International Quality Regulations For the Coating of Aluminium Building Components GSB AL 631. Edition July 2009

Transcription

1 International Quality Regulations For the Coating of Aluminium Building Components Edition July 2009 Editor: GSB International Franziskanergasse Schwäbisch Gmünd F.: / Fax: / Uinfo@gsb-international.deU Internet: Uwww.gsb-international.de Re-printing in full or in part is prohibited. GSB reserves all rights, including other language versions. GSB International 2009

2 Contents Contents 1 Areas of Application Classification of Weathering 4 2 General Quality Regulations General User Rights Ownership of the Quality Label Ownership of Material Licences Cessation of User Rights Test and Surveillance Costs Publications Test Institutions 8 3 Award and Retention of the Quality Label Coaters Application and Award of User rights Preconditions for the Award of Quality Label User Rights Test Procedures Method and Level of Testing Testing of Finished Goods Measures applicable in Case of Violation Procedures applicable in Case of Violation Complaints Procedure Re-Issue of the Quality Label 11 4 Issue and Conferment of Material Licences General Application and Product Information Material Samples Powder Lacquers Liquid Lacquers Licence application for one colour group Licence Testing General Provisional Coating Material Licences Licensing Controls applicable to Coating Materials General Provision of Samples Licence Extension Negative Extension Test Quality Label for GSB Material Licences 16 5 Issue and Conferment of Material Licences applicable to Pre-treatment Chemicals (Conversion Coating / Passivation) General Application and Product Information Licence Testing General Provisional Licences for Conversion Coating / Passivation Full Licences for Pre-treatment Chemicals Conversion Coating / Passivation Surveillance Testing applicable to Licences for Pre-treatment Chemicals 18 6 Requirements applicable to Coaters General Surface Pre-treatment General Suspension and Positioning Etching Rate Weight of Conversion Coating / Passivation 20 1

3 Contents Final Rinse or Rinsing Process prior to Non Rinse Treatment Drying of Adhering Water Wastewater Treatment Interim Storage Cleanliness and Handling Application and Thermal Curing or Forced Drying Laboratories and their Technical Equipment General Standard Equipment Additional Equipment Product and Coating Material Store Product Storage Coating Material Storage Product and Safety Data Sheets In-House Controls Control of Incoming Materials Production Control and In-House Control Level of Production Controls Training Training Seminars In House Training Requirements to be Licensed as GSB Premium Coaters General Pre-treatment Process Coating Plants Requirements for the Application and Curing Quality Control 25 7 Requirements applicable to Coating Materials General Preparation of Samples Application Coating Materials with specific Properties Acceptable Colour Tolerances Requirements applicable for the Licensing of Coating Materials Powder coating materials Liquid coating materials 29 8 Requirements applicable to Pre-Treatment Licensing of Chemical Surface Pre-treatment Systems General Stage Stage Stage Stage Tests and requirements for alternative Pre-treatment chemicals / Passivation Electro Chemical Pre-treatment (pre-anodising) General Pre-anodising Process Test and requirements for the Pre-anodising process 35 9 Test Procedures General Samples for Material Licences and Licence Extension Random Samples to be taken at the coating plant Film Thickness Assessment at the Coating Plant Visual Surface Assessment of Finished Goods 37 2

4 Contents 9.6 Cross Cut Test Mandrel Bending Test Erichsen Cupping Test Cross-linking tests Impact Test (powders) MEK-Test (for stoving and two-component liquid lacquers) - (under discussion) Adhesive Tape Removal Milling and Drilling Condensation Atmosphere with Constant Humidity Humid Atmosphere containing Sulphur Dioxide Acetic Acid Salt Spray Filiform Corrosion Test Procedure Assessment Boiling Water or Pressure Cooker Test Boiling Water with Cross Cut and Adhesive Tape Removal Test Pressure Cooker, Steam Cooker Test with Cross Cut and Adhesive Tape Removal Resistance to Moisture Application and Purpose Procedures Assessment Adhesion of Sealant Mortar Test Composition of the Mortar Procedure Assessment Colour Measurement Assessment of Colour Graduation in accordance with ISO (DIN 6174) Gloss Measurement (Reflectometer values) Weathering Accelerated Weathering QUV-B (313 nm) Natural Weathering in Florida Measuring Conductivity Test Procedures to Assess Etching Rate Test Procedures for the Assessment of the Mass Loss per Unit Area Assessment of changes to the metallic effect: Standards In House Control Requirements for Coaters Incoming Material Check Processing Controls Finished Goods / Specimen Testing (see section 6.6.2) Enclosures Committment Certificates Specimen Certificate Master Coater Specimen of Material Licence Master System Material Licence Pretreatment Application Form Application Form for Coaters Application for Material Manufacturers Application for Manufacturers of Pre-treatment Chemicals Application Form for Coatings 61 3

5 Section 1 Areas of Application 1 Areas of Application These Quality Regulations () are applicable to the piecework coating of aluminium building components and its alloys used in structural engineering. The piecework coating includes part-finished products, part-finished and finished piecework as well as prefabricated construction parts of uninstalled building components. Coil-coating and on the spot technical coating methods are excluded. The coating process requires the use of products for the surface pre-treatment and coating materials, which need to have been approved and licensed within the parameters of the. The standards and regulations bearing the date of the edition listed in section 10 apply. Any amendments to the must be proposed by the Technical Commission (TC) and subsequently approved by the Board in order to become valid. Basic technical amendments need the agreement of the members. Following their publication they will then come into effect after a period of 4 weeks or on the due date stated. The respective revised version or amendment invalidates all previous editions. The most recent approved and published version on behalf of the GSB International is legally binding. 1.1 Classification of Weathering To ensure adequate protection against corrosion and to safeguard the long term decorative appearance of the coated piecework, climatic conditions must be taken into account in the selection process of a suitable coating for Aluminium building components. These days, an extensive range of licensed pre-treatments and coating materials is available, all of which have been tried, tested and applied over many years of practical experience.this allows the implementation of classifications of weathering to facilitate coatings in line with the latest technological standards and techniques. Classification of Weathering GSB - Countryside (A1 / A2) GSB - Industrial (A3/A4) GSB - Sea Proof (A4/A5) GSB - Sea Proof Plus (A5) Corrosion Influence Low to medium High Very high Very high Climatic Conditions Low levels of pollution, surrounded by countryside, town with low impact industrial environment Industrial atmosphere with corrosive pollution and coastal areas with low salt content Coastal areas with medium salt content Coastal areas with high salt content, open sea Recommended Pre-treatment Chromating / Crfree Chromating/ Cr - free Chromating/ Cr-free with documented process (see section 8.2.6) Type of Climate (A1 A5) see EN , appendix A Chromating/ Crfree with documented process (see section 8.2.6) / Pre-anodising (see section 8.3.3) Corrosion Test Atmosphere with constant humidity AASS Filiformcorrosion (FFK) coefficient < 0,4 and acidic acid salt spray (AASS) Filiformcorrosion (FFK) coefficient < 0,15 and acidic acid salt spray (AASS) GSB Coating Standard GSB Coating Material Recommended Cleaning Frequency Approved Standard annual Master Master/ Premium Master/ Premium Standard/ Master Master/ Premium Master/ Premium annual annual Twice a year 4

6 Section 2 General Quality Regulations 2 General Quality Regulations 2.1 General The International Quality Regulations () for the coating of aluminium building components provide the criteria for the award of the Quality Label and the licensing of pre-treatment chemicals and coating materials. They are subject to ongoing review and development in line with technological advances and progress. The Quality Label and licences for pre-treatment chemicals and coating materials issued by GSB International must only be used for products, which have been awarded the relevant user right or licence. It is the responsibility of holder of the Quality Label or pre-treatment chemical and material licences to ensure that is being adhered to. As such they are committed to maintaining ongoing quality control procedures. GSB International is entitled and committed to the effective surveillance relating to the appropriate use of the Quality Label or pre-treatment and material licences through the implementation and execution of test procedures in line with. All communication with the GSB Head Office must be in writing. s and fax are only acceptable with proof of receipt of the GSB Head Office. 2.2 User Rights The Board reserves the right to issue specific conditions for the use of the Quality Label or pre-treatment chemical and coating material licences relating to individual or group advertising to safeguard against misuse in the interest of competitive integrity. This must not hinder individual advertising for which the conditions of fair-trading apply in equal measure Ownership of the Quality Label The provision, production and conditions for all applications relating to all materials used in the identification of the Quality Label (i.e. metal embossing, stamps for embossing, printed material, labels, marking of labels, rubber stamps etc) remain the exclusive right of GSB International. Coaters who have been awarded ownership of the Quality Label, may use the label shown below on all their stationery and printed material. Coaters who have passed the specific requirements as set out in section 6.1, quality level 1 may use the Quality Label Approved Coater. 5

7 Section 2 General Quality Regulations Coaters who have passed the specific requirements as set out in section 6.1, quality level 2 may use the Quality Label with the addition of Master Coater. Coaters who have passed the specific requirements as set out in section 6.1 quality level 3 may use the Quality Label with the addition of Premium Coater. Quality Labels that are being placed directly onto finished goods must also bear the company number as illustrated below: Company No. 000 Company No. 000 Company No. 000 However, the addition of Premium Quality may only be placed on finished goods that have been coated by a Premium Coater using coating materials licensed as Master or Premium materials as set out in section 7.6. Coaters who have successfully passed the AASS and FFC tests in accordance with section and have proof of meeting the relevant requirements, may apply to GSB International for the Sea Proof or Sea Proof Plus Quality Label, which once approved, will require regular annual routine extension testing. 6

8 Section 2 General Quality Regulations Premium-Coaters are automatically licensed to use the Sea Proof Quality Label. Quality Label users, whose ownership of the Quality Label has been withdrawn, must immediately return their certificates and all materials used in the identification of the Quality Label without financial compensation relating thereto. This also applies to all other situations that may have resulted in a withdrawal or expiry of the Quality Label under whichever circumstances. 2.3 Ownership of Material Licences Pre-treatment chemicals and coating material manufacturers must only use the appropriate licence number for products that have been approved and licensed in accordance with. Material manufacturers, whose material licence has been withdrawn, must immediately return their certificates without financial compensation relating thereto. This also applies to all other situations that may have resulted in a withdrawal or expiry of a material licence under whichever circumstances. 2.4 Cessation of User Rights The right to use the Quality Label or material licence ceases on termination of the membership as set out in section 5.1. of the GSB International Statutes. The right to use the Quality Label ceases in the following cases: If GSB International ceases to operate in the area(s) relevant and applicable to the Quality Label. At the withdrawal of the coater in accordance with GSB International Statutes and the complete fulfilment of all financial and other commitments towards GSB International. If the assembly of creditors decides that the coater should cease to operate once insolvency procedures have been instigated in accordance with 156, 157 InsO. If the insolvency process has been rejected. If the insolvency process has been abandoned. In cases of evidence of comparable pre-conditions in line with other national insolvency regulations. If the holder of the Quality Label enters into voluntary liquidation. 7

9 Section 2 General Quality Regulations The right to use a material licence ceases in the following cases: If GSB International ceases to operate in the area(s) relevant and applicable to the material licence. In cases of lacquer systems, if the required material samples are not submitted to the Test Institution by the 31st December of any given test year and if testing of the system had not been possible the previous year. GSB International is obliged to advise all Quality Label or material licence holders in writing of the cessation of their right to use the Quality Label or relevant material licence. If a large order is being processed in separate lots over a longer period of time and the coater loses the system licence during the production process, the coater retains the licence until the order is completed, with validation of the licence being restricted to the specific colour required for that particular order. In such cases, the coater needs to confirm in writing that the quality of the colour in question remains of the standard required by the Quality Regulations. On completion of the order, the coater must advise the GSB accordingly. This exception does not apply if the colour used for the contract order has failed to pass a prolongation test. In such circumstances the coater is obliged to advise the contractor/client accordingly. 2.5 Test and Surveillance Costs All applicants and holders of the Quality Label must carry in full any costs incurred for test and surveillance procedures relating to the award and extensions of the Quality Label and any additional tests that may be required by GSB International in line with the existing and valid regulations in respect of contributions. 2.6 Publications GSB International has the right to publish the following information to members by circular and / or through the internet: Award of Quality Label and material licences Suspension of material licences Cessation of material licences and Quality Label user rights Colours that are no longer licensed together with the year in which the licence was revoked This information must not be passed on to third parties. 2.7 Test Institutions GSB International is entitled and committed to ensure that the Quality Regulations () are being adhered to by all relevant parties. In accordance with DIN EN ISO/IEC17025 GSB will appoint an accredited Test Institute or a GSB approved and licensed expert to act on their behalf. 8

10 Section 3 Award and Retention of the Quality Label - Coaters 3 Award and Retention of the Quality Label Coaters 3.1 Application and Award of User rights All applications for the right to use the Quality Label "Approved Coated Aluminium" must be made in writing to GSB International, Franziskanergasse 6, Schwäbisch Gmünd and must be accompanied by a signed form of commitment (refer to section ). All applications are subject to approval by the TC. The commission reserves the right to visit any applicant s manufacturing plant, take coating samples and inspect paperwork as and when required on an ad hoc basis. Applications are restricted to coaters who have been operating for a minimum period of one year, unless the majority shareholder (s) is/are already approved users of the Approved Coated Aluminium Quality Label for another of their businesses. 3.2 Preconditions for the Award of Quality Label User Rights Once an application has been approved, GSB International awards the successful applicant the right to use the Quality Label Approved Coated Aluminium. The Quality Label for coaters distinguishes between three quality standards as set out in section 6.1 and it is the responsibility of the applicant to advise GSB International which standard they are applying for. For the Award of the Quality Label, the following preconditions apply: Meeting all requirements set out in section 6 Successful completion of the initial test (part 1 and part 2) Successful completion of the surveillance tests The Quality Label is awarded within the parameters of two independent single test procedures (initial test part 1 and part 2), with the first part of the test being advised in advance. All subsequent tests will be carried out unannounced. On the successful completion of the initial test procedures (part 1 and part 2) and upon the recommendation of the TC, the Board awards the applicant the Approved Coated Aluminium" Quality Label in the form of a certificate (section ). If any one part of the initial tests produces a negative result, the application is suspended. All applicants must be advised in writing of any such suspension giving full reasons for the decision to suspend the application. The applicant is then afforded the opportunity of applying for a repeat test of the relevant part. If the repeat test produces another negative result, the applicant must wait for 3 months before re-submitting their application. For the purpose of these regulations, a production plant is understood to consist of several pre-treatment process facilites including an adhesive water dryer, application equipment and curing ovens. The number of plants is determined by the number of pre-treatment processes and /or the number of curing ovens. 1 Plant: 1 Pre-treatment, 1 Curing Oven 2 Plants: 2 Pre-treatments, 1 Curing Oven 1 Pre-treatment, 2 Curing Ovens 2 Pre-treatments, 2 Curing Ovens If an applicant has more than one production plant, initial checks are carried out for all sites. As far as subsequent tests are concerned, the examiner will decide which plant is to be tested. Surveillance testing is carried out at each plant in accordance with Section 6 at least twice a year without prior notification. 9

11 Section 3 Award and Retention of the Quality Label - Coaters Upon the positive outcome of the surveillance test, the right to use the Quality Label is deemed to be confirmed, without the need for any written confirmation. If the coater wishes to carry the Master Coater addition, specific initial and surveillance test requirements must be met for this standard in accordance with section 6.1 quality level 2. If the coater wishes to carry the Premium Coater addition, specific initial and surveillance test requirements must be met for this standard in accordance with section 6.1 quality level Test Procedures Method and Level of Testing With the exception of part 1 of the initial test procedures, all subsequent tests are carried out unannounced. All test results will be recorded and documented by the examiner and copies of these are to be retained by the coater, GSB International and the TC. Any complaint/dispute must be supported by photographic/pictorial evidence or must be documented by the coater in written form. The examiner may ask for and take samples at any time and the coater must submit immediately to any such requests. The examiner may check any equipment installed by the coater at any time during testing, provided this is done within working hours. The following installations/procedures will be subject to testing in accordance with section 6: 1) The production plant 2) The laboratory equipment 3) Internal test control procedures Testing of Finished Goods Finished goods testing is restricted to parts that have already passed the Quality Label holder s internal control procedures. At least a half day s production has to be made available for testing. Samples are to be taken in accordance with the table set out in section Any finished parts/consignments that are stored, ready or being prepared for despatch at the time of testing, must be made accessible to the examiner for sampling upon request. 3.4 Measures applicable in Case of Violation Procedures applicable in Case of Violation If the TC finds any fault in the quality of goods, it will submit a proposal of measures to the Board. These measures depend on the severity of the violation and are: 1) additional requirements to be observed relating to internal control procedures 2) extended chargeable control testing 3) repeat testing 4) penaltiy up to Euro 1.500,-- 5) temporary or permanent withdrawal of the Quality Label or material licence The above listed measures 1 4 may be used in any combination, whereby measures 1 3 are determined by the Technical Commission. 10

12 Section 3 Award and Retention of the Quality Label - Coaters If repeat testing produces a negative result, the Quality Label will be withdrawn with immediate effect. Coaters who are found to persistently or severely violate will be subject to a temporary or permanent withdrawal of the Quality Label. This also applies to cases where coaters are found to purposely delay, prevent or obstruct any of the test procedures. The procedures and measures set out in also apply to any delivered clearly sub-standard goods, provided that the quality label holder s identity of the relevant consignments can be ascertained beyond any doubt. If up to a maximum of 10% of the pieces tested have produced a negative result, additional internal control procedures or increased frequency of external testing will be imposed. If more than 10% of the tested samples are found to be deficient, a fine, increased frequency of third party testing, which will be at the expense of the coater, or a permanent withdrawal of the quality label may be considered. Prior to action being taken as set out in point 4, the Quality Label holder is entitled to a hearing and must be afforded the opportunity to request that the consignment be examined by a test institution appointed by GSB International. If the violation is upheld by the test institution, then the Quality Label holder is liable to all costs incurred as a result of the examination. If the complaint proves to be unfounded, the complainant will carry any costs resulting from the examination. The procedures and measures in cases of violation as set out in this section are legally binding. In severe or urgent cases, the Chairman of GSB International can, with the approval of the Chairman of the TC, temporarily suspend the Quality Label with immediate effect, which must be confirmed in writing by the TC and the Board within a period of 14 days Complaints Procedure The holder of the Quality Label has the right to appeal against any violation measures within a period of 4 weeks from the notification. Any such appeals must be made in writing to the TC through the Head Office. If the appeal is quashed, the complainant may seek arbitration through a tribunal within a period of 4 weeks in accordance with section 11 of the GSB International Statues. 3.5 Re-Issue of the Quality Label If the right for the use of the Quality Label has been withdrawn, its re-issue may be applied for after a minimum period of three months in accordance with the procedures as set out in section 3.2. In cases of reapplication, the Board may impose additional conditions. 11

13 U+U 10 U+U Section 4 Issue and Conferment of Material Licences 4 Issue and Conferment of Material Licences 4.1 General Upon application, GSB International awards the coating material manufacturer a material licence for coating materials that meet the requirements of. The award of a material licence stipulates that the licence holder fully accepts these regulations. A licence can only be awarded for systems that are free from TGIC and do not contain any pigments that require specific declaration. Upon submission of a licence application the material manufacturer must specifically declare if one or several colours of the relevant material do not meet the required standards, especially those relating to weathering. GSB International will mark such coating materials in an appropriate manner (i.e. list of approved systems). By the same token, the material manufacturer is also obliged to mark any such material in the appropriate manner if supplied to a Quality Label holder. GSB International determines the way in which such marking should occur. Coating Materials can be licensed in the following quality standards: Standard System for the coating of piecework aluminium / Florida weathering up to 300 MJ UVradiation (approx. 12 months). Master System for highly weatherproof coating of piecework aluminium / Florida weathering up to 840 MJ UV-radiation (approx. 36 months). Premium System for the exceptionally high weatherproof coating of piecework aluminium / Florida weathering up to MJ UV-radiation (approx. 60 months). For materials manufactured at several production sites, the award or withdrawal of the licence is valid for all relevant production sites, provided they are members of GSB International and have applied for the licence relating to the relevant materials. The TC reserves the right to visit the plant of the applicant and demand access to any documentation relevant to. 4.2 Application and Product Information All applications have to be submitted in writing to GSB International and must be accompanied by a legally binding application form (see enclosure ). The applicant is advised in writing on the refusal of a licence together with the reasons why the application was not granted. If the application relates to the licensing of a specific colour group of a coating material, the certificate must include in brackets the colours that the licence is valid for. Coating materials containing special effect pigments (metallics) can only be licensed, if a relevant sample of the system was submitted with the application (see section 4.3). For coating materials with a structured finish, the type of gloss must be indicated (matt, semi-gloss, gloss). Gloss tolerances must be disclosed by the material manufacturer with the licence application (reflectometer value). The material licence allows the following nominal ranges in terms of gloss values: units at U<U units (matt) units at > 40 units (from semi-gloss on) The awarded material licence is valid within the nominal gloss parameters applied for. 12

14 Section 4 Issue and Conferment of Material Licences Permissible tolerances between individual products of a licensed coating material are to be agreed between the material supplier and the coater. Recommendation: U+ 5 units. In deviation from DIN EN ISO 2813 all gloss measurements are taken at 60 angle geometry. GSB International must be informed immediately of any changes in the curing conditions by the appropriate submission of a form and technical data sheet, upon the receipt of which the TC decides whether the changes submitted would require the re-licensing of the material. For coating materials with special properties that deviate from section 7.6, the material manufacturer can apply for a specific licence. The TC will decide the test requirements for such licences. 4.3 Material Samples To accompany their application the applicant must provide the following: Powder Lacquers Standard Quality Systems: 1 kg each of RAL colours 3016, 8014 and 9001 must be submitted. If the licence is to include metallics, then instead of RAL 9001 a metallic sample (RAL 9006 or RAL 9007) must be provided. Master and Premium Quality Systems: 1 kg each of RAL colours 3009, 5003 and 9001 must be submitted. If the licence is to include metallics, then additionally a metallic sample (RAL 9006 or RAL 9007) must be provided. the currently valid technical data sheet showing the manufacturers instructions.the technical data sheet must clearly indicate if the licence application does not relate to metallics or other specific colours. the currently valid safety data sheet the completed application form (see Section ) Liquid Lacquers Standard Quality Systems: 1 kg each of RAL colours 3016, 8014, 9001 must be submitted. If the licence is to include metallics, then instead of RAL 9001 a metallic sample (RAL 9006 or RAL 9007) must be provided with base lacquer, hardener and thinner Master and Premium Quality Systems: 1 kg each of RAL colours 3009, 5003 and 9001 must be submitted. If the licence is to include metallics, then additionally a metallic sample (RAL 9006 or RAL 9007) must be provided with base lacquer, hardener and thinner the currently valid technical data sheet showing the processing instructions with particular reference to the mixing ratios and added thinners. The technical data sheet must clearly indicate if the licence application does not relate to metallics or other specific colours. the currently valid safety data sheets the completed application form (see Section ) Licence application for one colour group 1 kg each of three random colours of the colour group applied for as well as the currently valid technical data sheet, safety data sheet and application form (in accordance with Sections and 4.3.2). 13

15 Section 4 Issue and Conferment of Material Licences The technical data sheet must clearly indicate if the licence application relates to an individual colour group only. The technical data sheet must clearly indicate if the licence application does not relate to metallics. A separate application form must be appropriately completed and duly signed by the applicant for each relevant coating material. 4.4 Licence Testing General Material licences for Standard, Master and Premium Quality systems will be awarded if the material has passed all the test requirements in accordance with section 7. The licence will be certified. If any of the test procedures produces a negative result, even in part - before end of natural weathering in Florida - the licence test is deemed as failed and the material manufacturer will be notified in writing. Appeals must be made in writing to the head office of GSB International within a period of 4 weeks from the receipt of the failure notice. A re-test may be applied for immediately. If natural weathering produces a negative result an appeal is not possible. The material manufacturer will be notified in writing. In such cases the provisional licence certificate must be returned to the GSB Head Office without delay. A new application may be submitted after a minimum period of 3 months Provisional Coating Material Licences If all test procedures relating to the coating systems - before end of natural weathering in Florida - produce a positive result, the material manufacturer will be awarded a provisional licence for the material tested. Instead of the QUV B test, the material manufacturer may supply with the application a positive proof of Florida weathering certified by an accredited test institution in accordance with section prior to the licence application. Such test results must not be older than one year.the issue of a provisional material licence is certified. 4.5 Licensing Controls applicable to Coating Materials General All licensed coating materials are tested annually. The first licence extension test is carried out one year from the provisional licence award, whereby a positive pass of this test cannot neutralise a negative Florida weathering result as part of the licence test. Licence extension testing ensures that coating materials meet the requirements in accordance with section 7.6. As opposed to licence testing, the licence extension test procedures are restricted to two random colours Provision of Samples Material samples required for extension testing are taken by the examiner in accordance with the regulations applicable to external test procedures of Quality Label holders. If sampling is not possible during the first seven months, an examiner appointed by the GSB International can take the relevant samples from the manufacturer s store, and if this is not possible either, GSB International can request that the manufacturer provide the necessary material samples within a period of 4 weeks. If a licensed material is manufactured at 14

16 Section 4 Issue and Conferment of Material Licences several production sites, material samples for extension test purposes are taken from one site only Licence Extension On the successful completion of the extension test, the licence is understood to remain valid until the next test is due, without any further need for notification Negative Extension Test If the extension test produces a negative result either in full or in part for both colours then the material is understood to have failed the test and the manufacturer will be notified accordingly in writing. The holder of the material licence has the right to appeal against this decision or apply for a repeat test within a period of 4 weeks for both the negatively evaluated colours. Any such appeal must be made in writing to the TC through the head office. If the appeal is quashed, the complainant may seek arbitration through a tribunal within a period of 4 weeks in accordance with section 11 of the GSB International statutes. If no application is made for re-testing within a period of 4 weeks from the receipt of notification or if the repeat test once again produces a negative result, the material licence will be withdrawn. The material manufacturer must immediately return the relevant licence certificate to the GSB International. If only one colour fails the test then a repeat test will be carried out restricted to that specific colour only. If the result of the repeat test is negative for one colour only or if no repeat test for that particular colour was applied for, the system remains licensed. In such cases any colour excluded from the licence must be indicated as such. If the brief weathering test is negative the following applies: Only one colour does not meet the requirements: A sample coated with the relevant colour is exposed to the appropriate weathering conditions (Florida-Test) in accordance with section Until the final outcome of the test, the colour must be marked as no longer licensed. On the successful completion of the Florida Test, the licence extension remains in force without restriction. If the colour fails the weathering test procedures, the coating system remains licensed, but the colour that has failed the Florida Test must be marked as no longer licensed. In case the material manufacturer intends to re-submit the failed colour for licensing, then the full licence application and test procedures will be applicable to the relevant colour. The material licence will be withdrawn if three consecutive extension tests were negative. In such cases a repeat test is no longer possible. Both colours do not meet requirements: Samples coated with both the relevant colours are exposed to the appropriate weathering conditions (Florida Test), as per section Until the final outcome of the test, both colours must be marked as no longer licensed. If one of the two colours fails the Florida Test, then this colour must continue to be marked as no longer licensed. In case the material manufacturer intends to re-submit the failed colour for licensing, then the full licence application and test procedures will be applicable to the relevant colour. If both colours fail the Florida Test the material licence will be withdrawn, in which case the manufacturer must immediately return the relevant licence certificate to GSB International. 15

17 Section 4 Issue and Conferment of Material Licences 4.6 Quality Label for GSB Material Licences Depending on the licenced standard (see section 4.1) following quality labels can be used for the coating material: 16

18 Section 5 Issue and Conferment of Material Licences applicable to Pre-treatment chemicals 5 Issue and Conferment of Material Licences applicable to Pre-treatment Chemicals (Conversion Coating / Passivation) 5.1 General Upon application, GSB International awards the material manufacturer a pre-treatment chemical material licence for pre-treatment chemicals to passivate the aluminium surface prior to coating that meet the requirements for. The award of a material licence stipulates that the licence holder accepts these regulations. For pre-treatment chemicals that are manufactured at several production sites, the award or withdrawal of a the licence is valid for all relevant production site, provided they are members of GSB International and have applied for the licence relating to the relevant pre-treatment chemical. The TC may visit the applicant s manufacturing plant, request access to and examine material samples and any documentation mentioned in. 5.2 Application and Product Information All applications have to be submitted in writing to GSB International and must be accompanied by a legally binding application form (see section enclosure ). The TC examines all material licence applications. The applicant is advised in writing on the refusal of a licence together with the reasons why the application was not granted. The applicant has the right to appeal against the refusal of a licence within a period of 4 weeks in writing to GSB International. Any such appeal will be heard and settled by the Board. 5.3 Licence Testing General Within the parameters of the test procedures for pre-treatment chemicals specifically include the endurance tests in accordance with section Provisional Licences for Conversion Coating / Passivation If all test procedures (Stages 1 3) as set out in section 8.1, produce a positive result; the pre-treatment chemical manufacturer is awarded a provisional licence for the relevant pre-treatment chemical, which is certified (see section ). If the coater introduces a new pre-treatment system for the first time, the pre-treatment manufacturer must advise the TC accordingly in writing so that an unannounced routine test can be arranged at the coating plant. Any such introduction must be documented appropriately by the pre-treatment chemical manufacturer and must be countersigned by the coater. GSB International will then appoint an accredited test institution to carry out the test Full Licences for Pre-treatment Chemicals Conversion Coating / Passivation If weathering (stage 4) in accordance with section produces a positive result, a full licence is awarded and certified, in which case the provisional licence certificate must be returned. If weathering produces a negative result, no appeal is possible. The material manufacturer will be notified of the reasons in writing. The provisional licence certificate must be returned to GSB immediately. 17

19 Section 5 Issue and Conferment of Material Licences applicable to Pre-treatment chemicals After a minimum period of 3 months from the date of the failure notification, the material manufacturer may resubmit his licence application. 5.4 Surveillance Testing applicable to Licences for Pre-treatment Chemicals Material samples required for extension testing in the form of ready coated profiled or sheet metal piecework and two of each pre-treated profiled or sheet metal sections are taken by the examiner during routine testing of the coaters, i.e. Quality Label holders. From the original packaging, the examiner takes 5 litres of conversion chemicals that are in use to allow for sufficient test material should a repeat test become necessary. The designated test quantity is then labelled, sealed up, and remains with the coater. The coated sample material is used to carry out test procedures as set out in section On the successful completion of the extension test, the pre-treatment licence is understood to remain valid until the next test is due without any further need for notification. Even if one part only of the repeat test is negative, then the pre-treatment material is understood to have failed the test and the material manufacturer and relevant coater will be notified accordingly in writing. The pre-treatment material manufacturer has the right to apply for a repeat test by writing to GSB within a period of 4 weeks. The repeat test is carried out in an accredited test institution in the presence of the supplier of the chemicals and in some cases an official representative of the TC, using the pre-treatment chemicals applied by the coater and the samples of conversion chemicals taken for extension testing. Once the parts have been coated at the test institution, the profiles and metal sheets are then examined in accordance with, section If no application for repeat testing is made, then the pre-treatment licence is withdrawn, in which case the pretreatment manufacturer must immediately return the relevant licence certificate to GSB International. In case of alternative pre-treatments which are not being used by coaters, based on the results of weathering for a period of 3 years in Hoek van Holland the pre-treatment supplier can make the decision to apply for an annual extension test at their cost or alternatively withdraw their system. Either decision must be communicated in writing to the GSB Head Office. Extension testing is carried out in accordance with Section (Stage 2), whereby the chemicals neccessary for testing must be made available to the test institute which has been appointed by the TC Once the parts have been coated at the test institution, the profiles and metal sheets are then examined in accordance with, section

20 Section 6 Requirements applicable to Coaters 6 Requirements applicable to Coaters 6.1 General This section sets out the requirements applicable to coaters distinguishing between three categories as follows: 1 Approved Coater 2 Master Coater 3 Premium Coater The table below shows the requirements applicable to coaters in accordance with the different levels of quality standard. More detailed information in respect of surface pre-treatment, application, thermal bonding and forced drying, organisation and training is provided in the following sections. Requirement Quality Standard see Section 1 GSB Approved Coater 2 GSB Master Coater 3 GSB Premium Coater Surface Pre-treatment 6.2 Process documented and submitted to the GSB X Licensed surface pre-treatment process with annual control testing 8.1 and X Contact marks on visible surfaces X Final rinse X X X Drying of Adhering Water X X X Immediate Coating < 24 h X X Immediate Coating < 12h X Hygiene and Handling pre-treatment X X X Handling of pre-treated parts with gloves only X X X Application and thermal curing or forced drying Hygiene and Handling - coating X X X Surveillance of curing conditions X X X Laboratory 6.3 Standard Equipment Additional Equipment Product and Coating Material Storage 6.4 Defined storage conditions for material to be coated X X X Defined storage conditions for coating materials X X Quality Control Documented quality management system X Provision of product and safety data sheets 6.5 X X X In-house control procedures 6.6 X X X Training 6.7 Completion of GSB-Training Seminar X X Completion of GSB-Premium Training Seminar X Documented in house training for employees X Use of Sea Proof Quality Label after additional AASS and FFC Testing Use of Sea Proof Plus Quality Label after additional AASS and FFC Testing Use of the Sea Proof Plus Quality Label with pre-anodising after additional testing and X X and X and X X X X X 19

21 Section 6 Requirements applicable to Coaters 6.2 Surface Pre-treatment General Pre-treatment, especially for passivation, must be selected depending on the location of the object. See table Section 1.1. The currently approved pre-treatment processes are detailed in section 8. Coaters introducing a new alternative pre-treatment system for serial coating, must advise the GSB Head Office in writing accordingly so that an unannounced control test can be carried out. This also applies to trial runs tested for longer than 4 weeks. Coaters who have successfully passed the AASS and FFC tests in accordance with sections 9.14 and 9.15 and have proof of meeting the requirements as set out in section may apply to the GSB International to use the Sea Proof Quality Label, which once approved, requires a chargeable annual routine extension test. Premium Coaters are automatically licenced to use the Sea Proof Quality Label Suspension and Positioning Preferably materials such as Aluminium, Stainless Steel or Plastic should be used to suspend and control the distance between parts, whereby the position of the parts must not restrict the liquid contact with the Aluminium piecework to be treated Suspension and Positioning (GSB Approved Coater) Parts must be suspended/positioned in such a way that each contact point on the visible coated surfaces is < 2 mm. The client must be advised of this accordingly Suspension and Positioning (GSB Master and Premium Coater) Parts must be suspended/positioned in such a way that avoids any contact points on the visible coated surfaces. If contact is not altogether unavoidable, contact points must be indicated on the part itself or a sketch ensuring that the client is advised accordingly Etching Rate As this largely depends on the composition of the alloys and the processing parameters relevant to the part finished Aluminium there are no set tolerance limits other than the recommended etching rate values for alloys EN AW-6060 and EN AW-6063: > 1 g/m². A suitable etching rate for other alloys has to be determined and defined Weight of Conversion Coating / Passivation Layer Weights must be as follows: - Yellow Chromating 0,4 1,0 g/m² - Green Chromating 0,4 1,2 g/m² The layer weight relevant to alternative pre-treatments and its tolerance levels and method of setting any such levels must be agreed with and documented by the chemical supplier. The verification of layer weight levels must be based on the part finished product, the use of test panels has to be avoided. 20

22 Section 6 Requirements applicable to Coaters Final Rinse or Rinsing Process prior to Non Rinse Treatment De-ionised water must be used for the rinsing process, and it is mandatory that the water of the last rinse has a conductive value of κ 20 C < 30,0 µs/cm Drying of Adhering Water Immediately after the chemical or electro-chemical pre-treatment all parts must be dried in an adhering water drier, whereby the temperature of the objects must not exceed 100 C, unless indicated otherwise by the supplier of the chemicals used in the surface pre-treatment process Wastewater Treatment The waste water treatment process must comply with the relevant regional laws and regulations Interim Storage All pre-treated parts must be in a clean and dry state and coated immediately or in less than 24h for Standard and Master Coaters and less than 12h for Premium Coaters. Interim Storage is to be avoided, but if this is inevitable, parts must be stored in such a way that contamination through dust or moisture is avoided and covered with plastic foil where appropriate Cleanliness and Handling The suspension and positioning, disconnection and transport of parts during the various treatment processes must avoid contamination through dust, sweat, sebum, electrolyte residue, condensation and mechanical damage. The pre-teated parts must be handled with clean gloves only Application and Thermal Curing or Forced Drying The application and coating process must be carried out in an appropriately equipped plant. The coated piecework must be thermally cured/force dried in a curing oven at the appropriate object temperature according to the material manufacturer s instructions relevant to the material licence. The coating thickness on the visible weathered surfaces (marked surface) must not fall below 50 µm and not exceed 120 µm (see paragraph coverage). The surrounding airflow temperature must be continually monitored and documented via integral measuing equipment at a minimum of 3 stationary measuring points, which must be positioned in such a way to guarantee an accurate overall assessment of the distributed air inside the furnace. The peak metal temperature of the piecework to be coated must also be recorded and documented at a minimum of 3 measuring points using a suitable measuring device. 6.3 Laboratories and their Technical Equipment General The laboratory must be physically removed from the manufacturing equipment. At each plant, the laboratory must be furnished with the following equipment as a minimum, which must be in full working order. Any equipment failure must be dated and documented. Repair orders and warranty inspection orders must be 21

23 Section 6 Requirements applicable to Coaters provided to the examiner upon request. All tests in Section 12, In House Controls, must be carried out in a laboratory environment Standard Equipment 2 film thickness measuring devices working on the eddy current principle i.a.w. with DIN EN ISO 2360 scales to establish the quality of the passivation layer and the etching rate to an accuracy of 0,1 mg cutting tools and accessories for the cross cut test in accordance with DIN EN ISO 2409 apparatus for the mandrel bending test in accordance with DIN EN ISO 1519 apparatus for testing adhesion and elasticity at deformation (Erichsen Cupping Test) i.a.w. DIN EN ISO 1520 apparatus for the impact test i.a.w. ASTM D 2794 (required for powder coating material only) means to test cross linking of liquid lacquer coatings (for coaters using liquid paints) gloss measuring equipment in accordance with DIN EN ISO 2813 (DIN ) measuring apparatus for the testing of peak metal and circulating air temperatures with at least 3 measuring points conductivity measuring device boiling water test equipment Additional Equipment colour measuring device 6.4 Product and Coating Material Store Product Storage The product to be coated (Al-Substrate) must be stored appropriately to avoid any contamination that can potentially affect the surface coating process, such as pre-corrosion or mechanical damage. The manufacturer s instructions must be observed Coating Material Storage Coating materials must be stored in accordance with the manufacturer s instructions. Any deviations must be notified to the supplier in writing. 6.5 Product and Safety Data Sheets Currently valid product information and safety data sheets for all relevant materials must be accessible at the appropriate stages of the manufacturing process, whereby the source of the data must be proven. Access to any such documentation and records must be unrestricted at any time. All data sheets must be checked annually to ensure that they are of the latest standard. 22

24 Section 6 Requirements applicable to Coaters 6.6 In-House Controls Control of Incoming Materials It is the responsibility of the coater to check: All deliveries of chemicals relevant to the coating process. The coating material at the point of delivery Obvious defects on the surface of the parts to be coated.s Production Control and In-House Control It is the responsibility of the coater to establish and follow ongoing internal control procedures relating to the pre-treatment and production processes. These must be documented and retained together with the relevant samples for a period of 5 years or in accordance with specific legal requirements that may apply. (This applies to consignments and charges in excess of 100 m² or a time period of 2 hours). These records must be accessible to the examiner. If possible, profiled pieces or other practicable parts should be used in preference to test panels. It is recommended that at least one sample should be taken from each production lot. In addition the coater is responsible for checking prior to coating that the processing parameters continue to comply with the data supplied in the application form for the licensing test [supplied in the list of approved systems (updated on the Internet or enclosed to the latest GSB-News)]. Any deviations must be notified immediately and in writing to GSB International Level of Production Controls The level of production controls is described and set out in section Training Training Seminars Upon the award of the Quality Label, the coater is obliged to nominate at least one member of their technical team to complete a GSB International Training Seminar every two years. New members must attend the first available training seminar. All delegates will receive an attendance certificate. Quality Label licence holders are obliged to every two years send at least one member of their technical team to attend a GSB International training course. Training courses conclude with a written test. Premium Quality Label licence holders are obliged to once a year send at least one member of their technical team to attend a GSB International training course. New members must enrol in the first available training course, the attendance of which will be certified. The course program covers seminars for GSB Approved Coaters, Master Coaters and Premium Coaters In House Training The coater must at regular intervals and at least once a year carry out in house training to educate their employees in matters relevant to AL 631. Attendance of any such training must be documented accordingly 23

25 Section 6 Requirements applicable to Coaters 6.8 Requirements to be Licensed as GSB Premium Coaters General Generally the Requirements for GSB Premium Coaters apply in conjuction with all other requirements as set out in the currently valid edition of. The licence to use the quality label with the addition of Premium Coater is awarded within the framework of two independent individual test procedures (Premium First Test Part 1 and 2). Coaters who are currently licensed to use the quality label of GSB Approved Coater will be given prior notice of a pre-test. For coaters who are already a licensed GSB Master Coater both parts of the first test are carried out as part of their control tests without prior notification. If the first test produces a negative result, then the test is deemed a control test and will be evaluated in accordance with Section 6.1, Quality Level 1 oder 2, whereby the pre-conditions as set out in Section 3.2 apply Pre-treatment Process It is understood that the regulations as set out in Section 8 apply to the licensing process of alternative passivation systems Chromium containing conversion coatings which are being used by Premium Coaters are deemed as licensed if they have been successfully applied at this Premium Coater for a minimum period of 3 years and both the product and extension tests in accordance with AASS-/FFK-Test have produced a positive result The processing sequence of the entire pre-treatment plant at every GSB Premium-Coater must conform to the requirements set out in Section 6.1, Quality Level 3, whereby the processing sequence must be documented and submitted to the GSB The sequence of each part of the pre-treatment process will be licensed individually, whereby samples are taken from each coated section during the proecess and tested as part of the control testing procedure by an accredited test institute in accordance with the requirements of 1000h in AASS- and FFK-Testing. Pre-treatment Baths: Temperature, concentration and time based on documentation submitted Layer Weight of passivation: Yellow Chromating: Chromate phosphate pre-treatment: 0,6 1,0 g/m² 0,6 1,2 g/m² The layer weight relevant to alternative passivations and its tolerance levels as well as the determination of any such levels must be agreed with the chemical supplier and documented (at least. 60 % of the max.value). The layer weight must be determined on the part finished product used during the production process. On account of the fact that the etching rate is largely dependent on the processing paramaters and the production of the part finished Aluminium product, it is not sensible to pre-set limits with narrow tolerance levels. The recommended etching rate for alloys EN AW-6060 and EN AW-6063 is > 1 g/m². A suitable etching rate for other alloys has to be determined and defined Pre-treated piecework must be coated within 12 h after the pre-treatment process. 24

26 Section 6 Requirements applicable to Coaters All pre-treatment plants licensed as GSB Premium Coaters must work exclusively with GSB approved chemcials. Pre-treatment plants not used for GSB licensed coatings, such as in the car industry are not subject to GSB licensing (the GSB Head Office must, however, be informed of any such plants) Pre-anodising as passivation is only deemed as conforming to GSB standards on the proviso that the process is supported by a documented GSB Additional Test Preanodising. The Premium Coater is obliged to adivse the GSB Head Office in advance of the date when they intend to use pre-anodising as a pre-treatment. The GSB will then inform the examiner who will decide whether to carry out a routine test on the relevant date Orders carried out by third party pre-anodising companies (electro-chemical pre-treaments carried out by third party contractors) are only deemed as conforming to GSB standards if the relevant coater can provide evidence that the treatment is supported by the appropriate additional tests required by the GSB for pre-anodising processes (see Section 8.3). As such the appointed third party anodiser must themselves be a GSB approved coater or licensed to carry the Qualanod Quality Label. As a rule, third party preanodisation does not meet the conditions required of the last dripping rinse water (conductivity at 20 C, κ 20 C < 30,0 µs/cm ) according to Sections 8.3. Therefore, the GSB coater is obliged to post-treat third party pre-anodised piecework to ensure that any such parts fully conform with Sections 8.3, whereby the maximum storage times of third party pre-anodised surfaces must be observed in accordance with Section If different metals are treated at the same processing plant on a regular basis, the individual treatment processes must be kept strictly separate. Maximum tolerance levels of foreign ions must be agreed with the pre-treatment provider and documented as part of the process in accordance with Section The concentration of such ions is to be determined and recorded after each pre-treatment of any substrates foreign to Aluminium (daily production log) Coating Plants Premium Coaters must advise the GSB about the number of their coating plants (see section 3.2) and which of these are being used for GSB Premium-Quality coatings. If a coater operates a vertical line at least one horizontal plant must conform with the requirements for Premium Coaters and be designated as such. All registered plants will be tested on a regular basis Requirements for the Application and Curing These requirements are subject to the recommendations published in the form of information/data sheets Quality Control Colour Measuring Device to assess the standard of the individual charges of different batches relating to a specific object In cases of Premium standard orders the results must be recorded. For metallic and special effect paints visual assessment using a reference sample replaces colour measuring. It is recommended to follow VdL-RL 10 Guidelines of permissible colour tolerances for single colour powder lacquers for use in architectural projects. 25

27 Section 6 Requirements applicable to Coaters The Premium Coater is oblidged to exercise continuous in house controls in accordance with QR AL 631, Part 12. If the Premium Coater is certified a copy of the certificate must be submitted to the GSB Head Office. The preferred recommended certification of Quality Management Systems is in accordance with DIN EN ISO Examiners must be given unrestricted access to the list of customer complaints. The keeping of a production log journal (general documentation relevant to the production process) is mandatory for Premium Coaters. 26

28 Section 7 Requirements applicable to Coating Materials 7 Requirements applicable to Coating Materials 7.1 General All coating materials must be free from TGIC and must not contain any pigments that require specific declaration. 7.2 Preparation of Samples Chemical, electro-chemical pre-treatment processes and passivation within the control thereof must be carried out in accordance with the appropriate procedures. Test sheets or profiled pieces must be tested and pretreated in accordance with DIN EN (Corrision Protection for Metals rinse and non rinse Chromatised Layers on Aluminium and its Alloys) 7.3 Application Coating materials must be processed in accordance with the manufacturer s instructions. The film thickness on samples must be at least 50 µm to 80 µm, unless specified otherwise by the manufacturer. Weather exposed visible surfaces coated with PVDF or Silicon based liquid lacquers must comply as a minimum with the film thickness submitted by the material supplier at the registration/licensing stage of the relevant material. An appropriate amount of samples must be taken in accordance with the relevant minimum curing conditions (peak metal temperature and durability). An additional 60 minutes ageing at 120 C is required for all two component lacquers. All processing parameters are to be recorded and documented appropriately. 7.4 Coating Materials with specific Properties This applies to all coating materials with a deviation in their property profile of 7.6. Sampling must comply with the manufacturer s instructions and the relevant technical data sheets, provided the system is appropriately licensed by GSB International. 7.5 Acceptable Colour Tolerances It is recommended to set parameters for permissible colour tolerances in accordance with the currently valid version of VdL-RL 10 Acceptable Colour Tolerances. These guidelines set out procedures for the comparison of samples, testing methods and acceptable colour tolerances between the target data and the delivered product as well as between two different batch deliveries. These regulations do not apply to the assessment of finished coated piecework, but are relevant only to samples produced in standardised laboratory conditions. 27

29 Section 7 Requirements applicable to Coating Materials 7.6 Requirements applicable for the Licensing of Coating Materials Powder coating materials Test (refer to section 9) See Standard Master Premium Section Cross Cut 9.6 Gt 0 Gt 0 Gt 0 Coverage 9.4 Film Thickness Thin Film Powder Standard Powder (depending on color shade) Average Film Thickness µm 120 µm µm µm 120 µm µm µm 120 µm µm Mandrel Bending Cracking Adhesive Tape Removal Erichsen Cupping Cracking Adhesive Tape Removal Impact test Cracking Adhesive Tape Removal Cutting, Milling, Drilling (naked eye examination at a distance of cm) Gloss 60 (Nominal parameters for the licensing of systems) mm not permitted mm not permitted inch/pound not permitted 5 mm permitted no delamination 5 mm permitted no delamination 20 inch/pound permitted no delamination 5 mm permitted no delamination 5 mm permitted no delamination 20 inch/pound permitted no delamination 9.11 No flaking No flaking No flaking 9.21 ± 10 E bei 40 E ± 15 E bei > 40 E ± 10 E bei 40 E ± 15 E bei > 40 E ± 10 E bei 40 E ± 15 E bei > 40 E Condensation atmosphere with constant humidity: Duration of Test Blistering Infiltration at the cross cut Changes to colour and Metallic effect Alternating Condensation (0,2l SOB2B) Cycles Blistering Infiltration at the cross cut Changes to colour and Metallic effect Boiling Water/ Pressure Cooker Test Degree of blistering Cross cut with adhesive tape removal Resistance to Moisture L* Resistance to Acetic Salt Spray (AASS) Duration of Test Infiltration in cross cut Degree of blistering Resistance to Mortar Changes in colour and effect Changes in colour and Metallic effect Adhesive Sealants Adhesion break Cohesion break QUV B (313 nm) Duration of Test Residual Gloss Natural Weathering in Florida approx. duration of test (months); UV-Energy (MJ/m²) Residual Gloss L*, C* h 0 (S0) d max 1 mm max. level (S0) d max 1 mm max. level 3 0 (S0) Gt 0/Gt 1 (with tape removal) 1000h 0 (S0) d max 1 mm max. level (S0) d max 1 mm max. level 2 0 (S0) Gt 0/Gt 1 (with tape removal) 1000h 0 (S0) d max 1 mm max. level (S0) d max 1 mm max. level 2 0 (S0) Gt 0/Gt 1 (with tape removal) max. L* 4 max. L* 4 max. L* h d max 1 mm 0 (SO) none max. level 3 not permitted permitted 300h 50 % 12 max % see section h d max 1 mm 0 (SO) none max. level 2 not permitted permitted 600h 50 % 36 max % see section h d max 1 mm 0 (SO) none max. level 2 not permitted permitted 1000h 50 % 60 max % see section

30 Section 7 Requirements applicable to Coating Materials Liquid coating materials Test (refer to section 9) See Standard Master Premium Section Film thickness 9.4 As per indication of manufacturer As per indication of manufacturer As per indication of manufacturer Cross Cut 9.6 Gt 0 Gt 0 Gt 0 Mandrel Bending 9.7 Cured Lacquers Two component lacquers Cracking Adhesive tape removal 5 mm 12 mm - not permitted 5 mm 12 mm - permitted no delamination 5 mm 12 mm - permitted no delamination Erichsen Cupping Cured Lacquers Two component lacquers Cracking Adhesive tape removal Bonding MEK Test Double Lifting (applies to cured lacquers and two component lacquers) Cutting, milling and drilling (naked eye examination) Gloss 60 (Nominal parameters for the licensing of systems) Condensation atmosphere with humidity: Duration of test Blistering Infiltration at the cross cut Changes to colour and Metallic effect Alternating Condensation (0,2l SOB2B) Cycles Blistering Infiltration at the cross cut Changes to colour and Metallic effect Boiling Water / Pressure Cooker Test Degree of blistering Cross cut + adhesive tape removal Resistance to Moisture L* Resistance to Acetic Salt Spray (AASS) Duration of test Infiltration at the cross cut Degree of Blistering Resistance to Mortar Changes in colour and finish Changes in colour and Metallic effect Adhesive Sealants Adhesion break Cohesion break QUV B (313 nm)t Duration of test Residual Gloss Natural Weathering in Florida approx. duration of test (months); UV-Energy (MJ/m²) Residual Gloss L*, C* mm 3 mm - not permitted Buchholz hardness min mm 3 mm - permitted no delamination Buchholz hardness min mm 3 mm - permitted no delamination Buchholz hardness min. 80 No flaking No flaking No flaking ± 10 E bei 40 E ± 15 E bei > 40 E 1000h 0 (S0) 1 mm max. Level (S0) d max 1 mm max. Level 3 0 (S0) GT0 /GT1 (with adhesive tape removal) ± 10 E bei 40 E ± 15 E bei > 40 E 1000h 0 (S0) 1 mm max. Level (S0) d max 1 mm max. Level 2 0 (S0) GT0 /GT1 (with adhesive tape removal) ± 10 E bei 40 E ± 15 E bei > 40 E 1000h 0 (S0) 1 mm max. Level (S0) d max 1 mm max. Level 2 max. L*4 max. L* 4 max. L* h d max 1 mm 0 (SO) none max. level 3 Not permitted permitted 300h 50 % 12 max % See section h d max 1 mm 0 (SO) none max. level 2 Not permitted permitted 600h 50 % 36 max % See section (S0) GT0 /GT1 (with adhesive tape removal) 1000 h d max 1 mm 0 (SO) none max. level 2 Not permitted permitted 1000h 50 % 60 max % See section

31 Section 8 Requirements applicable to Pre-Treatment 8 Requirements applicable to Pre-Treatment 8.1 General Pre-treatment comprises both chemical and electro chemical processes. The pre-treatment process should be selected in accordance with the location applicable to the relevant objects (see section 1.1). It is a well known fact, for example, that filiform corrosion can occur in particular climatic conditions (maritime climate with relatively high humidity). Alternative pre-treatment in the form of pre-anodising (i.e. to generate a conversion film through anodising) has proven to provide an effective solution. Conventional Rinse processes, such as Yellow Chromate, Chromating phosphate pre-treatment and alternative Chromium-free passivations may be considered a suitable alternative if de-greasing, alkaline etching and acidic desmutting treatments require the removal of the microcrystaline deformation layer, which is considered a catalyst for filiform corrosion. The Layer Weight is as follows: Yellow Chromate: 0,4 1,0 g/m² Chromate phosphate pre-treatment: 0,4 1,2 g/m² Layer weights relevant to alternative pre-treatment processes including tolerances and methods of evaluation must be agreed with the chemical supplier and documented accordingly. GSB Approved Coaters, GSB Master Coaters: rinse systems containing Chromium do not require any specific licensing. GSB Premium Coaters: the pre-treatment process applied by a GSB Premium Coater must be documented and submitted to the GSB, irrespective of whether the rinse system contains Chromium or not. The process run will be licenced individually. A coated batch sampled during surveillance testing, will be subject to 1000h of Acidic Acid Salt Spray and Filiform Corrosion testing by an accredited test institute, whereby the values given in table resp also apply for these tests. A positive test result within the framework of surveillance testing is considered a necessary criterion for the licensing of rinse systems containing Chromium, on the provison that the GSB Approved Premium Coater has been operating the relevant pre-treatment system for a minimum period of three years. No Rinse systems containing Chromium and alternative passivations need to be licensed in accordance with paragraph 8.2. This licence is non-plant specific, as all plants work individual. Therefore every coater must examine the pre-treatment process as to its compatibility with their own production equipment, process and coating materials through boiling water/pressure cooker testing followed by a cross cut and adhesive tape removal test for each production charge. The test results must be documented within the in house/internal control procedures. Manufacturer s instructions, such as rinsing with de-ionised water prior to the application of the pre-treatment chemical must be strictly adhered to. The electro chemical pre-anodising process does not require a specific licence. The TC must be advised on the application of such systems, which is to be taken into account during control/extension tests, and the coater will need to pass the relevant additional test criteria in accordance with section 8.3. Orders involving pre-anodising are only deemed to comply with GSB regulations if the additional test requirements can be proven to have been met within the parameters of control/extension testing. Third party pre-anodising treatments are only deemed to comply with GSB regulations if the GSB coater can provide proof of having met the relevant additional requirements within the parameters of control/extension testing. 30

32 Section 8 Requirements applicable to Pre-treatment 8.2 Licensing of Chemical Surface Pre-treatment Systems General New licences for pre-treatment systems or passivation are awarded through the TC in several stages. All costs incurred must be borne by the applicant Stage 1 The chemical supplier must make a licence application for the relevant pre-treatment system / passivation to the GSB International. This requires the following documentation and material: Records of internal test results in accordance with Tested samples Product information and technical data sheets Listing of reference objects where applicable Proof of product suitability for dipping and/or spray installations Proof of product suitability for powder and/or liquid lacquers. If the product is suitable for liquid lacquers, the relevant lacquer must be specified accordingly Stage 2 Samples are pre-treated, coated and tested in test institutions appointed by the TC. Widely used yellow chromating applies for reference purposes and the chromatised samples are coated and examined in the same way. A reference lacquer aproved by the TC must be used to coat the samples. Tests and requirements are set out in Section If the pre-treatment supplier requires their product to be tested using a liquid lacquer coating, this must be specified accordingly Stage 3 On the successful completion of stage 2, a pilot test will be carried out at a coating plant (the coater must be a member of GSB International). Stage 3 must be executed at a production plant where a minimum material surface of 500 m² must be pretreated. 25 m² taken from the middle and end of the pre-treated lot must be coated and subsequently tested for natural weathering. Objects and coating plants are selected with the prior approval of the TC. All coating trial runs must be documented and cover the following information: Products used Processing parameters: Concentrations ph values Temperatures of process baths 31

33 Section 8 Requirements applicable to Pre-treatment Duration of exposure times Application process Throughput and chemical usage, Assessment of the Mass Loss per unit area and analytical control procedures, All deviations from conventional standards must be recorded. All documentation is checked and countersigned by an examiner who must be appointed by the TC. Samples From the completed production process, the following samples must be submitted to the TC: 12 m Extrusions = 12 Pieces cut in length at 1 m or corresponding formats, 2 x 1 m² Sheets or corresponding formats Tests The test procedures are stipulated in section Practicable regulations must be submitted in respect of the assessment of the Mass Loss per unit area. On the successful completion of the accelerated weathering tests and the assessment of the TC, a provisional pre-treatment licence can be issued Stage 4 Sample material of the production of stage 3 must be exposed to industrial, maritime climatic conditions (preferably Hoek van Holland) as per section for a period of 3 years. On the positive completion of the natural weathering, a full pre-treatment system licence can be awarded. 32

34 / Section 8 Requirements applicable to Pre-treatment Tests and requirements for alternative Pre-treatment chemicals / Passivation (for Master- and Premium-Coatings in preparation) Tests Section 9 New Licences and Extension/Control Test / Standard Coating Determination of the mass loss per unit area 9.24 Process and measurements in accordance with the manufacturer s instructions Film Thickness 9.4 In accordance with coating material used Gloss 9.21 In accordance with coating material used Cross Cut 9.6 GT 0 Mandrel Bending Cracking mm not permitted- Erichsen Cupping Cracking Impact test (for powders only) Cracking mm not permitted inch pound not permitted Curing test of Liquid Lacquers o.k. Milling and Drilling (naked eye examination) Condensation atmosphere with constant humidity: Duration of test Blistering Infiltration at the cross cut Changes to colour and Metallic effect Alternating Condensation (0,2l SOB2B) Cycles Blistering Infiltration at the cross cutt Changes to colour and Metallic effect Boiling Water PT Pressure Cooker Test * Degree of blistering Cross Cut with Adhesive Tape Removal Resistance to Acetic Salt Spray (AASS) Duration of test Infiltration at the cross cut Degree of Blistering Filiform Corrosion Duration of test Fibril length IBmaxB Fibril Frequency H FFK-coefficient F = H x I FFK-coefficient F = H x I Hoek van Holland Weathering Duration of test Infiltration Fibril length IBmaxB FFK-coefficient F = H x I * not recommended 9.11 no flaking Sea Proof: 6.1 Sea Proof Plus h 0 (S0) d max 1 mm max. level (S0) d max 1 mm max. level 3 0 (S0) GT0 /Gt h d max 1 mm 0 (S0) 1000h 2 mm 1 per 10 mm 0,4 0,15 no extensive infiltration 36 Months d max 1 mm 2 mm 0,4 no extensive infiltration 33

35 Section 8 Requirements applicable to Pre-treatment 8.3 Electro Chemical Pre-treatment (pre-anodising) General Oxide coatings produced for decorative purposes in accordance with the Qualanod Regulations do not always meet the specific criteria required (high elasticity and low hardness). Therefore, it is recommended that the following process is applied to produce an oxide film (see section 8.3.2) using a direct current sulphuric acid process to a film thickness of 3-8 µm. If a GSB Approved Coater is proven to have achieved satisfactory pre-treatment results using a modified process, then its application will be allowed to continue provided the relevant additional tests within the parameters of control testing will be completed successfully Pre-anodising Process For anodising, objects are immersed in a moving electrolyte. To ensure a constant and even quality of the oxide layer, an appropriate cooling system and sufficient circulation (such as air) must be established. The rectifier must be sufficiently powerful to achieve the required levels of current densitiy. Prior to anodising, all surfaces must be clean and free from contamination of any kind, such as metal dust and tinsels, remaining grease or oil carbon and contamination from oils, fatty substances of any kind and sweat as a result of handling or corrosive products. All objects must therefore be cleaned and etched prior to anodising. After anodising, objects must be rinsed, dried in the unsealed stage and coated in accordance with the quality regulations. Depending on the surface condition, anodising requires a specific process to treat the relevant objects in stages as follows: 1. Degreasing 2. Rinsing with water at a temperature of T 20 C und 80 C 3. Etching 4. Rinsing with water at a temperature of T 20 C und 80 C 5. De-oxidising / Desmutting 6. Rinsing with water at a temperature of T 20 C und 80 C 7. Anodising using a direct current sulphuric acid process Parameters: Electrolyte Concentration: g/l H2S04 Aluminium Content: < 15 g/l Chloride Content: < 0,1 g/l Temperature: C (recorded continuously) Level of Current Density: 0,8 2,0 A/dm2 Film Thickness: 3 8 µm 8. Rinsing with water at a temperature of T 20 C und 80 C 9. Rinsing with water at a temperature of T 20 C und 80 C Rinsing with fully deionised water must be carried out to ensure that the last remaining rinsing water dripping from the object at 20 C shows a conductivity of less than κ 20 C < 30,0 µs/cm. 10. Drying below 100 C of peak metal temperature. 11. It is the responsibility of the coater to ensure the compatibility of this pre-treatment process variation with the relevant coating material through boiling water/pressure cooker testing and subsequent cross cut and adhesive tape removal tests and to document the results in an appropriate manner within the parameters of the internal control test procedures. 34

36 Section 8 Requirements applicable to Pre-treatment 12. Examination of the pre-anodisation s film thickness a) undamaged by eddy current processing in accordance with DIN EN ISO b) the final result is decided on by the reference check of a metallographic cross section in accordance with ISO 1463 (03.03) Test and requirements for the Pre-anodising process Tests: Section 9 New Licenses and Licence Extensions (Standard Coating) Final rinse prior to coating κ 20 C < 30,0 µs/cm Anodising film thickness µm Finishing treatment Coated Product: Total film thickness 9.4 Depending on coating material used Gloss 9.21 Depending on coating material used Cross Cut 9.6 Gt 0 Mandrel bending Cracking mm not permitted Erichsen Cupping Cracking Falling Weight (only powders) Cracking mm not permitted inch pound not permitted Curing test for liquid lacquers o.k. Milling and drilling 9.11 no flaking (naked eye examination) Constant Condensation: Duration of Test Blsitering Infiltration at the cross cut Changes to colour and finish in Metallics Alternating Condensation (0,2l SOB 2B ) Cycles Blistering Infiltration at the cross cut Changes to colour and finish in Metallics Boiling Water PT/ Pressure Cooker Test Degree of Blistering Cross Cut with Adhesive Tape Removal* Filiform Corrosion Duration of test Fibril Length IB maxb Fibril Frequency H FFK-coefficient F = H x I * under observation Sea Proof Plus: h 0 (S0) d max 1 mm max. level (S0) d max 1 mm max. level 3 0 (S0) Gt0/Gt1 1000h 2 mm 1 Fibril/10 mm 0,15 no extensive infiltration 35

37 Section 9 Test Procedures 9 Test Procedures 9.1 General The relevant requirements are set out in the tables 7.6.1, 7.6.2, and The instructions of the manufacturers have to be followed for installation and calibration the units. 9.2 Samples for Material Licences and Licence Extension The following aluminium alloys are preferred: Metal Sheets EN AW-5005 H 12 [AlMg1(B)] mill finish The samples size depends on the relevant test instructions (preferred 70x140x0,7-0,8 mm). Extrusions EN AW-6060 T 66 [AlMgSi]/EN AW-6063 T 6 or T 66 [AlMg0,7Si] 9.3 Random Samples to be taken at the coating plant The number of random samples to be taken during testing depends on the number of parts of the lot as set out in the table below: Number of parts of Number of samples taken at Permissible number of failed the lot > 800 random all samples A lot consists of an entire order or a part order (charge) that is with the coater at the time of testing. 9.4 Film Thickness The film thickness is determined in accordance with DIN EN ISO Effects on the measuring device that may be caused by the composition of the substrate must be taken into account Assessment at the Coating Plant Each sample should be tested in a minimum of 5 places across the designated surface (1 cm²). O individual reading O O O O 36

38 Section 9 Test Procedures If one of the individual readings shows less than 80% of the required film thickness, the sample must be rejected as failed and recorded in column 3 of table 9.3. The average reading taken at the 5 measuring points must correspond to the required film thickness as a minimum. If the average reading is below the required film thickness, but above the 80% limit, the relevant sample must be rejected as failed and recorded in column 3 of table 9.3. The test result is deemed to be negative if the average reading taken from a sample is below 80% of the required film thickness. The assessment should be carried out in line with the following examples: Example 1: Example 2: Example 3 Example 4: Measurement in µm: Assessment Measurement in µm: Assessment Measurement in µm: Assessment Measurement in µm: Assessment This sample is entirely satisfactory This sample is satisfactory because the average film thickness is above 50 µm and none of the measurement taken falls below 40 µm (80% of 50 µm) This sample is unsatisfactory and is therefore deemed as failed in line with section 9.2 in the table This sample is unsatisfactory despite the fact that the average film thickness is above 50 µm, as the measurement of 38 µm falls below the tolerance limit of 80% (40 µm). The sample is therefore deemed as failed. The above does not apply for parts, which need to meet specific requirements on account of their geometric properties.specific requirements as specified by the client may also be excluded, provided these can be substantiated by an appropriate written agreement. 9.5 Visual Surface Assessment of Finished Goods A visual assessment of the decorative appearance of the industrial manufactured surfaces in terms of the uniformity of colour, gloss and structure must be carried out without any measuring devices at a range of > 3 m for exterior parts and > 2 m for internal components. As a rule, all samples must be uniform in terms of gloss, colour and structure. For the accurate evaluation of the overall uniformity in the appearance of building facades, it is recommended to extend the visual assessment range. Any form of unevenness at the base of the surface such as scratches, drag marks and scars caused by corrosion or welding seams are to be discounted in the assessment of the quality of the coating. Alternative visual assessment ranges and criteria may be agreed between the relevant contract partners. 9.6 Cross Cut Test The Cross Cut Test is carried out in accordance with DIN EN ISO

39 Section 9 Test Procedures 9.7 Mandrel Bending Test The mandrel bending test is carried out in accordance with DIN EN ISO For coating materials of Master or Premium quality levels the assessment is concluded by an adhesive tape removal test as set out in section Erichsen Cupping Test The Erichsen Cupping test is carried out in accordance with DIN EN ISO 1520.For coating materials of Master or Premium quality levels the assessment is concluded by an adhesive tape removal test as set out in section Cross-linking tests Impact Test (powders) The impact test is carried out in accordance with ASTM D 2794 and applies to powder coating materials only.the test must be executed at 20 inch-pounds using a weight diameter of 15,9 mm, 70µm +/- 10µm of film thickness one hour after coating at a temperature of 20 C to 25 C. The result must be assessed by the naked eye. For coating materials of Master or Premium quality levels the assessment is concluded by an adhesive tape removal test as set out in section MEK-Test (for stoving and two-component liquid lacquers) A 5 cm square 4-layer paper fleece is placed on the surface to be tested, then soaked with 1ml MEK (Methyl Ethyl Ketone) and covered immediately with an watchglass. Processing time: 2 mins. All residual solvent must be wiped away immediately on the removal of the paper. Prior to hardness testing the sample must be aged artificially for 60 mins at 120 C. The subsequently measured Buchholz Hardness must be at least 80 (at a depression length of 1.25 mm). There must be no disturbances to the surface (such as wrinkling, loss of gloss, gloss reduction, flaking etc) Adhesive Tape Removal The adhesive tape is placed firmly onto the coated surface of the sample sheet after mechanical deformation in accordance with DIN EN ISO 2409, avoiding the formation of cavities or air pockets. After one minute the adhesive tape is removed swiftly at a right angle to the surface. The result must be assessed by the naked eye Milling and Drilling The coated building components must be able to withstand treatment with conventional tools and cutting equipment without showing any signs of flaking or splitting in the coating. These tests must be carried out on suitable samples (i.e. profiled parts) that have been pre-treated and coated appropriately. 38

40 Section 9 Test Procedures 9.12 Condensation Atmosphere with Constant Humidity The test must be carried out in accordance with DIN EN ISO Prior to exposure the samples must be cross cut (Andreas Cross) using a scratching stylus according to Sikkens (1mm). Assessment: Degree of Blistering in accordance with DIN EN ISO Infiltration at the cut in accordance with DIN EN ISO Humid Atmosphere containing Sulphur Dioxide The test is carried out in accordance with DIN EN ISO 3231 (0,2 l). Prior to exposure the samples must be cross cut (Andreas Cross) using a scratching stylus according to Sikkens (1mm). Assessment: Degree of Blistering in accordance with DIN EN ISO Infiltration at the cross cut in accordance with DIN EN ISO Acetic Acid Salt Spray The test is carried out in accordance with ISO 9227 (AASS). Prior to exposure the samples must be cross cut (Andreas Cross) using a scratching stylus according to Sikkens (1mm). Assessment: Degree of Blistering in accordance with DIN EN ISO Infiltration at the cross cut in accordance with DIN EN ISO Filiform Corrosion Test Procedure The filiform corrosion test is carried out in accordance with DIN EN Assessment The assessment is made by evaluating the relevant samples. If the fibrils are very fine or difficult to detect, the samples should be stripped prior to their evaluation. (the stripping solution must not interact or attack the aluminium substrate). The fibril length is determined by measuring the distance between the mechanical damage (drag/cut mark) and the head of the fibril below 90. Fibril curving is to be discounted in the measurement. Counting the fibrils along the cut mark assesses the fibril frequency. Fibril frequency (H) is evaluated to the left and right of the cut mark, whereby 5 mm at either end of the mark are to be discounted. All horizontal and vertical corrosion fibrils to the left and right of the cut mark must be examined, whereby only the cut mark that shows the most obvious damage should be assessed on each sample. At least two samples have to be tested. The average fibril length I (mm) and fibril frequency is taken and used to determine the coefficient F of the filiform corrosion. H = Z/L F = l * H l = mean fibril length (mm) Z= number of fibrils L= length of the drag/cut mark (mm) H= fibril frequency F= coefficient denoting the level of filiform corrosion 39

41 Section 9 Test Procedures 9.16 Boiling Water or Pressure Cooker Test If blistering occurs during either the boiling water or pressure cooker test, a further sample must be coated using commercially available chromatised aluminium sheeting and re-tested. If the blistering of the coating recurs, the test result is deemed to be negative Boiling Water with Cross Cut and Adhesive Tape Removal Test Two hours in boiling VE (Frage Mr. Osmond: What is VE ) deionised water followed by the immediate assessment of the surface. Subsequently the sample must be rested for one hour at room temperature prior to the execution of the cross cut or the cross cut with adhesive tape removal test Pressure Cooker, Steam Cooker Test with Cross Cut and Adhesive Tape Removal The sample must be dipped in such a way that a maximum length of 25 mm is immersed in the water. The sample must be tested in the steam cooker for one hour at an excess pressure of kpa. After cooling the sample is visually assessed. Once the sample has been rested at room temperature for one hour, the cross cut test with adhesive tape removal concludes the test Resistance to Moisture Application and Purpose This is to assess the suitability of coated aluminium building components for storage under the influence of condensation and temperature in closed/wrapped conditions. This process requires lower moisture levels than the constant condensation or boiling water tests at increased temperatures Procedures Five round filters Kat. Nr with a diameter of 55 mm of Whatman are placed on top of each other onto an appropriately coated sample and are then saturated with 1,5 ml + 0,1 ml of fully demineralized water. The damp paper inserts are pressed down gently and are then covered with a watchglass. The watchglass is taped to the sample using insulating tape (Scotch Super 33+ of 3M) to ensure that no moisture can escape. The such prepared sample is then stored for 4 hours + 5 mins in an drying cupboard at a sample temperature (peak metal temperature) of T Sample = C. After cooling for 15 minutes, the watchglass and filter paper inserts are removed from the sample. The sample is conditioned at room temperature (T= C) for a period t = h. Such tested surface is then examined according Assessment To assess any colour changes, the colour of both an exposed and unexposed reference sample must be measured at three spots, excluding gloss. The mean value is assessed. 40

42 Section 9 Test Procedures 9.18 Adhesion of Sealant An appropriately coated sample is cleaned with a paper napkin soaked in Isopropanol. Vertical and horizontal wiping must not cause any traces of lacquer to be detected on the napkin and the coated surface must not show any damage. After 5 minutes approx two 100 mm long tracks of the relevant sealant, which is pre-determined by the TC (currently DC 791 Dow Corning) are applied. Alternative sealants may be used, provided the GSB International has been pre-advised accordingly by the material manufacturer and the sealant is recorded in the technical data sheet. The sample is then stored at room temperature and 50% relative moisture for a period of 7 days to bond the sealant, after which the adhesion of the first sealant track is examined, whereby the track is removed by hand, a small cut with a knife to the sealant as starting point is possible. The sample is then stored in de-ionised water (conductivity < 10µS/cm²) for a period of 7 days, on completion of which the second track of sealant is examined. The applicability of the coating for structural glazing cannot be derived from this test Mortar Test Composition of the Mortar Mix 75 g of building lime and 225 g of dried sand, then sieve using a 10-mesh wire sieve and blend with the appropriate amount of water approx 100 g until the mass is soft and pliable. When preparing the mortar it should be taken into account that lime contains 95 % CaO and is therefore highly reactive with water. Prior to application onto the coated surface, the mortar should be left to cool. The approved suppliers of the mortar compounds are: Building Lime: HARZ-KALK, Weißfeinkalk WFK ½ FELS WERKE GmbH, Verkauf und Anwendungstechnik Kalkprodukte Geheimrat-Ebert-Straße Goslar Sand: River Sand (available from all suppliers of building materials) Procedure The damp mortar clumps measuring approx 5 cm, are then applied to the surface that must have been coated at least 24 hours previously. The samples are then exposed instantly for a period of 24 hours to a relative air humidity of % at a temperature of T = 40 C. After the removal of the mortar, any lime residue may be removed using an acid dip in accordance with AAMA : A round filter of Whatman, Kat. Nr , 55 mm is placed on the coated surface, which is saturated with 1,5 ml of 10 % hydrochloric acid. After 15 mins of processing the sample is thoroughly cleaned using deminaralized water and then dried. After 24 h in the test chamber, the mortar must be easily removable without any residue. Any mechanical damage to the coating caused by grains of sand is to be discounted Assessment Aseessment of changes of metallic effect according to If special effect lacquers are used that record an effect change (9.26) of > 3 following the mortar test, these must be accepted by the client by prior written agreement, whereby an original sample must be used for tabling and evaluation purposes. 41

43 Section 9 Test Procedures 9.20 Colour Measurement Three separate colour measurements are taken at different points at a minimum distance of 50 mm from each other on both the exposed and unexposed reference sample. The mean average is then taken from the colour measurements. The pre-conditions for metric colour measuring are as follows: A spectrometer or tribasic measuring device should be used in accordance with DIN 5033 part 4 and part 6; The graduation applicable is 45/0 or alternatively 8/d or d/8 under exclusion of gloss values (DIN 5033 part 7), The colour metric assessment must be carried out for the standard illuminant D65 and the 10-degree standard observer in accordance with DIN 5033 part 2 and part 7; The co-ordinates are calculated according to the CIELAB-colour graduation formula in accordance with ISO (DIN 6174) for both the exposed and the reference sample and the difference L* and C* ab must be documented accordingly. The differences are rounded up to the first decimal place and must not exceed the limits as set out in section (basic measuring geometry 45/0). In case the thresholds as per section are exceeded, the TC will visually assess the samples. If there is no matching RAL colour, the limits for the most similar RAL-colour should be used as a reference. The assignment may be done visually or using the colour metric method. On application, the final decision and examination can be made by the Bundesanstalt fuer Materialforschung und prüfung (Federal Institute of Material Research) (BAM) in Berlin using a spectrophotometer with a measuring geometry of 45/0. 42

44 Section 9 Test Procedures Assessment of Colour Graduation in accordance with ISO (DIN 6174) Exposed/unexposed reference samples: colour according to RAL-Registration 841 GL Basic measuring geometry 45/0 RAL L* C*ab RAL L* C*ab RAL L* C*ab RAL L* C*ab 1000 ± 1 ± ± 2 ± ± 6 ± ± 2 ± ± 1 ± ± 4 ± ± 3 ± * ± 3 ± ± 1 ± ± 4 ± ± 3 ± * ± 3 ± ± 2 ± ± 4 ± ± 3 ± ± 2 ± ± 4 ± ± 3 ± ± 2 ± ± 2 ± ± 2 ± ± 3 ± ± 2 ± ± 2 ± ± 2 ± ± 3 ± ± 2 ± ± 2 ± ± 2 ± ± 3 ± ± 2 ± ± 1 ± ± 3 ± ± 4 ± ± 2 ± ± 1 ± ± 3 ± ± 3 ± ± 2 ± ± 1 ± ± 2 ± ± 3 ± ± 2 ± ± 1 ± ± 2 ± * ± 2 ± ± 3 ± ± 1 ± ± 2 ± * ± 2 ± ± 2 ± ± 2 ± ± 2 ± ± 2 ± ± 1 ± ± 2 ± ± 3 ± ± 2 ± ± 2 ± ± 2 ± ± 3 ± ± 2 ± ± 1 ± ± 2 ± ± 3 ± ± 2 ± ± 1 ± * ± 2 ± ± 3 ± ± 2 ± ± 2 ± * ± 2 ± ± 4 ± ± 3 ± ± 2 ± ± 4 ± ± 5 ± ± 1 ± ± 3 ± ± 4 ± ± 3 ± ± 1 ± ± 3 ± ± 4 ± ± 2 ± ± 2 ± ± 2 ± ± 4 ± ± 3 ± ± 2 ± ± 4 ± ± 4 ± ± 3 ± ± 2 ± ± 3 ± ± 3 ± ± 1 ± ± 2 ± ± 3 ± ± 2 ± ± 2 ± * ± 2 ± ± 4 ± ± 4 ± ± 1 ± * ± 2 ± ± 3 ± ± 2 ± ± 2 ± ± 2 ± ± 3 ± ± 4 ± ± 2 ± ± 3 ± ± 4 ± ± 1 ± ± 2 ± * ± 2 ± ± 3 ± ± 2 ± ± 2 ± * ± 2 ± ± 3 ± ± 2 ± ± 2 ± ± 2 ± ± 1 ± ± 2 ± ± 3 ± ± 2 ± ± 2 ± ± 2 ± ± 3 ± ± 3 ± ± 1 ± ± 2 ± ± 3 ± ± 2 ± ± 1 ± ± 2 ± ± 3 ± ± 4 ± ± 3 ± ± 2 ± ± 6 ± ± 3 ± ± 1 ± ± 2 ± ± 3 ± ± 3 ± ± 1 ± ± 2 ± ± 3 ± ± 3 ± ± 1 ± * ± 2 ± ± 3 ± ± 2 ± ± 1 ± ± 3 ± ± 4 ± * ± 3 ± ± 2 ± ± 4 ± ± 3 ± ± 2 ± ± 6 ± ± 3 ± ± 2 ± ± 2 ± ± 3 ± ± 2 ± ± 2 ± 2 43

45 Section 9 Test Procedures RAL L* C*ab RAL L* C*ab RAL L* C*ab RAL L* C*ab 8002 ± 3 ± ± 3 ± ± 4 ± ± 3 ± ± 4 ± ± 4 ± ± 3 ± ± 2 ± * ± 1 ± ± 3 ± ± 2 ± * ± 2 ± ± 3 ± ± 2 ± ± 1 ± ± 3 ± ± 4 ± ± 4 ± ± 3 ± * ± 2 ± ± 1 ± ± 3 ± ± 4 ± ± 3 ± ± 1 ± ± 1 ± ± 3 ± ± 1 ± * ± 1 ± ± 3 ± ± 1 ± * ± 2 ± 1 NB: colour shades marked with an asterisk are not part of the RAL 841 GL Register. Colour samples of these shades can be obtained in the RAL: 840 HR Main Register, which should, however, not be used as samples for decorative coatings. 44

46 Section 9 Test Procedures 9.21 Gloss Measurement (Reflectometer values) Measuring with a reflectometer must be carried out in accordance with. DIN EN ISO 2813 (DIN ) at a radiation angle of 60 for all tests. Reflectometer values must be documented in units (E). Exception: Matt lacquer surfaces with a reference value of 40 E (measured at 60 ) may on agreement be measured at a 85 geometry Weathering Accelerated Weathering QUV-B (313 nm) This test is carried out in accordance with DIN EN ISO 11507, using accelerated weathering equipment QUV/SE with solar eye adjustment. Emitter: UVB-313 nm Cycle: 4 h Dewing, T = 40 C +/- 2 4 h Radiation, T = 50 C +/- 2 C Emission: 0,75 W/m²/nm Natural Weathering in Florida The gloss and colour thresholds stipulated in the QR valid at the start of the natural weathering will used for assessment. Dimension of Samples: 100 x 300 x 0,7-0,8 (mm) Standard Coating Systems For a period of approx. 12 months from April on, the samples must be exposed to natural weather conditions in Florida at an inclination of 5 in a Southerly direction until 300 MJ/m² TUVR (Total UV Radiation) is reached. Prior to measuring reflectometer values, the samples should be cleaned applying gentle pressure, using a soft sponge with a 1% aqueous solution of a wetting agent and then rinsed with de-mineralized water. As far as possible, the surface should be uniform and free from contamination. Master Coating Systems For a period of approx. 36 months from April on, the samples must be exposed to natural weather conditions in Florida at an inclination of 45 in a Southerly direction until 840 MJ/m² TUVR is reached. Two samples are exposed for each colour per production year. The average values obtained from both samples are used to assess a positive / negative test result. Every 6 months, the samples should be cleaned applying gentle pressure using a soft sponge with a 1% aqueous solution of a wetting agent and then rinsed with de-mineralized water. As far as possible, the surface should be uniform and free from contamination. Premium Coating Systems For a period of approx. 60 months from April on, the samples must be exposed to natural weather conditions in Florida at an inclination of 45 in a Southerly direction until MJ/m² TUVR is reached. Every 6 months, the samples should be cleaned applying gentle pressure using a soft sponge with a 1% aqueous solution of a wetting agent and then rinsed with de-mineralized water. As far as possible, the surface should be uniform and free from contamination. 45

47 Section 9 Test Procedures Natural Weathering in Hoek van Holland Size of Samples: Sheets: approx.10 x 20 cm Extrusions: length approx cm depending on the type of extrusions used in the field trial Samples are exposed and assessed once annually in April/May. The total period of exposure is 10 years. Samples are positioned at an inclination of 45 degrees in a Southerly direction. Interim assessments are carried out annually, whereby the samples should be cleaned with water prior to their assessment for infiltration, fibril length and frequency. After 3, 5 and 10 years an interim report has to be done for the pretreatment manufacturer and GSB International 9.23 Measuring Conductivity Measurements are taken of the conductivity of the water, which drips from the pre-treated objects that have undergone the final rinse with de-ionised water. Additional measurements are taken at the spray valves and in the storage vessel used for the final rinse. The dripping water is gathered in a suitable vessel (glass beaker), which must be clean. The device used to measure the conductivity must be tested with a suitable calibrating solution and adjusted to the relevant range. For devices that work without temperature compensation, the water temperature must be controlled and the device adjusted accordingly 9.24 Test Procedures to Assess Etching Rate Samples (section 9.2) of a minimum length of 10 cm, must only be used once. Preparation of Samples Surfaces must be cleaned with Acetone or Isopropanol. Weighting of samples with the analytical balance (accuracy +/- 0,1 mg) Treatment of Samples Samples must be handled in manufacturing conditions. Depending on the pre-treatment plant, samples should be taken as follows from the production process: a) Pre-treatment dip sample to be taken prior to chromate treatment / alternative passivation or sample to be taken prior to the drying of adhering water, removal of chromate film by stripping the conversion layer (nitric acid 65%, density 1.4gr/cm 3, for 5 10 minutes at a temperature of 25 C). b) Spray Installation sample to be taken prior to the drying of adhering water, removal of chromate film by stripping the conversion layer (nitric acid 65%, density 1.4 gr/cm 3, for 5 10 minutes at a temperature of 25 C). Assessment of the Etching Rate Samples to be dried at 80 C Weighting of samples with the analytical balance (accuracy +/- 0,1 mg) Calculation of the etching rate (loss of weight / sample surface) 46

48 Section 9 Test Procedures 9.25 Test Procedures for the Assessment of the Mass Loss per Unit Area The thickness of the chemical pre-treatment layer (chromate treatment or alternative passivation) is evaluated in accordance with the manufacturer s instructions. If there are no documented procedures, the following applies, whereby it is a pre-condition that the relevant chemical pre-treatment may be removed with 65% nitric acid at a temperature of 25 C. This procedure can only be used for freshly generated pre-treatment films. Samples (section 9.2) of a minimum length of 10 cm must only be used once. Treatment of Samples Samples must be pre-treated in manufacturing conditions. Samples to be taken after chromate treatment / alternative passivation once drying from adhering water has taken place. Samples should be left to cool at C. Weighting of samples with the analytical balance (accuracy +/- 0,1 mg). Removal of chromate film or alternative passivation by stripping of the chemical pre-treatment layer with nitric acid 65%, density 1.4 gr/cm 3 for 5-10 minutes at a temperature of 25 C. Calculating the Weight of the Chemical Pre-treatment Film Samples to be dried at 80 C Samples to be left to cool at C. Weighting of samles with the analytical balance (accuracy +/- 0,1 mg). Calculation of the etching rate (loss of weight / sample surface) in mg/m² Assessment of changes to the metallic effect: Any changes to the finish must be evaluated in accordance with DIN EN ISO 4628 part 1 within the undermentioned parameters: Grade 1 No difference between the exposed sample and unexposed surface Grade 2 Grade 3 Grade 4 Barely visible changes to colour and finish Visible changes to colour and finish Clearly visible changes to colour and finish Grade 5 Distinct changes to colour and complete loss of finish The samples are evaluated in accordance with a reference table, available at the GSB Headoffice. 47

49 Section 10 Standards 10 Standards Test method/ Evaluation Bend test DIN EN ISO 1519 ISO 1519 Cupping test DIN EN ISO 1520 ISO 1520 Measurement of coating thickness Standard Edition Title DIN EN ISO 2360 ISO 2360 Cross-cut test DIN EN ISO 2409 ISO Bend test (cylindrical mandrel) Cupping test Non-conductive coatings on non-magnetic electrically conductive basis materials - Measurement of coating thickness - Amplitudesensitive eddy current method Cross-cut test Impact test ASTM D Standard Test Method for Resistance of Organic Coatings to the Effects of Rapid Deformation (Impact) Natural weathering DIN EN ISO 2810 ISO 2810 Gloss measurement DIN EN ISO 2813 Buchholz indentation test Humid atmospheres containing sulfur dioxide Filiform corrosion resistance ISO 2813 DIN EN ISO 2815 ISO 2815 DIN EN ISO 3231 ISO 3231 Degree of blistering DIN EN ISO Degree of delamination and corrosion around a scribe Natural weathering of coatings - Exposure and assessment Determination of specular gloss of non-metallic paint films at 20, 60 and 85 Buchholz indentation test Determination of resistance to humid atmospheres containing sulfur dioxide DIN EN Test methods for paints and varnishes - Filiform corrosion resistance test on aluminium alloys ISO DIN EN ISO ISO Evaluation of degradation of coatings; Designation of quantity and size of defects, and of intensity of uniform changes in appearance - Part 2: Assessment of degree of blistering Evaluation of degradation of coatings - Designation of quantity and size of defects, and of intensity of uniform changes in appearance - Part 8: Assessment of degree of delamination and corrosion around a scribe Colour measurement DIN Colorimetry; standard colorimetric systems Colour measurement DIN Colorimetry; tristimulus method 48

50 Section 10 Standards Colour measurement DIN Colorimetry; measuring conditions for object colours Colour measurement DIN Colorimetric evaluation of colour coordinates and colour differences according to the approximately uniform CIELAB colour space Acceptable Colour Tolerances Condensation-water atmospheres Calculation of Colour differences VdL-RL Guidelines of Acceptable Tolerances for unicoloured powder lacquers for architectural purposes DIN EN ISO (CH) Salt spray test DIN EN ISO 9227 ISO 9227 UV-Test DIN EN ISO Determination of resistance to humidity - Part 2: Procedure for exposing test specimens in condensation-water atmospheres ISO ISO Colorimetry; Part 3 : Calculation of colour differences Corrosion tests in artificial atmospheres - Salt spray tests Exposure of coatings to artificial weathering - Exposure to fluorescent UV lamps and water Chromate conversion coatings ISO DIN EN Corrosion protection of metals - Rinsed and nonrinsed chromate conversion coatings on aluminium and aluminium alloys 49

51 Section 11 In House Control Requirements for Coaters 11 In House Control Requirements for Coaters 11.1 Incoming Material Check Coating Materials Test Consignment corresponds to delivery note Control Guidelines GSB Approved / Master Coater Minimum test frequency Documentation Every delivery Yes, on delivery note GSB Premium Coater Minimum test frequency Every delivery Documentation Yes, on delivery note Aluminium Substrate Consignment corresponds to delivery note Every delivery Yes, on delivery note Every delivery Yes, on delivery note Chemicals Consignment corresponds to delivery note Every delivery Yes, on delivery note Every delivery Yes, on delivery note 50

52 Section 11 In House Control Requirements for Coaters 11.2 Processing Controls Pre-treatment baths Pre-treatment bath or spray with automated dosage Pre-treatment bath or spray with manual dosage Test Test Guidelines Minium test frequency Analysis of bath (Temperature, composition) Analysis of bath (Temperature, composition) Passivation film baths containing Chromium Pre-treatment bath or spray with automated dosage Pre-treatment bath or spray with manual dosage Analysis of bath (Temperature, composition) Analysis of bath (Temperature, composition) According to manufacturer s instructions According to manufacturer s instructions According to manufacturer s instructions According to manufacturer s instructions GSB Approved / Master Coater Documentation GSB Premium Coater Minimum test frequency Once daily Yes Once daily Yes Twice daily Yes Twice daily Yes Once daily Yes Once daily Yes Twice daily Yes Twice daily Yes Passivation film Weight of film Section 9.24 Once weekly Yes Once daily Yes Passivation film baths as an alternative pre - treatment Pre-treatment bath or spray with automated dosage Analysis of bath (Temperature, composition) According to manufacturer s instructions Passivation film Weight of Film According to manufacturer s instructions Twice daily Yes Twice daily Yes According to manufacturer s instructions, at least once weekly Yes According to manufacturer s instructions, at least once daily Documentation Yes 51

53 Section 11 In House Control Requirements for Coaters Final Rinse Test Test Guidelines Minium test frequency GSB Approved / Master Coater Documentation GSB Premium Coater Minimum test frequency Dripping water Conductivity Section 9.23 Once daily Yes Twice daily Yes Drying of adhering water Peak Metal Temperature Curing Oven Peak Metal Temperature Measure temperature with tape or other measuring device Measure temperature with 3-pronged measuring device Section Once weekly Yes, with measuring tape Section Retention time and peak metal temperatures according to manufacturer s instructions Once weekly Yes, recording of temperature Three times weekly Three times weekly Documentation Yes, with measuring tape Yes, recording of temperature 52

54 Section 11 In House Control Requirements for Coaters 11.3 Finished Goods / Specimen Testing (see section 6.6.2) Test Test Guidelines GSB Approved / Master Coater Minimum test frequency Documentation Film Thickness Film Thickness Section 9.4 Twice hourly Yes, lowest and highest values Gloss Gloss measurements Section times daily or at each colour change > 100 m² Colour Visual comparison to existing specimen (if agreed)) Section 9.5 / 9.20 At each colour change > 100 m² Adhesion Cross Cut Section 9.6 Twice per shift on finished goods Mechanical Handling Cutting, milling and drilling Section 9.11 Twice per shift on finished goods Yes, lowest and highest values yes yes yes GSB Premium Coater Minimum test frequency Twice hourly 4 times daily or at each colour change > 100 m² At each colour change > 100 m² Twice per shift on finished goods Twice per shift on finished goods Quality of Pre-treatment Boiling test Section 9.16 Twice per shift yes Twice per shift yes Quality of Pre-treatment Once a half year yes Sea Proof Sea Proof Plus Formability Degree of Curing (Powder Coating) Degree of Curing (Liquid Lacquer) Acid Salt Spray FFK-Test Erichsen Cupping, Mandrel Bending Section 9.14 Once a year Section 9.15 One semi-yearly Section 9.8/9.7 Twice per shift yes Twice per shift yes Falling Weight Section Twice per shift yes Twice per shift yes Buchholz Hardness Section Twice per shift yes Twice per shift yes Documentation Yes lowest and highest values Yes, lowest and highest values yes yes yes 53

55 Section 12 Enclosures 12 Enclosures 12.1 Committment VERPFLICHTUNGSERKLÄRUNG COMITTMENT Hiermit verpflichten wir uns, bei Benutzung des Gütesiegels Approved Coated Aluminium das uns unter der Firmen-Nummer... verliehen wurde, ausschließlich Beschichtungsmaterial zu verarbeiten, dessen Hersteller über die Materialzulassung zur Verwendung im Rahmen der GSB International verfügen. The undersigned company has been awarded by GSB International the Quality Label APPROVED COATED ALUMINIUM No.... When using the label, we herewith commit ourselves to process exclusively coating material tested, approved and licensed by GSB International for this particular use. Die Liste derjenigen Beschichtungmaterial-Hersteller bzw. -Systeme, die von der GSB International zugelassen sind, liegt uns vor. We confirm that a complete listing of coating material manufacturers and their GSB International licensed products is at our disposal.. Ort und Datum Place and Date... Firmenstempel, Unterschrift Company stamp, Signature 54

56 Section 12 Enclosures 12.2 Certificates Specimen Certificate Master Coater 55

57 Section 12 Enclosures Specimen of Material Licence Master System 56