QUALICOAT

QUALIBALmeeting in Belgrade

3 December 2014

Josef Schoppig, Managing Director

• Who is QUALICOAT ?

• What are the benefits ?

• What are the main

elements ?

QUALICOAT is an international non for

profit association defining Specifications

to assure the quality of coated

aluminium for architectural applications.

Benefits of QUALICOAT

• QUALICOAT gives

licensed plants a clear

competitive advantage

when tendering.

• Winning contracts in

Europe without a

QUALICOAT licence is

very difficult.

5

ADMINISTRATION

AC-Fiduciaire SA

Tödistrasse 47

CH-8002

Zürich www.actreu.ch

Josef Schoppig Managing Director

ACCREDITED ACCORDING TO

EN-45011 (ISO 17065)

Riccardo Boi (QUALITAL) Technical Director of QUALICOAT

Accreditation since 1997:

no SCESp 045

Working Groups Technical Committee

Executive Committee

Members organised in national and international associations

President M. Panam, UK

QUALICOAT structure today

Technical Director R. Boi, IT

Delegate representatives

Secretariat

Managing Director

J. Schoppig, CH

The Parties Involved

• Architect / Specifier / Owner

• A building built to specification at an

agreed price and delivered at the

agreed time

i.e. Coatings to look good, protect

the investment and last as long as

possible

Applicators Requirements

• Why don’t all applicators become QUALICOAT

licensed

• Only the highest quality applicators will be able to meet

the Qualicoat requirements

– Large investment required in terms of

• Quality System

• Equipment

– Ongoing costs in terms of licence fee and auditing

costs

Applicators Requirements

• In-house Laboratory

• Separate from the production facilities.

• Appropriate apparatus and chemicals, independently calibrated

11

• Selection of suitable standards

• Limit values for the quality assurance

• Testing instructions for in-house and external

control (independent third party control)

• Adaptation of the Specifications to new

developments

The nature of a Quality Label

12

What QUALICOAT does not stand for:

Such quality management

systems are, however, an

asset for each licensee.

QUALICOAT is not Quality Management System ISO 9000, ISO 16949, or QS 9000 quality

management systems provide procedures

to assure the quality management system of

an organisation.

Founded in 1986 QUALICOAT

Further aims - Sharing technical information

- Implementing innovations

- Issuing testing instructions for in-house control and external monitoring

- Developing market awareness for the QUALICOAT licence

Original mission – Assuring a high level of quality by establishing

onsistent standards (QUALICOAT Specifications)

and continually improving on them.

QUALICOAT Specifications

Pretreatment

systems

Licensed

coaters

Approved

Coating material

systems

Product quality

Working groups

Members

organised in

national

associations

QUALICOAT innovation process

Executive and

Technical

Committees

Requirements are

addressed and

relayed

Innovation

requirements

Analysis of

requirements,

development of

proposals

Working groups

Members

organised in

national

associations

QUALICOAT innovation process

Executive and

Technical

Committees

Proposals are

addressed and

verified

Implementation in

Specifications

Analysis of

requirements,

development of

proposals

Role of the Independent Test

Institute

Independent Testing Laboratories

• Inspection & Auditing.

• Perform the testing required

• The inspectors themselves are organised in a separate

association QUALISURFAL (annual inspector’s meeting).

Independent Test Institute

• All of the test institutes have to be EN ISO 17025 accredited

for the tests stipulated by QUALICOAT.

• This means that each test and operator is audited and all

equipment is calibrated to a traceable national standard.

QUALISURFAL

Sharing experience

Conducting interlaboratory tests

Inspectors

QUALICOAT structure

Laboratories

accredited to ISO 17025

Over 400 licensed coating

plants worldwide

Over 500 approved powder

systems at 31.10.14

Today – across the globe QUALICOAT

From 5 to18 national and

internatioal associations (members) • 1986: Belgium, France, Italy, Spain, Switzerland

• 1987: Netherlands

• 1989: Portugal

• 1993: Greece

• 1995: Hungary

• 1997: Turkey

• 1998: Australia, UK and Ireland

• 1999: Germany

• 2001: Poland

• 2006: Middle East

• 2006: Mexico

• 2008: Japan

• 2009: China

• 2013 Russia

• 2014 QUALIBAL

APPROVALS (paints)

0

200

400

600

800

1000

1200

1986 1991 1996 2001 2006 2011

number of approvals

valid systems

cancelled systems

APPROVALS

• First approval granted on 17.7.1987 to a French supplier

• First approval granted on 15.7.1995 to a supplier from

outside Europe

• First system cancelled on 28.6.1991

LICENCES

0

50

100

150

200

250

300

350

400

450

1986 1991 1996 2001 2006 2011

Development of licences

LICENCES (on all five continents)

• First licence granted to an European coater on 22.7.1986

(Belgium)

• First licence granted to a coater from Africa on 11.11.1994

(Morocco)

• First licence granted to a coater from Asia on 11.01.1999

(Lebanon)

• First licence granted to a coater from Australia on

04.07.2000

• First licence granted to a coater from the Americas on

23.03.2001 (Colombia)

Today – in Europe QUALICOAT Over 350 licensed coating

plants across Europe

At 31 October 2014

Austria

Czech Republic

France

Germany

Greece

Italy

Ireland

Latvia

Netherlands

Poland

Romania

Switzerland

Turkey

Cyprus

Croatia

Portugal

Russia

Spain

Sweden

Ukraine

United Kingdom

Belgium

Bulgaria

Bosnia and Herzegovina

Belarus

Hungary

Albania

Source of flags: CorelDrawCliparts and Wikipedia

Today – outside Europe QUALICOAT

At 31 October 2014

Over 50 licensed coating

plants outside Europe

Australia

Bahrain

China

Columbia

Dominican Republic

Egypt

Israel

Kuwait

Lebanon

Mexico

Morocco

Oman

Qatar

Saudi Arabia

South Africa

Tunisia

United Arab Emirates

India Argentina

Public Relations in the UAE

First licence granted on 15 March 2000

Public relations in „down under“ in 2000

30 April 2001

Public Relations in India

First licence on 14 December 2012

• Architects

• System manufacturers

• Global metal construction companies

• Consultants

• Building companies

Growing demand for QUALICOAT

QUALICOAT requirements

• Laboratory facilities

Requirements for coating plants

Requirements for coating plants

• The coating plant must have laboratory facilities.

• The laboratory must be sufficiently equipped to analyse

process solutions and test finished products.

• Laboratory facilities

Requirements for coating plants

• Plants must meet the requirements in the current

QUALICOAT Specifications.

• The layout of the facilities should be designed to avoid

contamination.

• Each plant must have a drying oven.

• Laboratory facilities

• Plant and equipment

Requirements for coating plants

In-house control – pretreatment

• Chemical parameters and temperature 1x per day / bath

• Conductivity of water 1x per day

• Temp. of pretreatment and rinsing baths 1x per day/ bath

• Etching degree 1x per week

• Stoving conditions 1x per week

• Weight of conversion coating 1x per day

• Laboratory facilities

• Plant and equipment

• Pretreatment

Requirements for coating plants

Etching

• At least 1g/m² for AA 6060 and

AA 6063 alloys.

• Etching is not specified for rolled

products and castings.

• The etching degree shall be

monitored regularly.

Chromate pretreatment EN ISO 3892

• Weight of the chromate conversion coating:

– Chromate treatment (yellow) between 0.6 and 1.2 g/m².

– Chromate-phosphate (green) between 0.6 and 1.5 g/cm².

• Final rinse max. 30 µS/cm.

• Coating maximum 16 hours after pretreatment.

Anodic pretreatment

• All impurities must be eliminated.

• Anodic film with a thickness of 3-8µm.

• Final rinse max. 30µS/cm.

• Coating maximum 16 hours after pretreatment.

• Continuous monitoring of baths and finished products.

Alternative pretreatments

• Alternative pretreatment methods may

only be used if approved by QUALICOAT.

• Coating plants shall comply with the

requirements stipulated by the chemical

suppliers and in the QUALICOAT

Specifications.

• Appearance

• Coating thickness

• Gloss

• Laboratory facilities

• Plant and equipment

• Pretreatment

• Inspection of finished products

Requirements for coating plants

Appearance (from a distance of 3 to 5 metres)

• No scratches through to the base metal

on the significant surface.

• No visual defects on the surface, e.g.: – excessive roughness, runs, blisters,

inclusions, craters, dull spots, scratches, etc.

• The colour and gloss must be even

with good coverage.

Coating thickness EN ISO 2360

Coating system requirements – minimum coating thickness

Powder coating

• Classes 1 & 2: 60μm Class 3: 50μm

• Two-coat powder system (1 & 2): 110 μm PVDF: 80 μm

Liquid coating

• Two-coat PVDF system: 35 μm

• Three-coat metallized PVDF system: 45 μm

• Silicone polyester without primer: 30 μm (minimum 20% silicone resin)

• Water-thinnable paints: 30 μm - 50 μm

• Two component paints: 50 μm

• Coating thickness must be measured on the significant

surface.

• Average (5 measuring points) must not be less than the

specified minimum value.

• None of the values measured may be less than 80% of

the minimum value.

Gloss ISO 2813 – incident light 60°

Requirements:

• Category 1: 0 - 30 +/- 5 units

• Category 2: 31 - 70 +/- 7 units

• Category 3: 71 - 100 +/- 10 units

Gloss ISO 2813 – incident light 60°

• Gloss

• Coating thickness

• Dry and wet ahesion

• Indentation

• Cupping test

• Bend test

• Impact test

• Machu test

• Saw test

• Polymerisation test

• Acetic acid salt spray resistance

• Laboratory facilities

• Plant and equipment

• Pretreatment

• Inspection of finished products

• Testing of test panels

Requirements for coating plants

Adhesion EN ISO 2409

• A cross-cut down to the substrate is made on the test panel.

• Then the adhesive tape test

is performed.

Requirements: viewed with the naked eye, the coating

must not show any sign of cracking or detachment.

Indentation EN ISO 2815

To determine a coating’s surface hardness.

Requirements:

• The indentation resistance according to Buchholz must be at least 80 with

the specified coating thickness.

Cupping test EN ISO 1520

• To test elasticity of coating.

• Classes 2 and 3 must pass the adhesive tape test.

Requirements:

- Min. 5 mm for powder coatings (Classes 1

and 2)

- Min. 5 mm for liquid coatings, except:

- two-component paints: min. 3 mm

- water-thinnable paints: min. 3 mm

- Min. 5 mm for electrophoretic coatings

Bend test EN ISO 1519

• To determine elasticity of powder coating on deformation.

• Adhesive tape test additionally performed for Classes 2 and 3.

Impact test for powder coatings only

• Class 1 (one- and two-coat systems) Energy: 2.5 Nm: EN ISO 6272: / ASTM D 2794

(impactor diameter: 15.9 mm)

• Two-coat PVDF powders Energy: 1.5 Nm: EN ISO 6272/ ASTM D 2794

(impactor diameter: 15.9 mm)

• Class 2 and 3 powders

Energy: 2.5 Nm: EN ISO 6272/ ASTM D 2794

(impactor diameter: 15.9 mm)

Followed by adhesive tape test

Impact test for powder coatings only

Machu test on sections only

• Accelerated corrosion test

• Cross-cut with a width of 1 or 2 mm.

Requirements:

• No infiltration exceeding 0.5 mm on both sides of the scratch.

Machu test

Acetic acid salt spray resistance ISO 9227

• Corrosion processes are accelerated in a corrosive atmosphere (e.g. acetic acid salt spray) with increased temperature.

• Classes 1 & 2 (1000h), Class 3 (2000h)

Requirements: • No blistering in excess of 2 (S2) according to ISO 4628-2.

• Infiltration of max. 16 mm² per 10 cm length is allowed.

• Length of any single infiltration must not exceed 4 mm.

Acetic acid salt spray resistance ISO 9227

Acetic acid salt spray test ISO 9227

on sections only

Evaluation of the negative result

of acetic acid salt spray reistance (max. 16mm2)

Sawing test

• Samples are cut with a saw to test the coating quality.

Requirements:

No cracks or chips are allowed.

Polymerisation test for liquid coatings only

• A swab saturated with solvent is rubbed lightly back and forth

over test panels for 30 seconds.

Requirements:

• Ratings 3 and 4 are satisfactory.

• Ratings 1 and 2 are unsatisfactory.

Polymerisation test for liquid coatings only

• The coater must maintain records of:

– Production

– In-house control

– Customers’ complaints

• Laboratory facilities

• Plant and equipment

• Pretreatment

• Inspection of finished products

• Testing of test panels

• Examination of records

Requirements for coating plants

First inspection of coating plants

First inspection

Repetition of first inspection

Second inspection

QUALICOAT licence will

be granted QUALICOAT licence will

not be granted

First inspection of coating plants

Routine inspection of

coating plants

Routine inspection of coating plants at least twice (two positive inspections)

Monitoring of the following requirements:

Laboratory equipment & production

Pretreatment & materials

Finished products & test panels

Records

Acetic acid salt spray test (once a year)

Machu test (once a year)

Require-

ments

met?

Licence to use

the quality label

will be renewed

Licence to use the

quality label will

be withdrawn

immediately

Second inspection

within one month

QUALICOAT requirements for

coating materials – latest

developments

7 Jul 2011 FLORIDA WG

POWDERS

Class1

Class 2

Class3

Class

1½

RAL “families” Failure in one RAL colour (colour change) during the annual

routine testing after Florida exposure, could be an indication of a technological deficiency affecting several colours and not just the RAL colour in question.

The present QUALICOAT requirements state that only the RAL colour failing will be banned. The status of other colours is not affected.

RAL “families”

RAL “families”

Critical colours

• “critical” means that either the suitable pigments for these colours are not available or that QUALICOAT does not support these colours.

•It can also be considered a kind of warning that these colours are not suitable.

• The following list will be considered the current state of the art but should be revised every year.

12 SOLID CRITICAL RAL COLOURS

RAL 1003 RAL 2004 RAL 3015 RAL 4001

RAL1012 RAL 2011 RAL 3017 TOTAL 1

RAL1018 TOTAL 2 RAL 3018

RAL1028 RAL 3020

RAL1033 TOTAL 4

TOTAL 5

Special application

SEASIDE

SEASIDE

• Quality designation within QUALICOAT

• Designed to meet higher corrosion protection requirements

in coastal areas

SEASIDE - pretreatment

3 techniques

Type A: simple acid etching

• The total etching degree of all acid steps must be at least 2g/m².

Type AA: dual etching (alkaline etching and acid etching)

• The total etching degree must be at least 2g/m².

• The etching degree in each step must be at least 0.5g/m².

Type OX: anodic pretreatment

• 3-8 μm film thickness

Surface preparation having been investigated

PRETREATMENT

CYCLE DEGREASING ACID ATTACK ALCALINE ATTACK ACID ATTACK

AA2 (A) X X X X

AA1 (B) X X X

A2 (C) X X X

A1 (D) X X

OX X X X X

Modified Filiform corrosion test

Cleaning

Statistics : negative inspection results

New investigations • Definition of corrosion classes

• Extension of the label to other applications

• Correlation between accelerated weathering and outside

exposure test

• About the QUALICOAT quality label

• Lists of licensed coating plants and approved coating and

alternative pretreatment systems

• Specifications

Information

To learn more,

please visit

www.qualicoat.net

Thank you for your attention and

WELCOME TO QUALICOAT!