Bonazinc Qualification Procedure
Bonazinc Qualification Procedure
In an effort to insure the proper application and performance of Bonazinc® coated steel products, PPG requires that all prospective coil coaters, desiring to apply Bonazinc® for commercial body panel application, conduct trials and receive approval from PPG. No coil coater will be allowed to supply Bonazinc® coated material to an OEM for testing or production application without demonstrating to PPG that they have met satisfactory application and performance requirements. The following procedure outlines those requirements for PPG’s approval.
1) The first step of the line qualification involves a meeting between PPG and the coil coater to discuss application procedures, equipment, paint requirements and related issues. A confidentiality agreement between the two companies must be signed prior to conducting any trials for qualification. The purpose of the confidentiality agreement is to guarantee that any information disclosed between parties, which may be of a confidential nature but necessary to properly and adequately conduct business, supply a quality product, and inspire communication, remains confidential.
2) As agreed by both parties, the coil coater begins by submitting 10 gallon wet samples from each of their cleaning and rinsing tanks for the targeted application line. Information on cleaner type, cleaner concentrations, cleaning and rinsing temperatures and immersion times for each cleaning stage while operating the line at desired application speeds is also required.
3) In our laboratory, we will set up cleaner tanks using cleaner baths at temperatures and concentrations identified by the coil coater. Metal samples (preferably from actual coils targeted for the qualification trial or at least from the same steel supplier) will then be cleaned by us within the dwell time parameters provided by the coil coater. We will then coat the panels with the desired coating according to specifications outlined in our product data sheets. Sufficient samples will be prepared to run the required tests outlined and to conduct corrosion and adhesion evaluations. If the test results prove satisfactory, we can proceed to the next phase of the qualification procedure.
Note: If the application tests and/ or corrosion tests, using the coil coater’s information and materials, fails to provide adequate performance, we will notify the coil coater and begin an investigation to develop cleaner concentrations and /or bath temperatures that achieve the desired performance. Once we have identified the requirements for proper performance, we will notify the coil coater of the conditions necessary to achieve this performance. Now we can proceed to the next phase and produce a small coil under the conditions identified by PPG.
4) We will donate the paint required to produce a small coil of metal coated with Bonazinc® coating for application approval. We require approximately 100 - 200 linear feet (depending on coil width) of coated material and 50 linear feet of bare metal (off decoil) after proper coating weights and physical performance are achieved. This material will be used to conduct a full evaluation of the Bonazinc® coated substrate. We will then conduct general paint adhesion and corrosion tests that include 100 cycles of GM9540 and 40 cycles of GM9511; 80 cycles J2334, welding evaluations; e-coat application and adhesion tests; as well as stone chip performance evaluations. After all the testing is complete, we will notify the coil coater of the results and render approval, in writing, where appropriate.
As outlined above, we feel this protocol is necessary to avoid the potential for poor performance in the field.
Once production begins, we require that the coater submit samples of every coil produced with PPG’s Bonazinc®, along with documentation of the application conditions. We will monitor the quality of the coated steel substrate to ensure that it meets all of the performance characteristics we expect.