SPECIFICATION SHEET FOR POWDER, PRETREATMENT & POWDER COATING

Scope: Specification & process check for Powder, Pretreatment & powder coating of mild steel
& sheet metal parts.
1. POWDER DETAILS

1.1 Powder Type:

• Epoxy Polyester –Internal parts of Local & Export Pumps.
• Pure Polyester – External parts of Local Pumps.

1.2 Shade: Ref.Component Drg.

1.3 Gloss: as per IS: 13871-1993.

1.4 Finish: Refer Component Drawing.

1.5 Powder storage: As recommended by Powder Manufacturer/ at 30º C

1.6 Powder shelf life: As recommended by Powder Manufacturer /Six months.

2 PRETREATMENT PROCESS

2.1 The mild steel /sheet metal components are to be pretreated by Hot zinc phosphate
process, using chemicals of reputed manufactured.

Ensure that the Components are free from Heavy Rust & Pit Marks.

Follow the instructions of chemical manufacturer to maintain Parameters pertaining

to Temperature, Concentration, Pointage, dipping time & for testing, control, and
replenishment of pretreatment baths.

2.1.1 Degreasing:
• Bath Composition: As recommended by chemical manufacturer.
• Operating temp: 70º C to 80º C
• Testing Methods: As recommended by chemical manufacturer.

• Tests:
 Pointage: As recommended by chemical manufacturer.
Testing Frequency- Daily
Note - Maintain Records in Annexure A.

 Oil contain: As recommended by chemical manufacturer.

Testing Frequency- Once in a Month
Note - Maintain Records in Annexure B.

• Replenishment: As per the recommendation of chemical manufacturer.

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2.1.2 Derusting (Pure Phosphoric acid based) :
• Bath Composition: As recommended by chemical manufacturer.
• Operating temp: Ambient
• Testing Methods: As recommended by chemical manufacturer.

• Tests:
 Pointage: as per the recommendation of chemical manufacturer.
Testing Frequency- Daily.
Note - Maintain Records in Annexure A.

 Irons contain: As per the recommendation of chemical manufacturer.

Testing Frequency- Once in a Month
Note - Maintain Records in Annexure B.

• Replenishment: As recommended by chemical manufacturer.

2.1.3 Zinc phosphate:

• Bath Composition: As recommended by chemical manufacturer.
• Operating temp: 70ºC to 75ºC
• Testing Methods: As recommended by chemical manufacturer.

• Tests:
 Total Acid: As recommended by chemical manufacturer.
Testing Frequency- Once in a shift
Note - Maintain Records in Annexure A.

 Free Acid: As recommended by chemical manufacturer.

Testing Frequency- Once in a shift
Note - Maintain Records in Annexure A.

 Accelerator: As recommended by chemical manufacturer.

Testing Frequency- Once in a shift
Note - Maintain Records in Annexure A.

• Replenishment & Compensating of Chemical: As recommended by chemical

manufacturer.

2.1.4 Passivation:
• Bath Composition: As recommended by chemical manufacturer.
• Operating temp: 65ºC to 75ºC
• Testing Methods: As recommended by chemical manufacturer.

• Tests:
 Checking of p H – p H value as recommended by chemical manufacturer.

• Testing Frequency: Per shift.

• Replenishment: As recommended by chemical manufacturer.
Note - Maintain Records in Annexure A
Note: Passivation bath should discard in a week.

2.1.5 Hot air drying: Temp. 60 to 80ºC.

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2.1.6 Flow chart for process of pretreatment

INPUT ACTIVITY OUTPUT

Loading at Degreasing at Maintain record in

Ambient 700 to 800 C Annexure A & B

Water Rinsing Maintain record in

Degreasing Annexure A
at Ambient

Derusting at Maintain record in

Water Rinse Annexure A & B
Ambient

Water Rinsing Maintain record in

Derusting Annexure A
At Ambient

Phosphating
Maintain record in
700 to 750 C Annexure A & B
Water Rinse

Maintain record in
Water Rinsing Annexure A
Phosphating
At Ambient

Maintain record in
Water Rinse Passivation Annexure A
At 600 to 700 C

Maintain record in
Hot air drying Annexure A
Passivation
At 650 to 750 C

Unloading

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2.1.7 CHECK POINTS FOR PRETREATMENT PROCESS

2.1.7. • Phosphate Coating weight to be achieved between 2.3 g/m² to 4.3 g/m²as
1 per IS: 3618-1966 (Reaffirmed 2002) Clause No.6.3
• Testing Frequency: Once in a week.

Note - Maintain Records in Annexure B

2.1.7. • 3% NACL Test –{Immersed sample panel for 12 hrs in 3% NACL

2 (LR Grade) solution} as per IS:3618-1966 (Reaffirmed 2002)Clause No.6.2

• Testing Frequency- Once in a week

Note - Maintain Records in Annexure B.

2.1.7. • Visual Inspection – Zink Phosphated components should be free of Rust,

3 Patchy Phosphate, yellow stain & other surface defects.

3 POWDER COATING

3.1 • Powder Type: Refer clause 1.1

3.2 • Ensure that Powder coating Process should start within 8 Hrs from
completion of Phosphating process.

3.3 • Powder Coating Thickness (Dry Film Thickness)

 For External Components
DFT- min 80 micron on outer surface
DFT- min 50 micron on inner surface

 For Internal Components.

DFT -All over min 50 micron

3.4 • Provide Masking on Threaded portion.

3.5 • Oven to be calibrated for TTR(To be Calibrated every Six Month)

3.6 • Stoving Time & Temp. : Typical stoving schedule is 10-15 min. at 180º C
However follow the instruction given by Powder Manufacturer.

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4 Testing of Powder Coating Components(Ref. IS 101 & IS 13871)

4.1 • Visual Inspection

4.1.1 • Finish: Powder coated surface should not show any scratch, crack marks, lumps
deposits, dust, pin holes, cissing.

4.1.2 • Gloss & shade: Gloss as recommended by Powder manufacturer (as per IS:
13871:1993.) and shade should be as per respective drawing requirement.

4.1.3 • Threaded portion should be free from powder deposits

4.2 • Test Panel Details-Powder Coated Panels Size 50 x 100 x0.6/0.8 mm are to be used
for test.

4.3 Mechanical Tests

4.3.1 • DFT (Dry Film thickness): Ref 3.3 for coating Thickness
{Refer IS 101 (Part 3 / sec 2.):1989}

4.3.2 • Hardness test

4.3.2.1 Cross Hatch test-Coating should not peel off (GT= 0) {Refer IS 101 part 5 / sec 2.)
:1988}

4.3.2.2 • Scratch hardness test – Should pass 3 Kg Load, {Refer IS 101 (Part 5 Sec.1) :
1988}

4.3.3 Flexibility and Adhesion0

4.3.3.1 • Mandrel bending test: ≤ 6. 25 mm as per IS 101 (Part 5 sec 2):1988

4.3.3.2 • Erichsen cupping test: As per IS 101 (Part 5 / sec2 clause No.4):1988

4.3.3.3 • Impact test: ( Ref. IS 13871 :1993)

Grade –A (Glossy Grade-B (Semi- Grade –C (Matt
Finish) Glossy Finish) Finish)
Impact
Resistance 250 150 150
kg/cm

4.4 Durability Test

• Resistance to humidity under condition of condensation: The painted sample shall

4.4.1 be subject to exposure under condition of condensation for seven days as per IS
101 (part 6/ Sec-1 Clause no.-2):1988. It shall not show rusting marks no blisters
or loss of adhesion

4.4.2 • Salt spray test: The painted sample when subject to this test for 1000 Hours as per
IS 101 part 6/ Sec-1 Clause no.-3:1988. It shall show no rust Formation

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4.5 Environmental tests

Liquid Method Duration Results

4.5.1 MEK Put one drop of 1 min @ ambient No change in hardness.

MEK on Powder (Recovery Period = ½ (After rubbing with
coated surface hrs.) cloth powder film
should not comes out)
4.5.2 Petrol Dipping 48 hrs@ ambient No change in gloss or
colour.
4.5.3 Resistance to boiling water 1/2 hr at 100 deg.C.(Ref.IS:101 Part 7/Sec.1 -1989)

4.5.4 Resistance to lubricating oil, SAE 30. – 72 Hrs at 70 deg. C (Ref.IS:101 Part
7/Sec.2 -1990)
4.5.5 Resistance to heat double bake schedule.-180 deg. C for 30 minutes (Ref.IS:101
Part 7/Sec.3 -1990)
4.5.6 Resistance to bleeding. (Ref.IS:101 Part 7/Sec.4 -1990)

4.5.7 Resistance to detergent-5% Solution for 150 hours. At 74 +/-1 deg. C

(Ref. IS 13871 :1993-Annex B)
4.5.8 Resistance to acid/alkali.(Ref. IS 13871 :1993-Annex C)

4.6 Optical Test

4.6.1 Gloss: To be measure with gloss meter. (Ref.- IS: 101 part 4 / Sec4 -1988)

4.6.2 Resistance to UV: To pass 50 Hrs test as per ASTM D 4587-91, light (313 mm)
test method D. No significant change in shade, loss of gloss – 60% expected

4.7 Note: Traceability sticker indicating: vendor’s name, item code no, inspected by
& date (Ref. GL-946 for sticker detail) to be affixed on each component by
vendor.

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4.8 Type Test Report Records are to be maintained by processor

Test Frequency Ref. Document

4.4.1 Resistance to humidity Every six Suppliers report/TPI
under condition of Month
condensation
4.4.2 Salt spray test Every six Suppliers report/TPI
Month
4.6.2 Resistance to UV Once in year Suppliers report/TPI

3.5 TTR of Ovan Every six TTR Report of TPI

Month
2.1.7.1 Phosphate Coating weight Once in week Suppliers report/TPI

2.1.7.2 3% NACL Test Once in week Suppliers report/TPI

4.5.2 Petrol Every six Suppliers report/TPI

Month
4.5.3 Resistance to boiling Every six Powder coater to get DOC/test
water 1/2 hr at 100 ° C Month certificate from powder
manufacturer & submit along
with inspection report.
4.5.4 Resistance to lubricating Every six Powder coater to get DOC/test
oil, SAE 30. Month certificate from powder
manufacturer & submit along
with inspection report.
4.5.5 Resistance to heat double Every six Powder coater to get DOC/test
bake schedule Month certificate from powder
manufacturer & submit along
with inspection report.
4.5.6 Resistance to bleeding. Every six Powder coater to get DOC/test
Month certificate from powder
manufacturer & submit along
with inspection report.
4.5.7 Resistance to detergent Every six Powder coater to get DOC/test
Month certificate from powder
manufacturer & submit along
with inspection report.
4.5.8 Resistance to acid/alkali. Every six Powder coater to get DOC/test
Month certificate from powder
manufacturer & submit along
with inspection report.

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4.9 Routine Test –Test Certificate & test panels should submit with each lot

Test Frequency Ref. Document

4.1 Visual Inspection Each supply Suppliers report
4.3.1 DFT Measurement Each supply Suppliers report
(Dry Film
thickness)
4.3.2.1 Cross Hatch test Each supply Suppliers report
4.3.2.2 Scratch hardness Each supply Suppliers report
test
4.3.3.1 Mandrel bending Each supply Suppliers report
test
4.3.3.2 Erichsen cupping Each supply Suppliers report
test
4.3.3.3 Impact test Each supply Suppliers report
4.5.1 MEK Each supply Suppliers report
4.6.1 Gloss Each supply Suppliers report

5 Packing-Powder coated component to be packed with Corrugated sheet & bubble sheet
to avoid damages during Handling & Transportation.
(If two or more than two components are packed in one Box, Thick Corrugated sheet to
be use between two components.)

6 Process Specification Sheet for Powder, Pretreatment & Coating” to be audited by

QA on Monthly Basis.

Prepared By: XXXXX

Approved By: XXXXXX

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 Annexure A

Daily Pretreatment Record :

Date:-
Time:-

Sr. Process Chem Pointage Temp °c Dip Time Ph Value Total Acid Free Acid Accelator Remarks
No. ical
Used
Req. Actual Req. Actual Req Actual Req. Actual Req Actual Req Actual Req Actual

01 Degreasing

02 Water
Rinse-1
03 Water Rinse-2
(If applicable)

04 Derusting

05 Water Rinse-1

06 Water Rinse-2
(If applicable)

07 Zn
Phosphating

08 Water
Rinse-1

09 Water Rinse-2
(If applicable)

07 Passivation

08 Hot Air Dry

Inspected By.: Verified By:

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 Annexure B

CHECKING OF OIL CONTAIN OF DEGREASING BATH

Date Oil Contain
Required Actual Remark

CHECKING OF IRON CONTAIN OF DERUSTING BATH

Date Iron Contain
Required Actual Remark

TEST REPORT FOR 3 % NACL TEST

Date Testing Time Results Remark
From To

TEST REPORT OF PHOSPHATE COATING WEIGHT

Date Req. Actual
2.3-4.3gm/m²

Inspected By- Verified By-

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Revision Details:
Revision No. Date: Change Details:
01 25.12.2009 Modified for addition of
A) Following tests
1) Resistance to boiling water 1/2 hr. 2) Resistance to lubricating oil, SAE 30 3)
Resistance to heat double bake schedule. 4) Resistance to bleeding. 5) Resistance to
detergent 6) Resistance to acid/alkali
B) Temp of pretreatment chemical is changed as per chemical manufacturer
C) Testing Frequency of Resistance to humidity under condition of condensation is
changed from One year to six month.
D) Use of Durable Pure Polyester Powder for export pump is removed.

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