Quality and Test Specifications

HEAVY-DUTY CORROSION PROTECTION OF VALVES and FITTINGS

BY POWDER COATING
(Version: January 2008)

Quality assurance
RAL - GZ 662

Gütegemeinschaft Schwerer Korrosionsschutz

von Armaturen und Formstücken
durch Pulverbeschichtung e.V. (GSK)
Laufertormauer 6, 90403 Nürnberg
Tel.: +49 911 20 44 41
Fax: +49 911 22 67 55
E-Mail: info@gsk.de
www.gsk-online.de
 General Quality and Test Specifications
for Heavy-Duty Corrosion Protection of Valves and Fittings
by Powder Coating

1 Scope

1.1 General

These General Quality and Test Specifications pertain to the general requirements
regarding heavy-duty corrosion protection of valves and fittings by epoxy powder coating.
Furthermore they are valid for the general requirements regarding of surveillance and
marking.

1.2 Special attributes

The General Quality and Test Specifications are supplemented with the Special Quality
and Test Specifications regarding the requirements for coating plants and all those
involved in the coating process (Part I – process approval), the Special Quality and Test
Specifications regarding the coating requirements for valves and fittings (Part II – product
approval), and, finally, the Special Quality and Test Specifications for the admission
requirements of epoxy powder (Part III – material approval) .

Besides, the pertinent Special Quality and Test Specifications also list the specific
requirements for the individual sections regarding the sampling and the technical details
of the control tests.

2 Quality Specifications

These Quality and Test Specifications describe the complete heavy-duty corrosion
protection of valves and fittings by epoxy powder coating (hereinafter briefly referred to as
EP powder) applied to all surfaces, inside and outside. The list includes valves and
fittings made of metallic materials which are used for gas and drinking water supply
facilities as well as waste water disposal.

The quality surveillance specified in the General and the subsequent Special Quality and
Test Specifications meet the requirements for EP coatings for natural gas, drinking water,
and waste water units (Appendix 1) in accordance with the DIN 30677-2, EN 14901, and
DIN 3476 standards. Furthermore, compliance with additional requirements is specified
and ensured by a quality assurance system requiring internal as well as external
surveillance.

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These Quality and Test Specifications are to give rise to a manufacturers quality
assurance system for complete EP powder coatings of valves and fittings, covering all
surfaces, inside and outside.

The specific requirements for the sections listed in Paragraph 1.2 are described in the
particular Special Quality and Test Specifications.

3 Test Specifications

Regarding the test specifications, please see Paragraph 2.

4 Surveillance

External monitoring is performed by indepetent experts or suitable independent testing

institutes appointed by the Quality Assurance Association (initial testing respectively
qualifying test for the quality mark, external monitoring, and/or repeat testing).

Surveillance includes:

- Initial testing (qualifying test)

- Internal monitoring
- External monitoring
- Repeat testing.

4.1 Initial testing (qualifying test)

All companies applying for the usage of the quality mark “Heavy-duty corrosion protection
of valves and fittings“ with the corresponding inscription to the Gütegemeinschaft
Schwerer Korrosionsschutz von Armaturen und Formstücken e.V. [Quality Assurance
Association for Heavy-Duty Corrosion Protection of Valves and Fittings] must complete
the initial testing.

Passing the initial testing is a mandatory requirement for award and use of the quality
mark.

The initial testing (qualifying test) consists of two complete tests in accordance with
Section I-4.2. The tests should be performed at intervals of at least 6 weeks in order to
guarantee adequate documentation of the internal monitoring.

The applicant shall bear the cost of initial testing.

4.2 Internal monitoring

To ensure compliance with the General and the particular Special Quality and Test
Specifications, every quality mark holder must conduct continuous internal monitoring to
make sure that the company’s products and services bearing the RAL Quality Mark meet
the requirements of quality assurance.

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The quality mark holder records and documents the internal monitoring results. These
reports are to be kept for at least 5 years in a suitable waý. The quality mark holder is
obliged to keep the reports detailing the results of internal monitoring and to present them
to the inspector during external monitoring.

4.3 External monitoring

Reports detailing the results of internal monitoring shall be presented to the inspector
during external monitoring. Apart from reviewing the completeness and accuracy of these
documents, the testing institute appointed by the Quality Assurance Association for
external monitoring may conduct random tests of the quality mark holder’s quality-
assured products resp. his performance in accordance with the General and the
particular Special Quality and Test Specifications. Samples requested for testing
purposes shall be placed at the inspector’s disposal.

Such external monitoring shall be conducted without prior notice on site at the quality
mark holder’s premises at least twice annually during normal business hours. The
inspector is required to identify himself/herself before testing. The inspector will prepare
a report of the external monitoring results. He/She has to use the forms developed for
this purpose by the Quality Assurance Association.

One copy of this monitoring report will be handed over to the quality mark holder and the
original to the office of the Quality Assurance Association.

The quality mark holder shall bear the external monitoring costs.

4.4 Repeat testing

If external monitoring reveals any deficiencies in the quality assurance of the quality mark
holder, the quality panel of the Quality Assurance Association will order repeat testing
and determine contents, extent, and the date and time of such repeat testing.

The inspector who is already charged with external monitoring shall execute any repeat
testing.

In the event that repeat testing fails again, the external monitoring will be considered
failed as a whole. All further proceedings are governed by the Quality Assurance
Association’s provisions for award and use of the quality mark.

The quality mark holder shall bear any and all repeat testing costs.

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5 Marking of products

All products coated in accordance with these Quality and Test Specifications are to be
marked as follows:

It is preferable to mark the product itself; although the label may occasionally be attached
to the packaging.

Coating material complying with these Quality and Test Specifications may be marked as
follows:

The quality mark holder is obliged to use the quality mark awarded by the Quality
Assurance Association exclusively in conjunction with the special marking. The Quality
Assurance Association specifies the precise marking rules.

Award and use of the quality mark are exclusively governed by the rules and regulations
for the award and use of the quality mark laid down by the Quality Assurance Association
for Heavy-Duty Corrosion Protection of Valves and Fittings [Gütegemeinschaft Schwerer
Korrosionsschutz von Armaturen und Formstücken e.V.].

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6 Alterations

In order to be effective, any alterations of these General Quality and Test Specifications
as well as the following Special Quality and Test Specifications require the prior written
approval of RAL. The executive committee of the Quality Assurance Association has to
inform the quality mark holders of any such alterations, a reasonable period of time
before these alterations become effective.
They are implemented by the committee of the Quality Assurance Association.

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Appendix 1 to the General Quality and Test Specifications

Normative references

List of the standards referred to in the General Quality and Test Specifications and the
following Specific Quality and Test Specifications, together with the valid standarts,
directives and worksheets (each in its valid version) pertaining to the scope of the
particular Quality and Test Specifications:

DIN 3476 Valves and fittings for untreated and potable water -
Protection against corrosion by internal epoxy coating with
coating powders (P) or liquid varnishes (F) - Requirements
and tests.

EN ISO 4624 Paints and varnishes - Pull-off test for adhesion

EN 14901 Ductile iron pipes, fittings and accessories - Epoxy coating

(heavy duty) of ductile iron fittings and accessories -
Requirements and test methods

DIN 30677-1 External corrosion protection of buried valves; coating

(external coating) for normal requirements

DIN 30677-2 External corrosion protection of buried valves; heavy-duty

thermoset plastics coatings (external coatings) for increased
requirements

DIN 50014 Climates and their technical application; standard

atmospheres

EN ISO 12944-4 Paints and varnishes - Corrosion protection of steel

structures by protective paint systems - Part 4: Types of
surfaces and surface preparation

EN ISO 8501-1 Preparation of steel substrates before application of paints

and related products - Visual assessment of surface
cleanliness

ISO 8130-1 Coating powders - Part 1: Determination of particle size

distribution by sieving

ISO 8130-3 Coating powders – Part 3: Determination of density by liquid

displacement pyknometer

ISO 8130-6 Coating powders – Part 6: Determination of gel time of

thermosetting coating powders at a given temperature

ISO 8130-7 Coating powders – Part 7: Determination of loss of mass on

stoving

EN 10204 Metallic products - Types of inspection documents

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EN ISO 2812 Paints and varnishes - Determination of resistance to liquids

EN ISO 8502-3 Preparation of steel substrates before application of paints

and related products – Tests for the assessment of surface
cleanliness – Part 3: Assessment of dust on steel surfaces
prepared for painting (pressure-sensitive tape method)

EN 598 Ductile iron pipes, fittings, accessories and their joints for
waste water disposal – requirements and test methods

DVGW Worksheet G 260 Gas condition

DVGW Worksheet G 262 Use of gases from renewable sources in the public gas
supply

DVGW Worksheet W 270 Propagation of microorganisms on materials for the drinking-

water sector – testing and assessment

UBA Coating guidelines for the hygienic assessment of

guideline organic coatings in contact with drinking water (coating
guideline)

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 Special Quality and Test Specifications
regarding the requirements for coating plants
and all those involved in the coating process
- Process approval -

I-1 Scope

These Special Quality and Test Specifications contain the requirements for coating plants
as well as for the employees involved in the coating process. This aspect of quality
assurance is briefly referred to as „process certification“ and is also documented in the
inscription of the quality mark with the same name.

These Special Quality and Test Specifications are valid only in conjunction with the
General Quality and Test Specifications.

I-2 Quality Specification

I-2.1 Process approval requirements

Requirements for the coating of valves and fittings:

• the mechanical pretreatment,

• the oven,
• the EP powder coating plant,
• the test facilities resp. the test equipment and
• the adequate technical know-how of the employees charged with this task.

I-2.2 Requirements for the coating plant

I-2.2.1 Mechanical pretreatment

Immediately before applying the coating, all surfaces to be coated must be cleaned to
make sure they are free of dirt, oil, grease, moisture, rust, and other impurities.

The subsequent blasting process must accomplish Sa 2 1/2 as level of purity in

accordance with EN ISO 12944-4 for steel. The operational procedures have to be
arranged in a way that the coating process starts immediately after blasting.

Blasted parts may never be touched with bare hands; instead, fiber-free, clean gloves or
mittens must be worn and the blasted parts must be transported to the oven as quickly as
possible, without undue delay.

The blasting quality is verified by the pressure-sensitive tape method according to DIN
EN ISO 8502-3 “Preparation of steel substrates before application of paints and related
products – Tests for the assessment of surface cleanliness – Part 3: Assessment of dust
on steel surfaces prepared for painting (pressure-sensitive tape method)”. In addition, the
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grading curve (the particle size distribution curve) of the (high quality) blasting shot should
be regularly tested.
Regular testing of the function of the blasting unit and the filter system is recommended
as well.

Before further processing, any contaminations by blasting abrasive or dust must be

removed, for instance with suitable compressed air equipment.

I-2.20.2 Oven

The oven is used to preheat the valves and fittings in accordance with the powder
supplier’s specifications in order to transfer the thermal energy needed to achieve perfect
chemical cross-linking of the EP powder.

This may be realized with or without applying residual heat after coating.

In order to guarantee reliable processing parameters, the oven temperature and the
temperature of the parts during each shift must be monitored by random testing and
documented prior to the coating process.

I-2.20.3 EP powder coating

Only quality-assured EP powder may be used for coating. In this context please also
compare the „Special Quality and Test Requirements“ which are a condition for the
material approval of EP powder – Part - III.

The powder may be applied either electrostatically with a spray gun (ES procedure) or by
immersing the valves and fittings in a “powder bath“(fluidized bed application). It is
important in this context to abide to the processing parameters specified by the EP
powder supplier.

The EP powders in storage at the coating company must be conclusively identified. The
period of use must be visibly indicated on the container. Compliance with the storage
conditions specified by the EP powder supplier is essential.

I-2.3 Technical know-how of the employees who are responsible for the coating
process

All those employed in the coating unit must possess the necessary knowledge and skills
needed for their scope of work with regard to these Quality and Test Specifications, the
test instruments, their operation, and the data sheets for the coating materials.

I-3 Test Specifications

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The following test equipment must be available and in good working order:

• Coating thickness gauge,

• High-voltage porosity testing instrument up to 3 kV,
• Impact test instrument, (5kN)
• Thermometer to monitor the component temperature.

The following test equipment should either be available at the quality mark holder’s
company or via the testing institute or other GSK member companies:

• Water bath with heating and thermostat,

• Adhesion test instruments according to EN ISO 4624,
• Test equipment for the cathodic disbanding test.

The test equipment is subject to the coating company’s monitoring system for measuring
device.

I-4 Surveillance

I-4.1 Basic principles

For details regarding the monitoring procedures please see the basic description in
Paragraph 4 of the General Quality and Test Specifications.

I-4.2 Initial testing

Performing an initial test is a mandatory requirement in conjunction with the quality mark.
In order to perform this test, a corresponding application is to be submitted to the GSK
office in accordance with the ”Provisions for award and use of the quality mark for the
heavy-duty corrosion protection of valves and fittings", along with a test plan for each
individual product.

The initial test includes the following aspects:

- the mechanical pretreatment and the coating plant in accordance with

Paragraphs I-2.2.1 to I-2.2.3,
- the existence and condition of the test equipment in accordance with Paragraph I-
3,
- the employees know-how and skills in accordance with Paragraph I-2.3,
- Verification of the previously performed internal tests.
´

I-4.3 Internal monitoring

Continuous internal monitoring of all pretreatment and production processes in

accordance with these Quality and Test Specifications in keeping with the test plan is a

mandatory requirement for quality mark holders, who must also document the results and
file the reports for a period of five years.

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An example of such internal monitoring records is provided in Appendix A 9.

I-4.4 External monitoring

External monitoring is performed to verify compliance with the requirements listed in

Paragraph 2. External monitoring is performed in accord with the internal monitoring
regulations. The scope of this test also includes verification of the internal monitoring
reports.

I-4.5 Repeat testing

If external monitoring reveals any deficiencies in the quality assurance of the quality mark
holder, corresponding action will be taken in accordance with Paragraph 4.4 of the
General Quality and Test Specifications.

I-5 Alterations

Any alterations to these Special Quality and Test Specifications are subject to Paragraph
6 of the General Quality and Test Specifications.

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 Monat, Datum

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Unterschrift
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 Special Quality and Test Specifications
regarding the coating requirements
of valves and fittings
- Product approval -

II-1 Scope

These Special Quality and Test Specifications contain the requirements regarding heavy-
duty corrosion protection of valves and fittings by epoxy resin powder coating (hereinafter
briefly referred to as EP powder). This aspect of quality assurance is briefly referred to as
“product approval“ and is also documented in the inscription of the quality mark with the
same name.

These Special Quality and Test Specifications are valid only in conjunction with the
General Quality and Test Specifications.

II-2 Quality Control

II-2.1 Requirements regarding product approval

Quality assured coating of valves and fittings is based on the quality assured process
approval of the coating company as well as compliance with the specific test plans of the
coating companies.

When applying for award of the quality mark issued by the Quality Assurance Association
with the “product approval“ inscription, the applicant will have to submit the company’s in-
house test plans regarding the coating of valves and fittings (in duplicate) to the office of
the Quality Assurance Association.

A separate test plan is to be submitted for each product to be certified.

Such in-house test plans have to contain the following specifications regarding the
individual tests:

(1) Number of measuring points,

(2) Position of the measuring points,
(3) Type of testing to be performed,
(4) Scope of the submitted test plan (such as the nominal diameter, the media, ...)
(5) the specified areas.

Appendix A 7 exemplifies an appropriate test protocol.

In the case of subsequent alteration of any test plans that have successfully passed the
Quality Assurance Association’s review and have duly been released, the quality mark
holder is obliged to immediately inform both the Quality Assurance Association and the
test institute of the envisaged test plan alteration. The new test plans, as mentioned
above, are to be submitted with the intended alteration.

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II-3 Test Specifications

The tests required in accordance with the following paragraphs (layer thickness, non-
porosity, impact resistance, cross-linking) must be performed on the respective valves
and fittings in keeping with the specific in-house test plans, because the valves and
fittings supplied by different manufacturers have a different design, which makes it
impossible to standardize the test method.

The coating adhesion test and cathodic disbonding test are performed on the valves and
fittings or on GSK specimens in accordance with Appendix A4.

Unless otherwise specified, all tests are performed in compliance with DIN 50014 at room
temperature (23 ±5 °C).

II-3.1 Layer thickness

The layer thickness is measured at the measuring points mentioned in the test plan. The
minimum layer thickness is 250 µm (150 µm in certain specified areas).

Note: Specified areas are surface areas on a casting on which – due to limited
connecting tolerances, testing problems, or cover-up by gaskets, etc. – the coating
thickness will inevitably be reduced. Such areas include:

- Surface areas in the connecting section (with the exception of flange gaskets
areas)
- Screw holes
- Admissible markings
- Ribs
- Edges

II-3.2 Non-porosity

The non-porosity is measured according to the test plan. The coating ought to have no
full-length pores at all. Non-porosity is associated with a coating that is an electrical
insulator. This is measured with a high-voltage test instrument at an applied test voltage
of 3 kV. A rubber electrode has to be used for this test.

II-3.3 Impact resistance

The impact resistance is measured in accordance with the test plan, using a hammer type
impact tester. After each impact, the electrical discharge is to be measured in accordance
with Paragraph II-3.2. Electrical discharge is not allowed.

For details regarding this test, please see Appendix A1.

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II-3.4 Cross-linking

The degree of cross-linking at the valve or fittingis measured using methyl isobutyl ketone
(MIBK) on the valve or the fitting:

At room temperature, several drops of methyl isobutyl ketone are added to a horizontal
test surface coated with EP powder. After 30 seconds, the drops are wiped off with a
white cloth, making sure not to smear the coating and neither getting it to look matt or
getting sticky. The cloth is to remain clean.

After applying the coating, there is a waiting time of at least 24 hours before this test is
performed.

used, the coating characteristics (i.e., the glass transition temperature difference ∆Tg)
If the outcome of the MIBK test is not unequivocal or if a different coating material is

must be within the limits specified by the coating manufacturer.

II-3.5 Adhesion

The pull-off test is used to determine the adhesive properties of an EP powder coating in
accordance with EN ISO 4624 in keeping with the test plan, using a valve part resp. a
fitting or the GSK test specimen (see Appendix A4). This test is to be performed at least
four times a year. This test may be performed by the manufacturer, an inspection
authority, or at another manufacturer’s company. This eliminates the need for in-house
test facilities.

For this test, the layer thickness of the test specimen must be within a range of 250 µm to
400 µm.

For details regarding this test, please see Appendix A2.

II-3.6 CD test

In accordance with the test plan, the CD test is to be performed on a side facing the
medium, using a valve part resp. a fitting or the GSK test specimen (see Appendix A4).
This test is to be performed at least twice a year. This test may be performed by the
manufacturer, an inspection authority, or at another manufacturer’s company. This
eliminates the need for in-house test facilities.

Make sure that no bubbles are formed in the coating when testing for the cathodic
disbonding.

For this test, the layer thickness of the test specimen must be within a range of 250 µm to
400 µm.

For details regarding this test, please see Appendix A3.

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II-3.7 Appearance and uniformity

The EP coating of the finished product should

- Have a uniform colour, with the exception of the admissible identification;

- Show a uniform appearance and smoothness, with the exception of admissible
repair spots;
- Show no visible defects (pinholes, bubbles, creases, fissures or air voids).

The appearance of the finished coating must be visually inspected.

Slight surface discolorations due to repairs or prolonged exposure to sunlight (chalking)

are acceptable.

Note: Chalking is a reaction on the surface of EP coatings caused by UV radiation. The

process stopped at a depth of 2 to 5 µm by the reaction products and reduce surface
gloss. The protective properties of the coating, however, are not affected.

II-3.8 Repairs

Repairs are allowed. They have to be effected in accordance with the manufacturer’s
written specifications.

The materials used to repair defects must fulfill with three requirements:

- They must be suitable for the protection of valves and fittings under the required
operating conditions (for instance at the operating temperature),
- They must, in all respects, be compatible with the previously applied EP coating
- They must comply with the national regulations regarding the quality of drinking water if
the repaired surfaces are to be in contact with drinking water.

The application conditions of the repair materials must either meet the conditions,
mentioned in the manufacturer’s technical data sheets or the agreements between the
parties involved (the EP coating manufacturer and the material user).

The finished repair job must conform to the values specified in the manufacturer’s
technical data sheets.

The coating thickness in the repaired area should correspond to the layer thickness of the
surrounding areas; it should never be less thick.

II-4 Surveillance

II-4.1 Basic principles

For details regarding the monitoring procedures please see the basic description in
Paragraph 4 of the General Quality and Test Specifications.

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II-4.2 Initial testing

Performing an initial test is a mandatory requirement in conjunction with award of the

quality mark. In order to perform this test, a corresponding application is to be submitted
to the GSK office in accordance with the ”Provisions for award and use of the quality
mark for the heavy-duty corrosion protection of valves and fittings", along with a test plan
for each individual product.

This test is only for those valves and fittings that are already being monitored. At least
one manufacturing batch is required for this test. All of the manufacturing batches in stock
that are ready for dispatch or already prepared for shipping at the time of the test shall,
on demand, be placed at the inspector’s disposal for additional random sampling tests.

The valves and fittings to be tested for layer thickness and cross-linkage are to be
sampled according to the following test plan:

Number of parts in Number of test specimens Admissible number of rejects

the batch* (selected at random) (noncompliant samples)

1 – 10 all 0
11 – 200 10 1
201 – 300 15 1
301 – 500 20 2
> 500 30 3
*Batch = Complete manufacturing order respectively a share of the order (batch) during production.

If the admissible number of rejects is exceeded, the number of test specimens shall be
doubled. If there are too many rejects in this batch as well, then the whole batch must be
discarded. Defective parts must be reworked.

Absolute compliance with the minimum layer thickness of 250 µm (150 µm in certain
specified areas) is essential.
Passing the impact resistance test is equally relevant in all cases. The coating adhesion
test is performed four times a year after passing the initial test; while the cathodic
disbanding test is conducted twice annually.

II-4.3 Internal monitoring

The internal monitoring requirement in conjunction with product approval is met by the
internal monitoring needed for the process approval.

II-4.4 External monitoring

External monitoring reviews to the requirements listed in Paragraph II-2. External

monitoring is performed in accord with the internal monitoring regulations. The scope of
this test also includes verification of the internal monitoring reports.

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II-4.5 Repeat testing

If external monitoring reveals any deficiencies in the quality assurance of the quality mark
holder, corresponding action will be taken in accordance with Paragraph 4.4 of the
General Quality and Test Specifications.

II-5 Alterations

Any alterations to these Special Quality and Test Specifications are subject to Paragraph
6 of the General Quality and Test Specifications.

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 Monat, Datum

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Unterschrift
 Special Quality and Test Specifications for the Material approval of
Epoxy Powder for the Coating
of Valves and Fittings

III-1 Scope

These Special Quality and Test Specifications contain the requirements for the
certification of EP powder as a coating material for heavy-duty corrosion protection of
valves and fittings. This aspect of quality assurance is briefly referred to as “material
approval“ and is also documented in the inscription of the quality mark with the same
name.

These Special Quality and Test Specifications are valid only in conjunction with the
General Quality and Test Specifications.

III-2 Quality Specification

III-2.1 Requirements for the EP powder material approval

The provisions mentioned in this section are decisive for the certification of coating
materials (EP powder) to be used for quality-assured coatings.

Manufacturers label their quality-assured coating materials in accordance with the

paragraph on the marking of these Quality and Test Specifications with the quality mark
of the Assurance Association and the pertinent inscription.

The coating materials are not to release any substances affecting the compatibility, the
taste, the odor, or the colour of drinking water. They must comply with the national
drinking water directives.

Coating materials coming into contact with drinking water are not allowed to cause the
reproduction of microorganisms. They must therefore show a neutral reaction in
bacteriological tests in accordance with the national directives.

The material manufacturer must make sure that the coating materials are suitable for
gases in accordance with DVGW Worksheet G 260.

The GSK office is to be notified immediately if a manufacturer changes the composition of

certified coating materials.

III-2.2 Samples for material certification

Samples of the coating material to be certified (at least 2 kg for each colour) shall be
presented to the test institute, together with a valid technical data sheet listing the data as
well as the working instructions for the material to be tested. Regarding the expiry date,
samples are to be taken from closed containers.

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III-3 Test Specifications

The coating material samples are to be subjected to the following tests:

(1) Density in accordance with ISO 8130-3,

(2) Infrared spectrum,
(3) Determination of the loss in mass on heating as per ISO 8130-7, at 200 °C and a
hardening time of 20 minutes,
(4) Reactivity by measuring the gel time in keeping with ISO 8130-6,
(5) Particle size distribution in accordance with ISO 8130-1,
(6) Verification of the expiry date and the storage temperature, and
(7) Determination of the ash content at 625 °C + 20 °C in weight percent.

Additional tests for coatings to be used in conjunction with waste water include:

(8) Chemical stability at pH2 to pH13 in accordance with Appendix A5,

(9) Abrasion test in accordance with Appendix A6,
(10) Determining the glass transition temperature in keeping with ISO 11357-2 (“DSC
method“),
(11) Indentation depth in accordance with Appendix A7, and
(12) Resistance to thermal aging in an air atmosphere as per Appendix A8.

The test results must comply with meet the powder specification in accordance with the
manufacturer’s material data sheet.

In accordance with the above Paragraphs 1 to 9, all certified coating materials must be
tested every two years by the test institute in question.

(10), (11), and (12) are tested just once during the initial testing of the coating material.

III-4 Monitoring

III-4.1 Basic principles

For details regarding the monitoring procedures please see the basic description in
Paragraph 4 of the General Quality and Test Specifications.

III-4.2 Initial testing

When applying for a quality mark for the produced coating material, the coating
manufacturer is obliged to submit the respective formulations to the Quality Assurance
Association. The coating material is then subjected to initial testing.

The hygienic safety of the coating and its neutral reaction to the bacteriological tests are
to be substantiated by presenting a test certificate issued by an authorized institute in
accordance with the valid national directives.

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III-4.3 Internal monitoring

The quality mark holder is responsible for the continuous internal monitoring of the
manufacture of his quality-assured coating materials, as well as the associated tests, and
to record and document the pertinent test results in accordance with a QM system. These
reports are to be kept for at least 5 years and must be presented to the inspector in
charge of external monitoring.

III-4.4 External monitoring

Reports detailing the results of internal monitoring shall be presented to the inspector
during external monitoring.

External monitoring is to be performed in accordance with the requirements listed in

Paragraph III-3. Samples are to be taken at the quality mark holder’s company.

Valid hygienic safety certificates must be presented during external monitoring.

III-4.5 Repeat testing

If external monitoring reveals any deficiencies in the quality assurance of the quality mark
holder, corresponding action will be taken in accordance with Paragraph 4.4 of the
General Quality and Test Specifications.

III-5 Marking

The marking of coating materials is described in Paragraph 5 of the General Quality and
Test Specifications.

Coating materials are labeled in accordance with the German Ordinance on Hazardous
Substances (Gefahrstoffverordnung). In addition, this marking must also include at least
the manufacturer’s name, the product name, the processing parameters, the shipping
date, and the risk and safety statements ("R and S statements").

Once a year, the material manufacturer confirms the material properties by issuing a
declaration of conformity.

III-6 Alterations

Any alterations to these Special Quality and Test Specifications are subject to Paragraph
6 of the General Quality and Test Specifications.

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GPB March. 2009 24/34
 Appendices to the pertinent Special Quality and Test Specifications

Appendix A 1: Impact resistance

Testing of the impact resistance must be carried out 24 hours after coating or after
cooling to ambient temperature at the earliest.
During testing, the test specimen should be supported in such a way that the specimen
does not act as a spring when the drop weight impacts it.

The drop weight used consists of a holding device with a ball (25 mm diameter) made
from roller bearing steel on the impact side. The ball must have a Rockwell hardness in
the range 58-66 HRC.
As soon as the impact side of the ball is visibly flattened, it has to be turned to a different
position or replaced.
Self-machined ball surfaces are not allowed.

The impact energy, E, has to be set at 5 Nm (e.g. a drop height of 1 m and a drop weight
of 0.5 kg) with a measurement uncertainty of max. 5%. One should make sure that the
drop weight falls vertically onto the test surface. For this, it can be guided inside a tube
with low friction and without any influence of entrapped air to a distance of 10 cm above
the test surface.
Multiple impacting of the drop weight on the test specimen must be avoided.

• The impact test must be carried out at least three times (i.e. three impacts) on the
respective product.
• The minimum distance from all edges must not be less than 10 mm.
• The spacing between the individual impacts must not be less than 30 mm.
• Testing must not be carried out on surfaces that have been machined or are
markedly curved (radius less than 40 mm).
In the case of pronounced curvature, testing has to be carried out on a plate
specimen processed in parallel.

At least three different valves or fittings from each coating unit have to be tested
every working day and the results have to be recorded.

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Appendix A 2: Adhesion test

1 General notes regarding the adhesion test

A pull-off test is performed to measure the adhesion in accordance with EN ISO 4624.
This test may either be performed on valve parts or fittings obtained from ongoing
production batches or on test plates matching the GSK test specimens (see Appendix
A4). Actual product testing is to be preferred over test plates.

The test plates, in order to avoid contamination, should be handled only with clean, fiber-
free gloves or mittens.

1.1 Coating conditioning

Before testing, the test plates must be kept in deionized water for 7 days at 90°C. This

immersion, the plates are re-dried in an oven for 3 hours at (70 ± 5)°C. The subsequent
water bath immersion starts 1 to 7 days after applying the coating. After water batch

conditioning phase at normal climatic conditions lasts for 3 to 5 days.

No bubbles should be formed during water bath immersion.

1.2 Bonding of the test stamp

The surface of the test plates is degreased with propanol or MIBK and then roughened
with P60 grit sandpaper. The roughened surface is then dedusted with dry, deoiled
compressed air and is subsequently cleaned again with propanol or MIBK.

The test stamp is sandblasted, dedusted, and then degreased with propanol or MIBK.
Sandblasting should be performed immediately before bonding.

The adhesive (such as ARALDIT 2011, components AW 106/HV 953U) is to be

processed according to the manufacturer’s specifications.

While allowing for the bonding adhesive to cure, the punch and the test specimen should
be inserted into a suitable centralizer and exposed to a load in order to avoid adhesive
cracks (EN ISO 4624). The test stamp are to be glued alternately to the core side and the
molding sand side in order to be able to measure the adhesion on both sides.

The coating surface round the stamp should be cut with a core driller.

The adhesion should be measured using a tensile testing device with double-gimbal
suspension so as to avoid lateral forces. The tensile stress during this test must be at
least ≥ 12 N/mm².

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Appendix A 3: CD test

For each test specimen, a plastic pipe section with d = 75 mm and h = 100 mm is sealed
onto the coated surface using an electrically non-conducting adhesive, making sure to
effectively seal the joint. The pipe is filled with a sodium chloride solution at a
concentration of c(NaCI) = 0.5 mol/L. Before bonding, remove the coating in the middle of
the test plate with a face cutter so that there is a uncoated area with a diameter of 6 mm.
Cathodic polarization of the pipe is achieved with a potentiostat, setting a nominal voltage
of U0.1 AgCI = -1550 mV (corresponding to UH = -1260 mV, Ukalomel ges = -1500 mV).

A similar polarization effect may also be achieved by simply causing a short circuit with a
magnesium anode, provided that the voltage is approximately UH = -1200 mV.

This test lasts 30 days and is performed at a temperature of (23 ± 2) °C.

In order to determine the cathodic disbondment, make 6 radial cuts, starting from the
uncoated area and proceeding to the coating surface of the cast. An hour after the end of
the test, the coating is removed from the uncoated middle area with a blade.
In this context, the mean disbonded depth (= adhesion loss of the coating) is determined
from the edge of the uncoated area to the adherent coating.

The following limiting limits for the cathodic disbandment are valid:

Temperature Test duration Catodic disbondment

23 ± 2 °C 30 days ≤ 10 mm

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Appendix A 4: GSK test plate

The test plates described below may be used instead of valves and fittings whose shape
or size makes them ineligible for adhesion testing or cathodic disbonding tests.

The test plate has a size of 100 x 110 x 15 mm. The material, however, must be the same
as the valves and fittings to be coated. One of the flat faces is to be shaped with molding
sand, the other side with core sand.

The core sand side is to be labeled with the letter K (one corner).

The test plate – with the “core side” do facing inward - is clamped into a DN 150 T-piece.
The entire test specimen is then sandblasted in this position. Clean, fiber-free gloves or
mittens must be worn when removing the test plates.
The test plate only is used for coating.

For inquiries on where to obtain the test plates, please contact the GSK office.

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Appendix A 5: Chemical stability

Chemical stability is essential for waste water use. This is why this test is to be carried out
only with coatings that are targeted for use in conjunction with waste water.

Chemical stability is measured in accordance with EN 598, Paragraph 7.7, by immersing

the test specimens in sulfuric acid (pH 2) for 6 months and steeping them in sodium
hydroxide solution (pH 13) for 6 months at room temperature. The test specimen is
dipped immersed halfway in the test solution.

The immersion test is followed by an optical inspection for microblistering or bubble

formation.

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Appendix A 6: Abrasion test

This test is performed in accordance with EN 598, Paragraph 7.8.

350 µm. This pipe section or fitting is filled with test material - natural gravel with a mean grain size of 6 mm
The test is performed on a (1000 ± 10) mm long pipe section or fitting with a minimum layer thickness of

(grain size between 2 mm minimum and 10 mm maximum) - to a level of (38 ± 2) mm above the tube
bottom. The pipe section or fitting is then filled to the same level with water.

The pipe section is to be attached horizontally to a testing facility that can tilt the pipe section or fitting every
3 to 5 seconds in turns by an angle of plus 22,5° and minus 22,5° to the horizontal.

The pipe section or fitting is tested after 100 000 cycles. The abrasion depth is derived from 15

at the tube bottom. The mean layer thickness reduction by abrasion must not exceed 200 µm.
measurements all performed 50 mm over a distance of 700 mm, with the exception of 150 mm at each end,

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Appendix A 7: Protocol for the coating test

Test protocol for the coating test

Product name: Dimension: Article number:

Batch size Number of random Number of rejects:

samples:

Temperature control:
Oven Component Time Signature:
temperature temperature

Component layout with measuring points

Component test:
Sample Layer thickness [µm] Impact Non-porosity Cross-linking
number A B C D E resistance Inside/outside
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
5 Nm
≥ 250µm no No discoloration
No discharge
discharge

Inspector: Date: Released:

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Appendix A 8: Resistance to thermal aging in air

This test is to be performed on six steel planels coated with epoxy powder (with a size of
approximately 40 mm x 5 mm and 130 mm long), all of which were coated parallel to
each other during production.

In the next step the coated test planels are bent, making sure that the coating on the
outer bending curve shows a plastic elongation of 3 %. The test planels are then stored in
a hot air oven at (110 ± 2) °C.

After 30, 60 resp. 90 days, two test planels each are removed from the oven and tested
for non-porosity in accordance with II.-3.2.

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Appendix A 9: Indentation hardness

In conjunction with this test, the indentation depth; i.e., how far the punch penetrates into
the coating, is measured under precisely specified temperature and load conditions.

The test device consists of:

- A thermostat-controlled heating oven at (70 ± 2) °C,

- A penetrometer with a cylindrical punch showing a diameter of 1.8 mm (punch
surface 2.5 mm²), with a weight attached to its upper end. The punch and
weight assembly together must create a pressure of 10 MPa and
- A measuring instrument with a dial indicator or a different measuring system
with a precision of 1/100 mm.

Test method:

This test is performed on metal test plates with an epoxy powder coating of (250 ± 25) µm
heated to a temperature of 70 °C ± 2 °C. After one hour of preconditioning, the punch
without added weight is slowly and carefully lowered onto the test specimen. The zero
value is obtained within 5 seconds. In the next step, additional weight is added to create a
pressure of 10 MPa across the penetrometer; the punch is to be loaded slowly and
carefully. The penetration depth is measured after testing periods of 1 hour, 24 hours,
and 48 hours, respectively, with a precision of 1/100 mm.

The respective arithmetic mean for each testing period is derived from three penetration
depth measurements.

When using the described test method, it is to be noted that the indentation depth
obtained after 48 hours must not exceed 30 % of the originally measured coating
thickness. The increase of indentation depth, measured between 24 and 48 hours, must
be less than the increase measured between 0 and 24 hours and should never exceed 5
% of the originally measured indentation depth.

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Appendix B: Handling, transport, and storage

B.1 Handling
Coated fittings and accessories should be handled with great care so as to protect the
coating from damage. Steel cables, sling gears, or other devices that may damage the
coating should never be used without adequate protection.

B.2 Transport to the storage area

During transport to the storage area at the coating factory, the coating company should
make sure to do everything in their power to protect the valves and fittings as well as the
coating from being damaged.

B.3 Storage
Appropriate precautionary measures should be adopted during storage to make sure that
the coating is not in any way mechanically or optically affected (by chalking).

Loading fittings and accessories for delivery

When loading fittings and accessories at the coating factory, the coating company should
do everything in their power to protect the coating from possible damage.

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