MnDOT Powder Coating Qualification Testing Procedure

4/19/2018MnDOT Powder Coating Qualification TestingProcedureThe test procedures contained herein describe the process for submittal, testing, and evaluationof powder materials for use in MnDOT powder coating applications. Applied powder materialswhich meet or exceed the stated performance criteria will be eligible to be listed on the MnDOTApproved Products List (APL). Provide lab test results establishing that the powder coatingapplicator’s system for a particular Powder Product applied over Hot-dipped galvanized or abrasiveblasted steel, works as a system, as defined below:1. Send a submittal package to:Allen GallistelChemical Laboratory DirectorMnDOT Office of Materials1400 Gervais Ave.Maplewood, MN 55109651-366-5545allen.gallistel@state.mn.us2. Include the following in the submittal package: Completed New Products Application Form (attached);Powder Coating Applicator contact name, address, phone numberand email address;Letter identifying each individual powder coat trade name;Powder manufacturer’s recommended DFT for each powder used in the tested system;Hard copy lab tests proving compliance that the Powder Coating material(s) meet theindustry specification AAMA 2604 requirements;Product Data Sheets on all components;Safety Data Sheets (SDS);Certification from the powder manufacturer that products meet Minnesota Statute 115A.9651requirements for heavy metals;One pound of each component for Infrared Spectrum matching Federal Standard RAL K5Classic No. 7031 (blue gray), in semi-matt finish. Any un-approved change to systemformulation will result in removal from the Approved Products List. Infrared Scans will beused as references for Quality Assurance Testing for future awarded jobs;If galvanized, DFT documentation from the Galvanizer which demonstrate compliance tothis document;Completed test data per table in section 3e.Provide written documentation per ASTM D2244 stating the color meets the standard by aΔE 2, andCompleted MnDOT Office of Environmental Services Hazardous EvaluationProcess Documentation (attached).1 Page

4/19/20183. Performance TestingPerformance testing shall be performed by a laboratory that is acceptable to the Engineer. Allassociated testing will be at the expense of the submitter.a) Steel Panels: Supply the following: All systems: five – 6 in. x 6 in. x ¼ in. steel (MnDOT 3306 steel) testpanels [one control, two salt fog, two adhesion]; For all systems: two – 27/8 in. x 6 in. x ¼ in. steel (MnDOT 3306 steel)test panels for UV-Con testing. Permanently identify each panel by means acceptable to the MnDOT.b) For Duplex systems, Hot-dip Galvanize steel panels per MnDOT 3394 and 2402Special Provision for Ornamental Metal Railing – Powder Coating, Perform SSPC-SP6 blast cleaning prior to galvanizing; Use a MnDOT Approved Galvanizer on file ppliers.pdfc) Powder Coating Material: For testing purposes make the color of the final topcoat conform to FederalStandard RAL K5 Classic No. 7031 (blue gray), in semi-matt finish.Provide written documentation per ASTM D2244 stating the color meets thestandard by a ΔE 2 prior to testing the plates and ΔE 5 after UV-Contesting is completed.d) Application of Powder:This portion of the qualification process has the Powder Coating Applicator documentspecific criteria that powder coated components must conform to in order to meet thequality and intent of the finished product. Contact MnDOT Bridge Office StructuralMetals Unit prior to starting abrasive blasting of the test panels. Perform the SSPC-SP10 (powder only systems)/SSPC-SP16 (duplex systems)abrasive blast cleaning as applicable, and the powder coating application in thepresence of a Structural Metals Unit Inspector at the Powder Coating Facility.For each panel, document an average of 3 blast profile readings.Apply powder coat system according to manufacturer’s recommendation.Provide the minimum requirements and frequencies in the Quality Control Procedure as shown in thistable.Powder Coating Inspection RequirementsRequirementDate and timeCriteriaEach lot of workCompressed air testASTM D4285Final Dry Film Thickness(DFT)As submitted by Manufacturer (listedon the MnDOT APL)Frequency/ExtentEach lot of workDaily – When abrasive blasting or blowdown operations are occurringSSPC-PA 2Surface Preparation2 Page

4/19/2018Abrasive blast cleanDuplex System (prior to galv.)Duplex System (prior to powder)Powder Only System (prior topowder)Surface cleanliness (all systems)SSPC-SP 6SSPC-SP 16/ASTM D7803SSPC-SP 10Each component to be powder coatedEach component to be powder coatedEach component to be powder coatedSSPC-PA 1100% Visual examination prior to coatingPre-Bake for Outgassing (Duplex System)Surface cleanlinessSSPC-PA 1Pre-bake material temperatureBaking procedure100% Visual examination prior to coatingAdequate to prevent defects dueto outgassing during powderapplicationASTM D7803Each lot of workEach lot of workPrime / Intermediate CoatPowder product numberTrack for each lotSurface cleanliness inspectionSSPC-PA 1Oven temperatureManufacturer recommendationTemperature of component attime of coatingVerification of prime /intermediate coat coveragePowder product numberSurface cleanliness inspectionTop coat oven temperatureFinal cure temperature ofcomponentManufacturer recommendation100% Coverage of powderTop CoatTrack for each lotSSPC-PA 1Manufacturer recommendationManufacturer recommendationManufacturer recommendationCuring timeCoating evaluation / repairVisual InspectionCoating shall be smooth anduniform free of runs, drips, sags,pinholes, blisters, and otherdeleterious conditions. (Pinholedensity shall not be greater than5 pin holes per sq. ft. in any givenarea)Each batch of powderVisual examination prior to coating (within1 hr of coating)Each lot of workEach lot of work100% Visual InspectionEach batch of powderVisual examination prior to coatingEach lot of workEach lot of workEach lot of work100% Visual Inspection(without the aid ofmagnification)e) Performance Testing of Coated Test Panels:CriteriaTotal Film ThicknessVisual InspectionPinholesMnDOT Powder Coating Performance RequirementsStandardRequirementNew Panels (initial testing)MilsAs submitted by Manufacturer(listed on the MnDOT APL)MnDOT SpecificationCoating shall be smooth and uniform,free of runs, drips, sags, blisters, andother deleterious conditions.MnDOT SpecificationPinholes density shall not be greaterthan 5 pin holes per sq. ft. in any givenarea.3 Page

4/19/2018Pencil HardnessAdhesionColor / GlossUV-ConASTM 3363H-2HASTM D 4541- ApparatusReport adhesion valuesListed in Annex 1-5ASTM D 2244Color match to standard of ΔE 2.0ASTM D523 –Gloss – reportSpecular GlossAged Panels (post testing)- PhotosASTM D4587- Report change in color from standard (ΔE, 5.0 max)Cycle 4 (1500 hours)- Gloss – reportASTM B117 (2000 hours)Salt Spray(All systems)Blister Resistance ASTM D714- Photos- Rust Creep ASTM D 1654 Procedure A Method 1, 7- Blister size rating 7 with a frequency rating of Fewf) Notification:MnDOT will notify the Powder Coating Submitter of the approval status upon review ofsubmittal package.Upon meeting acceptance criteria, the submitted powder products will be placed onMnDOT’s Approved Products List www.dot.state.mn.us/products.Commentary:The phenomenon of pin holing in powders applied over hot dip galvanized surfaces hasbeen identified as a serious problem associated with coating integrity and aesthetics. The presenceof pinholes gives chlorides and other corrosives access to the zinc substrate with consequentproduction of bulky zinc corrosion products which leach out through powder coatings.Pinholes of concern are identified as small around 1 mm in diameter swelled blister likeareas that when bursting form a small hole through the entire thickness of the coating down to thehot-dipped galvanized layer. The formation of these pimply defects in the cured film isunacceptable and should be minimized or eliminated.Powder manufacturers, along with powder coaters, have combined to develop systems andtechnology that minimizes or eliminates pin holing.Control pin holing by: Pre-heating the work prior to applying powder, Use of degassing’ grades of powder that cure slower increasing flash off time,Cleaning surfaces prior to powder coating to eliminate hydrophobic organic contaminants that wouldattract moisture.4 Page

1/2015Revised 7/28/2005New Product ID #(For MnDOT Use Only)State of MinnesotaDepartment of TransportationNew Product Preliminary Information -----------------INSTRUCTIONS: Answer ALL questions. Where a question is not applicable enter "N/A".Attach additional sheet(s) as required with reference to item --------------------Date:1.Trade NameManufacturerPhone No. ()AddressYes2.4.5.NoState ZipPatent pendingPatent No.Local DistributorAddress3.CityPhone No. (CityRecommendedUse:State)ZipPrimaryDescribe product, material equipment or process:Describe any limitations or use restrictions:5 Page

1/20156.Material composition (attach laboratory test results, storage requirement, shelf life,Material Safety Data Sheet and disposal procedure):7.Outstanding feature or advantage claimed:8.Date introduced on market9.a. Total Estimated Cost Per Unit Material (including delivery). Alternate for what existing product?b. Total Estimated Cost Per Unit Furnished and Installed10.Does product meet requirements of any of the following specifications?(Give specific number.)AASHTOASTMFed. Spec.MnDOTOthers (state and attach specifications)11.Indicate whether this product has been evaluated by a national or regional productevaluation program? (Attach any results.)HITEC12.NTPEPOthers (specify)Cite use by other agencies and persons to be contacted concerning experience with use,including how many years used, and whether use has been experimental or routine (listnames, titles, mailing address and phones):6 Page

1/201513.Note here and attach any test results, reports, etc., from the organizations above:14.Is a documented quality control process available for this product?15.Who has been contacted within MnDOT about this product?Has this person been sent a copy of this form?16.Additional comments:Name and Title of person completing this form:Address, State, Zip:Date:Phone: ()Email Address:ManufacturerRepresentative7 Page