QUESTIONING THE OBVIOUS: THE WAY TO PERFECT PRODUCT FINISHING Malcolm Griffiths & Graham Armstrong

Many Surface Coatings Problems Occur Because: The Correct Specification Is Never Established No Testing Regime Has Been Put In Place Why the Obvious?

Involve: The End Specifier The Product Manufacturer The Coatings Applicator The Coatings Manufacturer A Multi Way Event

The Use of The Coated Component The Environment It Is To Be Used In A Sensible Testing Regime For: Type Testing Batch Testing The Ability For All Parties To Keep To Requirements Documentation/Record Keeping What To Consider?

1.)Vehicle Cabs 2.)Over-coating Pre-Coated Steel 3.)Architectural Acoustic Panels 4.)Aluminium Windows 5.)Playground Equipment Some Examples Of It Going Wrong!

TGIC Polyester Powder Coated Steel Cab Glazed Windows Set Into A Silicone Sealant No Compatibility Testing between Powder & Sealant (Type or Production) Vehicle Cabs

Change In Quality Of Powder to A TGIC Free Version (Environmental & Safety Issues) New Grade Powder Contained Surface Additives Change Effected with No Thought To Testing Result: No Adhesion Of Sealant To Powder Windows All Fell Out!!! Vehicle Cabs

Polyester Powder Applied Over Pre-Coated Steel Trade Coater Application No Built In Controls On Oven Oven Varying In Temperature Over-Coating Pre-Coated Steel

Result:Varying Adhesion Of Powder Coating To Pre-Coated Substrate Some Random Total Adhesion Loss Simple Regular Oven Testing (Data Logger) Would Have Eliminated Problems Over-Coating Pre-Coated Steel

Steel Wall Panels For Use in Prestigious University Foyer Design Featured Multi Hole Acoustic Effect Polyester Powder Coating The Chosen Finish Colour Selected From RAL Range Multiple Batches of Powder Coating Application Through One (Respected) Powder Trade Coater Architectural Acoustic Panels

Lack Of Correct Control Of Colour: At Powder Manufacturer At Applicator At Site Inspection Included A Lack Of Knowledge Of Colour Judgement Both Instrumentally & Visually Architectural Acoustic Panels

Result: Patchwork Quilt Effect on Built Wall Architectural Acoustic Panels

Acrylic Finish Black For Aluminium Mullion Window Sections Coating Applied At Trade Coater, But Pre- Treatment Applied At Another Coater No Durability Testing Over Aged Chromate Pre- Treatment (Including Variations In Dwell Time) Aluminium Windows

Result:Rapid Corrosion Of Aluminium Extrusions Under Acrylic Coating; Visible As White Spotting On Black Surface All Windows Required Stripping and Re- Coating: £250K COST Aluminium Windows

Manufacturers Of Heavy Duty Playground equipment (Council Use) Heavy Section Tubular Steel Construction Original Specification:Zinc Rich Powder Primer Polyester Powder Finish Playground Equipment

Cost Saving Generated Change To Primer: From:Zinc Rich (Proven Corrosion Performance) To:Standard Powder Primer No Performance Testing Completed Before Change Effected Playground Equipment

Result:Severe Corrosion Problems In Service Severely Reduced Life Cycle Of Equipment Zn Rich Std Playground Equipment

WHERE TESTING IS THE NORM Aerospace Industry

Pre-Treatments & Coatings Coated Components Documentation/Traceability Result: Minimal Component & Coating Failure Type & Batch Testing

Involve All Parties Agree Specifications and Testing Regimes (Prototype Phase & Production Phase) Document Process & Test Results Question The Obvious Result: PERFECT PRODUCT FINISHING Conclusions

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