_INTEGRAL COACH FACTORY , CHENNAI- 600 038 ICFIMDISPEC-357 TECHNICAL REQUIREMENTS FOR SUPPLY AND ISSUE STATUS:01 APPLICATION OF ANTI CORROSIVE PAINT FOR | Rev. -00 RAILWAY COACHES _ 7 DATE: a:08:2010 IDENTIFICATION SHEET No. of Pages: 9 Amendment Nos. 1 2 3 4 5 Date Of Issue NATURE OF DOCUMENT COPY NUMBER ISSUED TO ISSUED BY A Dy. CME/D RETURN OF COPIES In case of transfer / retirement, the holder of controlled copies shall return the same either to SSE/D/MS or to his/her successor under intimation to SSE/D/MS. NOTE 1. Controlled copy holders of this DOCUMENT are expected to bring the content of this document to the knowledge of the concerned officials who are working in his {her department /section. 2. Unauthorised copying of this document is prohibited. CONTROLLED COPY HOLDERS C. COPY No. 1. CME/QA 7 01 2. Dy CC&M s 02 3. PE/PLFur a 03 4. SME/MPO/ Fur : 04 5. DESIGN/LIBRARY : os PREPARED BY CHECKED BY VERIFIED BY APPROVED BY i | Oho _ SME/D Dy. CME/D CDE/MECK ssaL : ' INTEGRAL COACH FACTORY , CHENNAI- 600038 | SNIP | ICFIMDISPEC-357 TECHNICAL REQUIREMENTS FOR SUPPLY AND} isgue sTaTUs:01 APPLICATION OF ANTI CORROSIVE PAINT FOR |Rev. 00 RAILWAY COACHES DATE: 30.03.2019 Page 1 of 3 SCOPE This standards covers the technical requirements and method of testing of anti corrosive paint intended to be used at areas where improved corrosion resistance is needed. The paint shall have single pack PU that can be used as a primer & topcoat. This anti corrosive paint is intended to be used as first coat on bare metal without blasting and also as a primer to avoid corrosion on the bare metal.The material shall be suitable for application on interior of coaches and corrosion prone areas like lavatory area, tum under, bogie frame & bogie bolster etc. The paint shall have a protective coating film of superior adhesion, flexibility, abrasion and impact resistance when applied directly to the surface. The anti corrosive paint shall be suitable for spray application and also be suitable for application by brush for touching up smaller areas. Cumulative DFT of the paint after application should be 120 microns minimum which shall have not more than the two coats. 2. The paint shall meet the requirements of the properties as mention below in Table-I. Table4 S.No | PROPERTIES REQUIREMENT TEST METHOD 1. | Consistency ‘Smooth and uniform, suitable | 1S : 101-89 for brush/spray application | (Part 1/ Sec.5) | Reaffirmed 2014 2. | Colour Silver grey RAL 7001 IS: 101-89 (Part 4/ Sec. 2) Reaffirmed 2014 3. | Finish ‘Smooth — mattisem-siosey, | IS: 107 free from sagging & wrinkling | (Pt.3/Sec.4)-87 Reaffirmed 2014 4. | Drying time at 2742°C TS 101-86 Surface dry, max 2hrs (Part 3 sec 1) Hard dry, max 8 hrs e Reaffirmed 2017 5. | Dry film Thickness (DFT) | 60 p minimum 1S: 101 (Pt3/Sec.2)- Iper coat 89 Reaffirmed 2014 (by brush / spray) by Electrometer Thickness Gauge metet PREPARED BY CHECKED BY VERIFIED BY APPROVED BY se xe —— SSED ‘SMED Dy.CME/D CDE/MECH' INTEGRAL COACH FACTORY , CHENNAI- 600 038 __ ICF/MD/SPEC-357 TECHNICAL REQUIREMENTS FOR SUPPLY AND ligcue staTus:01 APPLICATION OF ANTI CORROSIVE PAINT FOR |Rev.: 00 RAILWAY COACHES 7 DATE: 30.03.2019 Page 2 of 9 6. | % Volume solids (min) | 50% ‘Apppendix | of this specification ‘7. | Mass in Kg/10litres, min. | 12 min IS 101/87 (Part 1/Sec 7) Reaffirmed 2014 8. | Theoretical Coverage, _| 8.3 m’llitre, at 60 p DFT ‘Appendix Il min 9. | Flash point in °C Above 25°C 1S 101/87 (Part 1/Sec 6) Reatffirmed 2014 10] Abrasion resistance, Maximum loss = 170 mg ASTM D 4060 1000 cycles. CS-17 (0.170g)loss/1000 cycle __| wheel, 1 kg load 414) Scratch hardness, No such scratch to show the | IS 101-88 15 Kg base metal (Part 5 sec 2) Reaffirmed 2014/ASTM D 2486 12] Flexibility and adhesion, | No visible damage and 1S : 101-88 6.25 mm mandrel detachment of film (Part 5/Sec, 2) Reaffirmed 2014/ASTM D 522 73] Resistance to salt spray | No sign of corrosion & no sign | ASTM B 117 {Fag) of the finish coat of deterioration viz. blistering, detachment of film up to 15000 hrs 14] Resistance to No degradation of the film, | ASTM G 154 accelerated weathering | chalking, checking, cracking, | And appendix-Ill of for the finish coat flaking, blistering & corrosion } this specification up to 1000 hrs 15| Humidity resistance of _ | No sign of corrosion & no sign | 1S 101-88 the finish coat of deterioration Viz. blistering, | (Part 6 sec 1) detachment of film up to 2000 | Reaffirmed hrs 2015/ASTM D 2247- 15 PREPARED BY CHECKED BY VERIFIED BY APPROVED BY SMEID. Dy.CME/D CDE/MECHINTEGRAL COACH FACTORY , CHENNAI- 600 038 TECHNICAL REQUIREMENTS FOR SUPPLY AND APPLICATION OF ANTI CORROSIVE PAINT FOR ICF/MD/SPEC-357, ISSUE STATUS:01 Rev.: 00 RAILWAY COACHES DATE: 30.03.2019 Page 3 of 9 16] Resistance to chemicals [Shall not show any sign of | Appendix lof this a)25% caustic soda | blistering ,wrinkling & lifting of | specification solution(w/v) paint up to 1800 hrs b) 20% hydrochloric ~-do~ acid(viv) ©) 30% sulphuric ~-do~ acid(viv) Resistance to Tap Water | _Shail not show any sign of blistering, wrinkling & lifting of paint film up to 3000 hours 17] Adhesion (min) Matches to 5B ASIMD 3359 48] Pull off adhesion test, | 1200 PSI (6 MPa) ‘ASTM D 4544 min 19] impact resistance test at | Shall be free from deformed | ASTM D 2704 height 31 inch and| coating by dropping the weight 1.46 kg indenter on coated side of the panel 20] Prohesion 1500 hours salt fog , ASTM G 65, (Dilute electrolyte cyclic | Min Rated-9 Annex-A5 fogldry test) a 3.0 TEST AND TEST CERTIFICATES 3.1 Anti Corrosive paint shall be accepted based on OEM test certificates. However purchaser reserves the right to conduct tests for any parameter at any point of time. 3.2 Certificate against above parameters mentioned in Table-I shall be submitted from any accredited lab to ISO 17025 like NABL/International agency. The lab shall have valid accreditation during the test of above parameters. 3.3. a) TYPE TEST: Sr. No. 13 to 16 and 20 shall be considered as a Type test. b) VALIDITY: ‘Type test certificate validity from the date of issue for, S. no 13 shall have 5 Year. S.no 14 to 16 and 20 shall have 2 Year. PREPARED BY CHECKED BY VERIFIED BY APPROVED BY ee we ye Foe SSE/D SME/D Dy.CME/D CDE/MECHINTEGRAL COACH FACTORY , CHENNAI- 600 038 ICF/MD/SPEC-357 | TECHNICAL REQUIREMENTS FOR SUPPLY AND] ¢gye sTATUS.O4 APPLICATION OF ANTI CORROSIVE PAINT FOR |Rev.:00 RAILWAY COACHES DATE: 30.03.2019 _| Page 4 of 9 3.4 a) ACCEPTANCE TESTS: All Test in table-| except tests. mentioned in clause-3.3 shall be considered as acceptance test and shall be submitted at each lot of purchase order. 3.5 First time supplier shall conduct both the test (Type test and Acceptance test). 3.6 Requirements of theoretical coverage in m*/litre and thickness in DFT for the anti corrosive paint shall be given by OEM duly meeting the requirements of Table-1. 4 MARKING Each pack shall be legibly marked with indelible marking ink/paint showing the following details: 1. Manufacturer's name or Initial or Trade mark. 2. Lot and serial number. 3. Volume of the material. 4. Month and year of manufacture . 5. Month and year of Expiry. 5. PACKING 5.1 The coating material shall be supplied in environment friendly container. The material shall be securely packed so as to avoid damage in transportation. A copy of spare test certificate and material safety data sheet shall also be kept in the box with each batch of supply. For Touch up/patch painting ,the material shall be supplied in one litre container. METHOD OF APPLICATION The manufacturer shall supply sufficient copies of literature explaining the method of application, surface preparation, important properties and precautions to be taken with each order. INSPECTION Inspection shall be carried out by RITES/any other ICF nominated agency at Firm's premises. ‘SHELF LIFE a The material shall have a shelf life of minimum 12 months. During this period the material shall have same qualities in all respects. PROTO-TYPE APPROVAL First time supplier has to submit samples for Testing & TRIAL to ICF. The prototype approvat shall be given by design ICF after successful trial reports of the material. PREPARED BY CHECKED BY VERIFIED BY APPROVED BY ah en SME/D Dy.CME/D. CDE/MECH' INTEGRAL COACH FACTORY , CHENNAI- 600 038 ICFIMDISPEC-357 ~ TECHNICAL REQUIREMENTS FOR SUPPLY AND |igsue staTUS:01 APPLICATION OF ANTI CORROSIVE PAINT FOR RAILWAY COACHES Rev.: 00 DATE: 30.03.2019 Page 5 of 9 10.. DOCUMENTS TO BE SUBMITTED ALONG WITH OFFER FOR FIRST TIME SUPPLIER The firm shall submit following documents along with the offer. a. Technical Data sheets and material safety data sheet. b. Test reports and valid accreditation certific given by accreditation agency. ¢. Trial reports for theoretical coverage and thickness of the paint. d Clause wise comments and Technical deviation. 11. WARRANTY The life of the coating system shall be minimum 7 years from the date of the applications. The supplier shall give warranty for above period against scratch .no visible damage or detachment of the film. The defect arises during warranty period shall be repaired by the supplier on their own cost. 42. TEST PANEL Test panel shall be prepared as per table-Il Table-Il ‘S.no | Test Type of | Sizein | Paintingl DFT | Method Duration of Special metal mm. detail of ir drying jnstruction panel Applica before tion fommencem nt of test (Applicable for panels ither air ried or dried t elevated a temperature) | 1 | Colour | SS 750x [Two | 60u|Spray/ [24 hours | - unblasted | 100 coats | min. | Brush x1.25mm fi 2 | Finish ~do- ~do- One |-do- |-do- [48 hours [= coat 3 [Drying | -do- -do- One| -do- [-do- | — No garnet time {coat blasting 4 | DFT -do- ~do- One |-do- [-do- | 24 hours | - coat PREPARED BY CHECKED BY VERIFIED BY ‘APPROVED BY —— ‘SME/D Dy.CME/D ‘CDE/MECHINTEGRAL COACH FACTORY , CHENNAI- 600038 | ICFIMD/SPEC-357 TECHNICAL REQUIREMENTS FOR SUPPLY ANDJ issue staTus:01 APPLICATION OF ANTI CORROSIVE PAINT FOR |Rev.: 00 - RAILWAY COACHES . DATE: 30.03.2019 Page 6 of 9 5 | Flexibility | Tinned 460.x50 |-do- |-do- |-do- | 7days & panels x.315 adhesion zs 6 Scratch ~do- ~do- -do- -do- | -do- s Hardness 7 esistance. | SS 150 x Two ~do- | -do- aint both to salt unblasted | 100 x coats sides of pray 4.25 mm the panel ind seal the edges a ee wax. 8 esistance | SS 150 x ~do- ~do- ~do- to unblasted | 100 x hemicals 1.25 - 7 eo = 9 jumidity | SS 450 x ~do- |-do- [-do- | -do- “do- resistance | unblasted | 100x 4.25mm _ 10 ‘esisiance | SS 150 x 75 x| -do- -do- | -do- ~do- tdo- unblasted | 1.25mm ccelerated st = 17 |impact -do- ~do- ~do- |-do- \-do- | -do- [Apply two resistance oats on rf side of he panel 12 Pull off ~do- -do- One -do- | -do- ~do- pply one adhesion coat oat on oth sides f the anels: PREPARED BY CHECKED BY VERIFIED BY APPROVED BY BE | ae | wen | Pete SSEID SMEID Dy.CME/D CDE/MECHINTEGRAL COACH FACTORY , CHENNAI- 600 038 TECHNICAL REQUIREMENTS FOR SUPPLY AND iccur esate APPLICATION OF ANTI CORROSIVE PAINT FOR |Rev.:00 RAILWAY COACHES DATE: 30.03.2019 Page 7 of 9 APPENDIX: | PROCEDURE FOR DETEMINING VOLUME SOLIDS PERCENTAGE 1. SCOPE This method is applicable for determination of the volume of non- volatile matter of paint coatings. 2. SIGNIFICANCE ‘This method is intended to provide a measure of the volume of dry coating obtainable from a given volume of liquid coating. This volume is considered to be the most equitable means of comparing the coverage (sq. meter of surface covered at a specific film thickness, per unit volume) and also for calculating the wet film thickness of the given paint. 3. APPARATUS i) Analytical balance ii) Steel disc — Preferably stainless steel, 60 mm dia and 0.70 mm thickness with a small hole 2to 3 mm from the edge. A fine wire such as chromel is attached through the hole and made of the appropriate length for suspending the disc in a liquid iii) Weight box iv) Beaker 1 litre , for weighing the disc in liquid. v) Weight per litre cup for determining the specific gravity of the paint material and of the suspending liquid if not known. vi) Oven. s PROCEDURE : i) Dry the disc in an oven at 105°C for 10 minutes and cool il) Weigh the disc in air. Let it be W1 grams. iii) Suspend the disc in water and weight again .Let it be W2 grams. iv) Calculate the volume of the disc V as follows : W1-Ww2 Ve— —- where d is the density of the water at room temperature. d V) Determine the weight of non-volatile content of the liquid coating material by drying a known amount of paint at 105° C for 3 hours. Let it be W grams. vi) Determine the specific gravity of the paint to the nearest 0.001 g/ml by using weight per gallon cup. Let it be P. PREPARED BY CHECKED BY VERIFIED BY APPROVED BY PE | oe | wo | oB_ SSEID ‘SME/D Dy.CME/D CDE/MECHINTEGRAL COACH FACTORY , CHENNAI- 600 038 TECHNICAL REQUIREMENTS FOR SUPPLY AND |iccur cratic APPLICATION OF ANTI CORROSIVE PAINT FOR |Rev.: 00 RAILWAY COACHES DATE: 30.03.2019 Page 8 of 9 vil) Dip the disc in the paint sample for 10 minutes and take out the dise and allow the excess coating material to drain off. Blot the coating material off the bottom edge of the disc so that heads or drops do not dry on the bottom edge of the disc. viii) Dry the disc. in an oven for 3 hours at 105°C and cool. ix). Weigh the coated disc in air. Let it be W3 grams. x) Suspend the coated disc in water and weigh again. Let it be W4 grams, xi) Calculate the volume of the coated disc as follows : W3 -W4 -- where d is the density of the water at room temperature Vie — xii) Calculate the volume of the dried coating as follows :- Volume of dried coating = V1 - V (Vd) xiii) Calculate the volume of wet coating as follows : W3-W1 : Vi= ——— where W = grams of non-volatile matter. WXxP P = specific gravity of the paint. xiv) Calculate the percentage volume solids of the paints as follows : vMi-v vd ———--—X 100 OR. — vw ww ‘The volume of non-volatile matter or the percentage volume solids of a paint is related to the covering capacity and thickness in the following manner :~ X 100 % Volume solids a) ——- X 10 = Covering Capacity Dry film thickness (microns) . Dry film thickness (microns) Eg eee ————-———-—-__ X 100 = wet film thickness % Volume solids PREPARED BY CHECKED BY VERIFIED BY APPROVED BY BE | oe | re FE SSE/D SME/D Dy.CME/D CDE/MECH| INTEGRAL COACH FACTORY , CHENNAI- 600 038 [TECHNICAL REQUIREMENTS FOR SUPPLY AND |iCFIMDISPEG-357 APPLICATION OF ANTI CORROSIVE PAINT FOR |Rev.: 00 | RAILWAY COACHES DATE: 30.03.2019 Page 9 of 9 \PPENDE; Accelerated Tests: (Resistance to Chemicals): Prepare the panels as per Table -II below. Allow the panels to air dry for 7 days and seal the edges with wax. a) Resistance to 25% caustic soda solution: Immerse 3/4" of the panel in 25% (wiv) caustic soda solution for 1800 hours. Remove the panel, wash in running water and allow it to air dry for an hour and record the observations. b). Resistance to 20% hydrochloric acid solution : Immerse 3/4!" of the panel in 20% (viv) hydrochloric acid for 1800 hours. Remove the panel, wash in running water and allow it to air dry for an hour and record the observations ©) Resistance to 30% sulphuric acid solution: Immerse 3/4" of the panel in 30% (vv) sulphuric acid solution for 1800 hours. Remove the panel, wash in running water and allow it to air dry for an hour and record the observations. d) Resistance to Tap water: Immerse 3/4" of the panel in tap water for 3000 hours. Remove the panel, wash in running water and allow it to air dry for an hour and record the observations APPENDIX — II RESISTANCE TO ACCELERATED WEATHERING TEST The test may also be carried out as per ASTM-G-154 TestPeriod : 1000 hours Apparatus : Operating Light and Water-Exposure Apparatus (Fluorescent UV-Condensation Type) Cycle : 4 Hrs. ULV. Light from UV-B lamps with a peak emission @ 313 n.m. and 4 hrs. condensation alternatively. ‘Temperature : 50 C The requirements of this test shall be taken to have been satisfied if performance in respect of the characteristics as noted in Clause C-3.2 of IS : 8662-2004 Reaffirmed 2014 ( or corresponding clause of latest version) is within the limits. PREPARED BY CHECKED BY VERIFIED BY. APPROVED BY BE |e | ye [fee SSE/D SME/D Dy.CME/D_ CDE/MECH