be observed.
26
A 3 0
B 2 1
C 1 2
D 0 3

B OK
C NOK Chemical resistance test must be redone
D NOK restarted. The corrosivity category must eventually
be verified with the coating company
6. Accelerated Weathering Test

This test simulates the resistance to discoloration and loss of gloss for an exterior
use of coated products, and is executed according to ISO 16474-2. This test is
only required for coating systems in corrosivity categories C3-C5.
After 1000 h exposure, the test specimen is rinsed in demineralized water, and
the following criteria are verified:
Loss of gloss ISO 2813 at 60° Gloss must be above 50 %

of the initial value
∆E* ∆E* in accordance with In accordance with ∆E*-values
ISO 11664 of the table in Annex 1.
7. Natural Weathering
The resistance of a coating system to weathering as a result of solar radiation is
evaluated. This test only applies to coating systems intended for outdoor
exposure. The test is executed by exposing the coating materials in Florida
according to EN 13438, A.4.8.2 and following the procedures according to
ISO 2810.
The test must start in April.
The samples must be exposed to the elements facing 5° south for one year. For
approval, four test panels are required (three for weathering purposes and one
reference panel).
Dimensions of the samples: 27pprox.. 100 x 305 x 0.8 – 1 mm
After exposure, the exposed samples must be cleaned using the following method:
Wash the test panels prior to inspection with water containing 1% neutral
detergent, using a sponge and avoiding polishing. Afterwards rinse the panels
with water with a maximum electrical conductivity of 10 µS/cm, or using any
27
other method approved by the Technical Committee. This process must not
scratch the surface.
Gloss must be measured in accordance with EN ISO 2813, at an angle of 60°.
The colorimetric assessment must be conducted for the standard illuminate D65
and the 10° normal observer.
The color variation ∆E* is determined with a CIELAB formula in accordance with
ISO 11664, specular reflection included.
To assess gloss and color, three measurements will be made on the cleaned,
weathered samples and on the unexposed reference panels. These measurements
must be made at different points at least 50 mm apart.
Since thermoplastic powder coatings might develop some brittleness, a
mechanical test must be done before and after the exposure.
RESULTS:
Gloss: The remaining gloss must be above 50% of the original gloss.
Color change: The E* values must not exceed the maximum values in the table
in Annex 1.
28
Annex 1 – Admissible ∆E* for RAL-numbers after Florida-exposure
Adopted from QUALICOAT
RAL Delta E RAL Delta E RAL Delta E RAL Delta E RAL Delta E RAL Delta E RAL Delta E RAL Delta E RAL Delta E
1000 3.0 2000 6.0 3000 6.0 4001 4.0 5000 4.0 6000 5.0 7000 4.0 8000 4.0 9001 2.0
1001 3.0 2001 8.0 3002 6.0 4002 4.0 5001 4.0 6001 5.0 7001 3.0 8001 4.0 9002 2.0
1002 3.0 2002 8.0 3003 4.0 4003 8.0 5002 4.0 6002 5.0 7002 4.0 8003 4.0 9003 2.0
1003 2.0 2003 6.0 3004 4.0 4004 5.0 5003 5.0 6003 5.0 7003 4.0 8004 4.0 9005 5.0
1004 6.0 2004 8.0 3005 4.0 4005 4.0 5004 5.0 6004 5.0 7004 4.0 8007 4.0 9006 2.0
1005 6.0 2008 6.0 3007 4.0 4007 5.0 5007 4.0 6005 3.0 7005 4.0 8008 4.0 9007 2.0
1006 6.0 2009 4.0 3009 4.0 4009 4.0 5008 5.0 6006 4.0 7006 4.0 8011 4.0 9010 2.0
1007 6.0 3011 6.0 5009 4.0 6007 4.0 7008 4.0 8012 4.0 9011 5.0
1011 3.0 3012 8.0 5010 4.0 6008 5.0 7009 4.0 8014 4.0 9016 2.0
1012 3.0 3013 6.0 5011 5.0 6009 4.0 7010 4.0 8015 4.0 9018 2.0
1013 2.0 3014 4.0 5012 4.0 6010 5.0 7011 4.0 8016 4.0
1014 3.0 3015 3.0 5013 5.0 6011 4.0 7012 4.0 8017 4.0
1015 2.0 3016 5.0 5014 4.0 6012 4.0 7013 4.0 8019 3.0
1016 6.0 3017 8.0 5015 3.0 6013 3.0 7015 4.0 8022 5.0
1017 3.0 3018 8.0 5017 5.0 6014 4.0 7016 3.0 8024 4.0
1018 6.0 3020 4.0 5018 5.0 6015 4.0 7021 4.0 8025 4.0
1019 3.0 3022 8.0 5019 4.0 6016 5.0 7022 4.0 8028 3.0
1020 6.0 3027 6.0 5020 5.0 6017 5.0 7023 3.0 8070 4.0
1021 6.0 5021 4.0 6018 4.0 7024 4.0
1023 3.0 5022 5.0 6019 2.0 7026 4.0
1027 3.0 5023 4.0 6020 2.0 7030 2.0
1028 8.0 6021 4.0 7031 4.0
1032 6.0 6024 3.0 7032 2.0
1038 2.0 6025 5.0 7033 3.0
6026 5.0 7034 3.0
6027 2.0 7035 2.0
6028 5.0 7036 3.0
6029 5.0 7037 3.0
6033 2.0 7038 2.0
6034 2.0 7039 4.0
7040 3.0
7043 3.0
29
Annex 1 – Admissible ∆E* for RAL-numbers after Florida-exposure
Adopted from QUALICOAT
7044 2.0
30
Annex 2 – Abbreviations used in the tables
A powder coating system is described as

Sys No I= inside systems
O= outside systems
P powder coating followed by system number
Primer Binder E=epoxy
P=polyester
S = Metal spray
Ef = Electrophoresis coat
Type C= colored
Z= zinc
Zinc or Zinc free Z/ZF
Different Substrates:
Substrate Explanation
ZE 50/50 Sheet electrolytic zinc on steel 5 µm
ZE 100/100 Sheet electrolytic zinc on steel 10 µm
Z100 Continuous hot dip galvanizing zinc 100 g/m2 double faced
HDG Steel thickness < 1.5 mm  250 g/m2/face approx. 35 µm, Hot Dip Galvanizing
HDG Steel thickness >1.5 and < 3.0 mm 325 g/m2/face approx. 45 µm, Hot Dip Galvanizing
HDG Steel thickness >3mm and < 6.0 mm 395 g/m2/face approx. 55 µm, Hot Dip Galvanizing
HDG Steel thickness > 6.0 mm 505 g/m2/face approx. 70 µm, Hot Dip Galvanizing
Surface preparation
Explanation
1 Only degreasing of substrate
2 De-oxidation
3 Phosphating EN 13438 + passivation or alternative processes
4 Blasting zinc substrate in accordance with EN 15773
Sa 2½ and Sa 3 Blasting in accordance with ISO 8501-1
31
Annex 3 – Powder Coating systems – Interior (Will be replaced by French proposal)
Intermediate
Surf. Primer Topcoat Coating System Durability
No Substrate coats
Prep.
B Type µm resin Type µm resin Type µm Layers µm (*) C1 C2 C3 C4 C5 I C5 M
I-P 01 Steel 1 P/E C 60 1 60 X
I-P.02 ZE 50/50 1 P/E C 60 1 60 X X
I-P.03 ZE 50/50 1 P C 60 1 60 X X
I-P.04 ZE 100 1 P C 80 1 80 X X
I-P.05 Z100 1 p C 60 1 60 X X
I-P.06 Z100 2 P C 60 1 60 X X
I-P.07 Z225 3 P C 80 1 80 X X X X
I-P 08 Z275 3 P C 80 1 80 X X X X
I-P 09 HDG 3 p C 60 1 60 X X X
I-P 10 HDG 3 P C 60 1 60 X X X
I-P 11 HDG 3 P C 80 1 80 X X X X
I-P 12 HDG 3 P C 80 1 80 X X X X
I-P 13 Steel 3 E Z 50 P C 60 2 110 X X X X
I-P 18 Steel Sa 2½ E Z 50 P C 80 2 130 X X X X X
I-P 19 Steel Sa2½ S Z 50 P C 60 2 110 X X X X
I-P 20 Steel Sa2½ S Z 50 P C 60 2 110 X X X X
I-P 21 Steel Sa 2½ S Z 50 P C 80 2 130 X X X X X
I-P 22 Steel 1 Ef C 15 P C 60 2 75 X X X
I-P 23 Steel 1 Ef C 15 P C 60 2 75 X X X
I-P 24 Steel 1 Ef C 15 P C 80 2 95 X X X X
(*) Total Coating thickness is without the thickness of the zinc layer
32
Annex 4 – Powder Coating systems – Exterior (Will be replaced by French proposal)
Intermediate Total coating

Primer Topcoat Durability
Surface coats system
No Substrate
Preparation
Binder Type µm Binder Type µm Binder Type µm Layers µm (*) C2 C3 C4 C5-I C5-M
0-P 01 Z 225 3 P C 60 1 60 X X
O-P 07
HDG 4 80 1 80 X X
Bis
O-P 02 Z 275 3 P C 80 1 80 X X
O-P 03 HDG 3 P C 60 1 60 X X
O-P 09 Steel 3 E Z/ZF 50 P C 60 2 110 X X
O-P 10 Steel 3 E Z/ZF 70 P C 80 2 150 X X
O-P 12 Steel Sa 2 ½ E Z/ZF 50 P C 60 2 110 X X
O-P 15 Steel Sa 3 S Z 35 P C 80 1 115 X X
O-P 04 HDG 3 P C 80 1 80 X X X
O-P 11 Steel 3 E Z/ZF 50 E/P C 60 P C 80 3 190 X X X
O-P 13 Steel Sa 2 ½ E Z/ZF 70 P C 80 2 150 X X X
O-P 16 Steel Sa 3 S Z 50 P C 80 1 130 X X X
O-P 20 Steel 1 Ef C 15 P C 60 2 75 X X X
O-P 05 HDG 3 E C 60 P C 60 2 120 X X X
O-P 06 HDG 4 E C 60 P C 60 2 120 X X X
O-P 14 Steel Sa 2 ½ E Z/ZF 50 E/P C 60 P C 80 3 190 X X X
O-P 17 Steel Sa 3 S Z 35 E C 60 P C 60 2 155 X X X
O-P 18 Steel Sa 3 S Z 100 P C 80 1 180 X X X
O-P 21 Steel 1 Ef C 15 P C 80 2 95 X X X
O-P 07 HDG 3 E C 60 E/P C 60 P C 60 3 180 X X X X X
O-P 08 HDG 4 E C 60 E/P C 60 P C 60 3 180 X X X X X
O-P 19 Steel Sa 3 S Z 150 E C 60 P C 80 2 290 X X X X X
O-P 22 Steel 1 Ef C 15 E/P C 60 P C 60 2 135 X X X X X
(*)Total Coating thickness is without the thickness of the zinc layer

33
Annex 5 – Powder Coating systems – Thermoplastic Systems
Total
Intermediate
Primer Topcoat coating Durability
coats
system
N° Substrate Preparation
Binder Type µm Binder Type µm Binder Type µm Coats µm C2 C3 C4 C5-I C5-M
TPP1 Steel Sa 2 1/2 N C 250 N C 250 2 500

TPP2 HDG 4 or 5 A C 5 PVC C 250 2 255 X X X X X
TPP3
TPP4
TPP5
TPP6
P Polyester
V Vinyl
N Nylon (polyamide)
E Ethylene acid copolymer
PVC Polyvinyl chloride
Fl Fluorized
A Acryl
34
Annex 6 – List of applicable standards
The latest version of the standard is valid
Nº TITLE
Paints and varnishes - Powder organic coatings for galvanized or
EN 13438
sherardized steel products for construction purposes
Hot dip galvanized coatings on fabricated iron and steel articles -
ISO 1461
Specifications and test methods (ISO 1461:2009)
ISO 1514 Paints and varnishes - Standard panels for testing (ISO 1514:2004)
ISO 1518 Paints and varnishes - Scratch test (ISO 1518:1992)
Non-conductive coatings on non-magnetic electrically conductive basis
ISO 2360 materials - Measurement of coating thickness - Amplitude-sensitive eddy
current method (ISO 2360:2003)
ISO 2409 Paints and varnishes - Cross-cut test (ISO 2409:2007)
ISO 2808 Paints and varnishes - Determination of film thickness (ISO 2808:2007)
Paints and varnishes - Natural weathering of coatings - Exposure and
ISO 2810
assessment (ISO 2810:2004)
Paints and varnishes - Determination of specular gloss of non-metallic paint
ISO 2813 films at 20°, 60° and 85° (ISO 2813:1994, including Technical Corrigendum
1:1997)
Paints and varnishes - Determination of resistance to humid atmospheres
ISO 3231
containing sulphur dioxide (ISO 3231:1993)
Geometrical product specifications (GPS) - Surface texture: Profile method
ISO 3274 - Nominal characteristics of contact (stylus) instruments (ISO 3274:1996)
Corrosion of metals and alloys -- Corrosivity of atmospheres --
ISO 9223
Classification
ISO 9227 Corrosion tests in artificial atmospheres - Salt spray tests (ISO 9227:2006)
ISO 15184 Paints and varnishes -- Determination of film hardness by pencil test
Industrial application of powder organic coatings to hot dip galvanized or
EN 15773 sherardized steel articles [duplex systems] - Specifications,
recommendations and guidelines
General requirements for the competence of testing and calibration
ISO/IEC 17025 laboratories (ISO/IEC 17025:2005)
General requirements for the competence of testing and calibration
ISO/IEC 17025
laboratories (ISO/IEC 17025:2005/Cor.1:2006)
Textiles - Tests for colour fastness - Part A02: Grey scale for assessing
ISO 105-AO2
change in colour (ISO 105-A02:1993)
Preparation of steel substrates before application of paints and related
ISO 11125-2 products - Test methods for metallic blast-cleaning abrasives - Part 2:
Determination of particle size distribution (ISO 11125-2:1993)
ISO 11127-2 products - Test methods for non-metallic blast-cleaning abrasives - Part 2:
Determination of particle size distribution (ISO 11127-2:1993)
ISO 11664 1-6 Colorimetry
Paints and varnishes - Corrosion protection of steel structures by protective
ISO 12944-1
paint systems - Part 1: General introduction (ISO 12944-1:1998)
ISO 12944-2
paint systems - Part 2: Classification of environments (ISO 12944-2:1998)
ISO 12944-3
paint systems - Part 3: Design considerations (ISO 12944-3:1998)
ISO 12944-4 paint systems - Part 4: Types of surface and surface preparation (ISO
12944-4:1998)
ISO 12944-5
paint systems - Part 5: Protective paint systems (ISO 12944-5:2007)
35

ISO 12944-6 paint systems - Part 6: Laboratory performance test methods (ISO 12944-
6:1998)
ISO 12944-7 paint systems - Part 7: Execution and supervision of paint work (ISO
12944-7:1998)
ISO 12944-8 paint systems - Part 8: Development of specifications for new work and
maintenance (ISO 12944-8:1998)
Corrosion protection of steel structures by protective paint systems -
Assessment of, and acceptance criteria for, the adhesion/cohesion (fracture
ISO 16276-2
strength) of a coating - Part 2: Cross-cut testing and X-cut testing (ISO
16276-2:2007)
Paints and varnishes - Determination of resistance to liquids - Part 1:
ISO 2812-1
Immersion in liquids other than water (ISO 2812-1:2007)
Paints and varnishes - Evaluation of degradation of coatings - Designation
ISO 4628 -2 of quantity and size of defects, and of intensity of uniform changes in
appearance - Part 2: Assessment of degree of blistering (ISO 4628-2:2003)
ISO 4628-3 of quantity and size of defects, and of intensity of uniform changes in
appearance - Part 3: Assessment of degree of rusting (ISO 4628-3:2003)
appearance - Part 4: Assessment of degree of cracking (ISO 4628-4:2003)
appearance - Part 5: Assessment of degree of flaking (ISO 4628-5:2003)
Geometrical Product Specifications (GPS) - Surface texture: Profile
ISO 5436-1 method; Measurement standards - Part 1: Material measures (ISO 5436-
1:2000)
ISO 5436-2 method; Measurement standards - Part 2: Software measurement
standards (ISO 5436-2:2001)
ISO 5436-2 method; Measurement standards - Part 2: Software measurement
standards (ISO 5436-2:2001/Cor 1:2006/Cor 2:2008)
Paints and varnishes - Determination of resistance to humidity - Part 2:
ISO 6270-2 Procedure for exposing test specimens in condensation-water atmospheres
(ISO 6270-2:2005)
Paints and varnishes - Rapid-deformation (impact resistance) tests - Part 1:
ISO 6272-1
Falling-weight test, large-area indenter (ISO 6272-1:2002)
products - Visual assessment of surface cleanliness - Part 1: Rust grades
ISO 8501-1
and preparation grades of uncoated steel substrates and of steel substrates
after overall removal of previous coatings (ISO 8501-1:2007)
products - Visual assessment of surface cleanliness - Part 3: Preparation
ISO 8501-3
grades of welds, edges and other areas with surface imperfections (ISO
8501-3:2006)
Preparation of steel substrates before application of paint and related
products - Tests for the assessment of surface cleanliness - Part 3:
ISO 8502-3
Assessment of dust on steel surfaces prepared for painting (pressure-
sensitive tape method) (ISO 8502-3:1992)
Preparation of steel substrates before application of paint and related
ISO 8502-4
products - Tests for the assessment of surface cleanliness - Part 4:
36
Guidance on the estimation of the probability of condensation prior to paint

application (ISO 8502-4:1993)

products - Surface roughness characteristics of blast-cleaned steel
ISO 8503-1 substrates - Part 1: Specifications and definitions for ISO surface profile
comparators for the assessment of abrasive blast-cleaned surfaces (ISO
8503-1:1988)
ISO 8503-2
substrates - Part 2: Method for the grading of surface profile of abrasive
blast-cleaned steel - Comparator procedure (ISO 8503-2:1988)
ISO 8503-3 substrates - Part 3: Method for the calibration of ISO surface profile
comparators and for the determination of surface profile-Focusing
microscope procedure (ISO 8503-3:1988)
ISO 8503-4 substrates - Part 4: Method for the calibration of ISO surface profile
comparators and for the determination of surface profile - Stylus instrument
procedure (ISO 8503-4:1988)
Paints and varnishes -- Methods of exposure to laboratory light sources --
ISO 16474-1
Part 1: General guidance
Paints and varnishes -- Methods of exposure to laboratory light sources --

ISO 16474-2
Part 2: Xenon-arc lamps
37

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Qualisteelcoat

Technical Specifications V3.0

Version 3.0 January 2015

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

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

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

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

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

Version 3.0 January 2015

Annex 1 Admissible ∆E* for RAL numbers after Florida exposure

Version 3.0 January 2015

Version 3.0 January 2015

II. License for Coating Applicators

Version 3.0 January 2015

III. Quality Assurance by the coating applicator

1. In-house control – Procedures

The register must contain the following information:

Blasted hot dip galvanized steel ≤ 4 hours

d. Storage of Coated Materials

Version 3.0 January 2015

A. Quality Control for Surface Preparation by Blasting

Version 3.0 January 2015

2. Laboratory and inspection equipment for Blasting Surface Preparation

B. Quality Control for Chemical pretreatment

Coatability of Parts Every lot

Version 3.0 January 2015

Assessment of the loss of zinc by Once per shift

2. Laboratory and inspection equipment for chemical pretreatment

V. Finished Products Quality Control

Version 3.0 January 2015

Version 3.0 January 2015

VI. APPROVAL OF COATINGS

1. Scope of the approval

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

2. Examples of coating systems

Version 3.0 January 2015

Version 3.0 January 2015

A. Approval of powder coating systems

1. Powder coating systems (Quick Guide)

Version 3.0 January 2015

Type Purpose Substrate Application Dimensions

b. Number of test panels Type B for the laboratory

c. Total number of necessary test panels

System Substrate + Coating Corrosivity Category

Version 3.0 January 2015

Test Panel Standard

B. Approval of liquid coating systems

1. Liquid coating systems

3. Required tests for the Initial approval

Test Standard Requirement

Version 3.0 January 2015

2. Determination of particle size distribution

3. Determination of Surface Roughness

4. Assessment of the zinc coating after sweep blasting

Version 3.0 January 2015

6. Determination of the conductivity of Dripping Water

7. Effectiveness of the pickling bath

8. Assessment of the Conversion Coating

9. The drying temperature for liquid coatings

DFT (µm) Results

Version 3.0 January 2015

12. Determination of Dry Film Thickness

Area/length of Maximum number of