Coil Rope Corrosion Protection: Test Regulations

1. ------IND- 2015 0711 D-- EN- ------ 20160106 --- --- PROJET
Federal Highway Research Institute
Technical terms of delivery and technical
test regulations for civil engineering
structures
TL/TP-ING
Part 4, Section 5
Technical test regulations for the external
corrosion protection of fully locked coil
ropes
TP KOR-VVS
Notified in accordance with Directive (EU) 2015/1535 of the European Parliament and of the Council of 9 September 2015 laying
down a procedure for the provision of information in the field of technical regulations and on rules on information society services
(OJ L 241 of 17 September 2015, p. 1)
15 July 2014
TP-KOR – VVS
Contents
1
Page
General remarks...................................... 3
5.3.7
Resistance to flow .................................. 12
5.3.8
Elastic recovery ...................................... 12
5.3.9
Resistance to ageing .............................. 12
2
Scope of application ............................... 3
5.4
Testing grouting substances .................. 12
3
Definitions ............................................... 3
5.4.1
Density .................................................... 12
4
Testing coating, sealing and grouting
substances .............................................. 3
5.4.2
Identity of the binder ............................... 12
5.4.3
Non-volatile matter content..................... 12
4.1
General remarks ....................................... 3
5.4.4
Ash content ............................................. 12
4.2
Requirements and testing procedures ...... 3
5.4.5
Shore hardness A ................................... 12
5
Test procedure ........................................ 3
5.4.6
Volume change ....................................... 12
5.1
General remarks ....................................... 3
5.4.7
Water absorption capacity ...................... 13
5.1.1
Steel surfaces ........................................... 3
5.4.8
Resistance to moisture ........................... 13
5.1.2
Galvanised surfaces ................................. 3
6
5.1.3
Application ................................................ 3
Standards and other technical
regulations ............................................ 13
5.2
Testing coating substances ...................... 7
5.2.1
Viscosity .................................................... 7
5.2.2
Density ...................................................... 7
5.2.3
Identity check on binding agent ................ 7
5.2.4
Determination of non-volatile matter
content ...................................................... 7
5.2.5
Determination of ash content .................... 8
5.2.6
Processing time (pot life) .......................... 8
5.2.7
Drying times .............................................. 8
5.2.8
Overcoating ............................................... 8
5.2.9
Tendency to flow ....................................... 8
5.2.10 Elasticity .................................................... 8
5.2.11 Elastic endurance ..................................... 8
5.2.12 Resistance to moisture ............................. 8
5.2.13 Resistance to salt spray fog ...................... 9
5.2.14 Resistance to chemicals ........................... 9
5.2.15 Short weathering ..................................... 10
5.2.16 Long-term resistance .............................. 10
5.2.17 Compatibility with rope filler .................... 10
5.2.18 Compatibility with sealants ..................... 10
5.3
Testing sealants ...................................... 11
5.3.1
Identity of the binding agent .................... 11
5.3.2
Non-volatile matter content ..................... 11
5.3.3
Ash content ............................................. 11
5.3.4
Shore hardness A ................................... 11
5.3.5
Volume change ....................................... 11
5.3.6
Water absorption capacity ...................... 11
2
Version 15 July 2014
TP KOR – VVS
4.2
1
General remarks
(1) The technical test regulations for the external
corrosion protection of fully locked coil ropes
(TP KOR-VVS) describe the requirements and test
procedures for the coating, sealing and grouting
materials used to protect fully locked coil ropes
from corrosion.
(2) Products from other EU Member States or
Turkey and goods originating from other Member
States of the European Economic Area which do
not comply with these regulations shall be treated
as comparable, including the tests and inspections
carried out in the country of manufacture, if the
required level of protection (safety, health and
serviceability) is achieved with such products on a
similarly permanent basis.
2
Scope of application
The TP KOR-VVS apply to the testing of
substances for the external corrosion protection of
fully locked coil bridge cables in accordance with
ZTV-ING Part 4 Section 5.
Tables 1 to 3 apply to the requirements and test
procedures applicable to the coating, sealing and
grouting substances.
5
Test procedure
5.1
General remarks
(1) Supplementary notes are provided below
concerning the listed test procedures; these must
be observed when performing the tests.
(2) The test panels are prepared at the test
institution. Depending on the agreement, the
preparation may also be done by a contractor of
the applicant under the supervision of the test
institution. DIN EN ISO 1514 must be followed
when cleaning the test panels.
(3) Unless specified otherwise, the panel thickness
should be 3 mm.
5.1.1
3
Definitions
The terms shall apply as defined in ZTV-ING
Part 4 Section 5.
4
Testing coating, sealing and
grouting substances
4.1
General remarks
Requirements and testing
procedures
Steel surfaces
The surface must be prepared by removing the
rust from the steel with the surface preparation
grade
Sa 2 ½
in
accordance
with
DIN EN ISO 12944-4, whereby the degree of
surface roughness of "medium (G)" in accordance
with DIN EN ISO 8503-1 must not be exceeded.
Any deviation in the preparation is to be arranged
individually.
5.1.2
Galvanised surfaces
(1) Samples are to be removed in accordance with
DIN EN ISO 15528 and prepared for further testing
in accordance with DIN EN ISO 1513.
Galvanising is performed as batch galvanising in
accordance with DIN EN ISO 1461. The surface
must be prepared by sweep blasting in accordance
with DIN EN ISO 12944-4.
(2) To enable samples to be taken during the basic
and repeat tests the manufacturer of the coating
sends the test samples to the test institution in an
original container which is suitable for handling.
5.1.3
(3) When taking samples for acceptance testing,
the quality officer of the coating manufacturer
removes the test specimen from the batch
concerned and sends it to the test institution. The
sampling record (date, sampler, sampling point,
batch number) drawn up by the quality officer on
his own responsibility must be part of the
consignment (3.2 Testing).
Version: 15 July 2014
Application
The corrosion protection system according to
information from the manufacturer must be applied
by the painting method. Unless specified differently
for the tests, the colour RAL 3031 is to be used as
the top coat.
3
TP KOR-VVS
Table 1: Specifications for coating substances and test procedures
Test title
No.
Requirements
1
Characteristic values in delivery state
1.1
Viscosity
DIN 53019
In accordance with 5.2.1
1.2
Density
DIN EN ISO 2811
In accordance with 5.2.2
1.3
Identity check on binding
agent
1.4
Determination of non-volatile
matter content
1.5
Determination of ash content
(residue on ignition)
No requirements; the characteristic values
DIN 51451, IR analysis
are determined during the basic test.
The test procedure must be stated.
DIN EN ISO 3251
In accordance with 5.2.4
In accordance with 5.2.5
2
Characteristic values in processing state
2.1
Processing time (pot time)
only in the case of
2K substances
GB substances  60 min
ZB substances  60 min
DB substances  60 min
DIN 16945
In accordance with 5.2.6
Standard
atmosphere 23/
50
+ 7°C / 85 %
rel. air humidity
DIN 53150 and DIN EN ISO 9117-3
Thickness of dry layer
(target layer thickness)
GB
Dryness
grade 1  4 h
Dryness
grade 6  36 h
Dryness
grade 1  6 h
Dryness
grade 6  168 h
DIN EN 23270
With standard atmosphere 23 °C, 50 % rel.
air humidity and with climate 7 °C, 85 % rel.
air humidity
ZB/
DB
Dryness
grade 1  8 h
Dryness
grade 6  48 h
Dryness
grade 1  16 h In accordance with 5.2.7
Dryness
grade 6  168 h
Drying times
2.3
Overcoating
Each coating substance must be suitable
for overcoating after a maximum of 16 h.
No blisters, craters or microfoam must occur.
The layers must not separate.
Tendency to flow
With a single application, it must be
possible to apply 1.5 times the envisaged
target thickness of the layer on a vertical
surface without producing runs.
2.4
In accordance with 5.2.3
DIN EN ISO 14680-2
2.2
4
Test procedure
Thickness of dry layer
(target layer thickness)
DIN EN 23270
At standard atmosphere 23 °C, 50 % rel.
humidity.
In accordance with 5.2.8
Application with a scraper blade
In accordance with 5.2.9
Version: 15 July 2014
TP KOR-VVS
Table 1: Continued
No.
Test title
3
Characteristic properties in dry film state
Test procedure
Elasticity
After bending around the 75 mm mandrel no
cracks must be visible in the coating system
based on normal vision.
DIN EN ISO 1519,
Mandrel bending test
In accordance with 5.2.10
Elastic endurance
No cracks in the coating
In accordance with 5.2.11
DIN EN ISO 4628-2 degree of blistering: 0(S0)
DIN EN ISO 6270-1
3.1
3.2
Requirements
3.3
Resistance to moisture
3.4
Resistance to salt spray
3.5
Resistance to chemicals
DIN EN ISO 4628-3 degree of rusting: Ri0
DIN EN ISO 4628-4 degree of cracking: 0(S0)
DIN EN ISO 4628-5 degree of flaking: 0(S0)
DIN EN ISO 16276-2 cross-cut test: KW ≤ 1
DIN EN ISO 4624 pull-off strength (24h):
≥ 2.5 MPa (no break in adhesion)
In accordance with 5.2.12
DIN EN ISO 4628-2 degree of blistering: 0(S0)
DIN EN ISO 9227, neutral salt spray
(NSS)
DIN EN ISO 4628-3 degree of rusting: Ri0
DIN EN ISO 4628-4 degree of cracking: 0(S0)
DIN EN ISO 4628-5 degree of flaking: 0(S0)
DIN EN ISO 16276-2 cross-cut test: KW ≤ 1
DIN EN ISO 4624 pull-off strength (24h):
≥ 2.5 MPa (no break in adhesion)
DIN EN ISO 4628-8 corrosion around a scribe:
≤ 3 mm
DIN EN ISO 4628-8 loss of adhesion around a
scribe: ≤ 3 mm
In accordance with 5.2.13
Mineral oil
No changes visible in accordance with
DIN EN ISO 4628
DIN EN ISO 4624 pull-off strength (24h):
DIN EN ISO 2812-1
≥ 2.5 MPa (no break in adhesion)
3.6
In accordance with 5.2.14
Short weathering
Colour change compared with non-weathered
sample:  Eab  3.5 for RAL 3031 and RAL 5015
DIN EN ISO 4628-4 degree of cracking: 0(S0)
DIN EN ISO 11 341
In accordance with 4.2.15
DIN EN ISO 4628-2 degree of blistering: 0(S0)
DIN EN ISO 4628-3 degree of rusting: Ri0
DIN EN ISO 4628-4 degree of cracking: 0(S0)
Outdoor exposure over 60 months
Long-term resistance
DIN EN ISO 4628-5 degree of flaking: 0(S0)
In accordance with 5.2.16
3.7
DIN EN ISO 16276-2 cross-cut test: KW ≤ 1
DIN EN ISO 4624 pull-off strength (24h):
≥ 2.5 MPa (no break in adhesion)
Colour change compared with non-weathered
sample:  Eab  3.5 for RAL 3031 and RAL 5015
3.8
Compatibility with rope filler
Comparison of test specimen with and without
rope filler.
No incompatibility visible (blistering, craters,
flooding)
DIN EN ISO 16276-2 cross-cut test: KW ≤ 1
DIN EN ISO 4624 pull-off strength (24h):
≥ 5 Mpa
3.9
Compatibility with sealants
Version: 15 July 2014
Comparison of test specimen with and without
sealant.
No incompatibility visible (blistering, craters,
flooding)
In accordance with 5.2.17
In accordance with 5.2.18
5
TP KOR-VVS
Table 2: Requirements for sealants and test procedures
No.
Names of
tests
Requirements
Test procedure
4
Characteristic values in delivery state
4.1
Identity check on
binding agents
Comparison between basic and repeat test.
DIN 51451, IR analysis,
(on cured coating)
In accordance with 5.3.1
4.2
Determination of non-volatile
matter content
Comparison between basic and repeat test.
DIN EN ISO 3251
In accordance with 5.3.2
4.3
Determination of ash content
(residue on ignition)
Comparison between basic and repeat test.
5
Characteristic values after curing
5.1
Shore hardness A
35 - 45
5.2
Volume change
Permissible volume change from initial
state:  5 %
DIN 52 451-1
5.3
Water absorption capacity
< 3 mg/cm² d as test duration increases the
absorption of water (mg/cm² d) must
decrease.
Water absorption after storage in water for
8 days
In accordance with 5.3.6
after 24 h at 5° C
sagging  1 mm
DIN EN ISO 7390
5.4
5.5
5.6
6
Resistance to ageing
In accordance with 5.3.3
DIN ISO 7619-1
In accordance with 5.3.4
In accordance with 5.3.5
after 24 h at 40 °C
sagging  3 mm
after 1 h storage in standard atmosphere,
testing in vertical position with U-section
20 x 10 mm
In accordance with 5.3.7
 70 %
(No change in sealant, no detachment from
contact surface)
DIN EN ISO 7389
(with altered test specimen, 4.16)
In accordance with 5.3.8
Change in tensile stress/
extension compared with unaged samples
 20 % (relative)
In accordance with DIN EN ISO 8340
Determination of tensile stress/
extension after alternating support
-25 °C/+50 °C per hour
Duration of test: 36 cycles.
In accordance with 5.3.9
Resistance to flow
Elastic recovery
DIN EN ISO 14680-2
Version: 15 July 2014
TP KOR-VVS
Table 3: Requirements for grouting substances and test procedures
No.
6
Test title
Requirements
Test procedure
Characteristics in delivery state
DIN EN ISO 2811
(to be determined for individual
components)
In accordance with 5.4.1
6.1
Density
6.2
Identity check on
binding agents
Comparison between basic and repeat test.
DIN 51451, IR analysis,
In accordance with 5.4.2
6.3
Determination of non-volatile
matter content
 98 mass-%
DIN EN ISO 3251
In accordance with 5.4.3
6.4
Determination of ash content
(residue on ignition)
 24 mass-%
DIN EN ISO 14680-2
In accordance with 5.4.4
7
Characteristic values after curing
7.1
Shore hardness A
after 14 d  70
7.2
Volume change
Permissible volume change from initial state:
4%
DIN 52 451
In accordance with 5.4.6
7.3
Water absorption capacity
< 3 mg/cm² d as test duration increases the
absorption of water (mg/cm² d) must
decrease.
Water absorption after immersion in water
for 8 days
In accordance with 5.4.7
Resistance to moisture
DIN EN ISO 4628-2 degree of blistering:
0(S0)
DIN EN ISO 6270-1
DIN EN ISO 4628-3 degree of rusting: Ri0
Duration of test: 720 h
DIN EN ISO 4628-4 degree of cracking: 0(S0)
DIN EN ISO 4628-5 degree of flaking: 0(S0)
DIN ISO 7619-1
In accordance with 5.4.5
7.4
DIN EN ISO 4624 pull-off strength (24h):
In accordance with 5.4.8
≥ 2.5 MPa (no break in adhesion)
5.2
Testing coating substances
5.2.1
Viscosity
The viscosity of individual components
determined in accordance with DIN 53229.
5.2.2
(2) IR spectra are to be absorbed from all the
coatings to be tested by the ATR method on the
cured film after a curing period of 7 d in a standard
atmosphere. The thickness of the film layer is to be
applied with relation to the application.
is
Density
The density of individual components is
determined in accordance with DIN EN ISO 2811.
5.2.3
Identity check on binding agent
(1) During the test, the main component of the
coating is diluted with a suitable solvent and the
pigments and filler materials are separated out by
centrifuge. Part of the centrifuged material is
carefully placed on a sodium-bromide platelet and
the solvent gently heated to evaporate it
completely. With the unpigmented component of
the hardener a capillary film forms between two
sodium-bromide discs without prior centrifuging.
Infrared spectra are absorbed with the binder or
hardener films obtained in this way.
Version: 15 July 2014
5.2.4
Determination of non-volatile matter
content
(1) The non-volatile matter content is determined in
accordance with DIN EN ISO 3251. For this
approx. 2 g (in the case of reaction resins of the
coating substance mixed from resin and hardener)
is weighed into a flat dish ( 75 mm) (weightin "E") and spread evenly over the entire surface.
(2) The coating initially cures under standard
atmospheric conditions 23/50 in accordance with
DIN EN 23270 for 24 h and is then placed in a
warming cabinet for 3 h at a temperature of
105 °C. The dish is then placed in a dessicator.
(3) After cooling to room temperature in the
dessicator, the residue is weighed (weight-out "A").
The volatile matter content (mass-%) is the
difference between the weight-in "E" and the
weight-out "A" and is referenced to the weightin "E".
7
TP KOR-VVS
5.2.5
Determination of ash content
(1) The ash content is determined in accordance
with DIN EN ISO 14680-2. This involves weighing
approx. 2 g (in the case of reaction resins of the
coating substance blended from resin and
hardener) into a porcelain crucible.
(2) The sample is reduced to ashes for 3 h at
800 °C in order to determine the ash content
(residue from ignition).
(3) After cooling to room temperature in the
dessicator, the residue is weighed (weight-out "A").
The ash content (mass-%) is the difference
between the weight-in "E" and the weight-out "A"
and is referenced to the weight-in "E".
5.2.6
Processing time (pot life)
(1) To determine the processing time, a test tube
of 20 mm  and 150 mm length is filled with the
coating material to a level of 40 mm ± 2 mm
5 minutes after mixing in the resin and hardener
and a glass rod (2 mm diameter) with thickened
base of about 6 mm diameter is placed into the
liquid resin-hardener mixture. The entire structure
stands in a thermostat which is set to room
temperature (23 °C). At certain intervals the glass
rod is lifted out of the coating substance. This is
performed until the test tube lifts with the
substance.
(2) The processing time (pot life) is the period
which elapses between the start of the experiment
(filling the test tube) and the lifting of the test tube.
5.2.7
Drying times
The test is carried out according to DIN 53150 and
DIN EN ISO 9117-3.
5.2.8
Overcoating
5.2.10 Elasticity
(1) The mandrel bending test in accordance with
DIN EN ISO 1519 is to be performed on a steel
sheet of dimensions 0.3 mm thick x 35 mm wide
and abraded by hand using abrasive paper of
120 grade and on galvanised sheet metal of
dimensions 0.5 mm thick x 35 mm wide in
accordance with DIN EN 10346 with the surface
prepared in accordance with 5.1.2.
(2) After preparing the test sheets, the coating
system is applied at 1.5 times the thickness of the
target coat. Thereafter drying is carried out for 10 d
in a standard atmosphere 23/50 in accordance
with DIN EN 23270 and with 30 d ageing at 80 °C.
After 1 h cooling at room temperature and 2 h
storage at -15 °C, the test is carried out in a
standard atmosphere 23/50 in accordance with
DIN EN 23270 after 10 min. conditioning.
5.2.11 Elastic endurance
(1) For this test three of the metal sheets with
oblique slots coated with the substances being
tested are interlinked in series and tensioned as a
continuous belt on two rollers each with a  of
250 mm (Kneifel test). The continuous belt runs
over the rollers driven by a motor. As the coated
belt runs round the rollers the coatings are
stretched whilst being returned to their original
tension-free state on the straight stretches
between the rollers.
(2) The passage of the continuous belt around
both sets of rollers and back to the starting point is
regarded as one cycle.
(3) If after 50 000 cycles at 5 °C or 3 500 cycles at
-15 °C there are no cracks in the coating, the test
is deemed to have been passed. Examining for
cracks takes place using a magnifying glass at
10 times magnification.
The test for overcoating should be performed in
the layer structure as prescribed. The top coat is to
be overcoated with top coat.
(4) If cracks are found, however, the test must be
extended to include the other three available metal
sheets. Of the total of six metal sheets to be tested
five must not show any cracks.
5.2.9
5.2.12 Resistance to moisture
Tendency to flow
The ready-to-use coating substance (mixed in the
case of 2K substances) is applied to a polished,
non-grit-blasted, horizontally supported test panel
with a scraper blade that is then vertically
positioned. It is assessed from which thickness of
layer sagging occurs (runs, curtains). The
characteristic value to be measured is the
thickness of the dry layer where these phenomena
do not yet occur. The measurement of layer
thickness in accordance with DIN EN ISO 2808 is
performed after reaching dryness level 6 in
accordance with DIN 53150.
8
5.2.12.1 Test specimen
(1) Ungalvanised steel sheets for system 1 and
batch-galvanised steel sheets for system 2 with the
dimensions 200 mm x 150 mm are used as the
substrate.
(2) Anti-corrosion coatings in accordance with
Tables 4 and 5 are to be applied.
Version 15 July 2014
TP KOR-VVS
Table 4: System 1
5.2.13 Resistance to salt spray fog
Number
Target
coating
thickness
Priming coat
2
50 µm
Intermediate coat
2
150 µm
Top coat
1
60 µm
Overall system
5
460 µm
5.2.13.1 Test specimen
Test specimens are to be used in accordance with
No. 5.2.13.1.
5.2.13.2 Stress
(1) Stress is applied through neutral salt spray
fog (NSS)
in
accordance
with
DIN EN ISO 9227 (NSS). The duration of the
stress is 1 440 h for system 1 and 2 160 h for
system 2.
(2) Before the start of the stress a scratch of
0.5 mm is applied to system 1 by milling.
Table 5: System 2
Number
Target
coating
thickness
Priming coat
1
50 µm
Intermediate coat
2
150 µm
Top coat
1
60 µm
Overall system
4
410 µm
(3) The samples are conditioned for 7 d in a
standard atmosphere 23/50.
(4) Three samples are to be used in each test.
(5) In accordance with ISO 12944-6 two of the
three samples must pass the test.
5.2.13.3 Testing
(1) As soon as the stress ceases, the degree of
blistering is determined in accordance with
DIN EN ISO 4628-2.
(2) After 24 h of conditioning in a standard
atmosphere
in
accordance
with
DIN EN 23270 (23/50) the samples are assessed
for the degree of rusting in accordance with
DIN EN ISO 4628-3, cracking in accordance with
DIN EN ISO 4628-4, flaking in accordance with
DIN EN ISO 4628-5,
cross-cut
values
in
accordance with DIN EN ISO 16276-2 and pull-off
strength in accordance with DIN EN ISO 4624. In
addition, after stressing system 1 with a salt spray
fog the average value of loss of adhesion and
corrosion around a scribe is determined in
accordance with DIN EN ISO 4628-8.
5.2.14 Resistance to chemicals
5.2.12.2 Stress
Stress is applied through continuous condensation
in accordance with DIN EN ISO 6270-1. The
duration of the stress is 720 h for system 1 and
1 440 h for system 2.
5.2.14.1 Test specimen
Test specimens are to be used in accordance with
No. 5.2.13.1.
5.2.14.2 Stress
5.2.12.3 Testing
(1) As soon as the stress ceases, the degree of
blistering is determined in accordance with
DIN EN ISO 4628-2.
(2) After 24 h of conditioning in a standard
atmosphere
in
accordance
with
DIN EN 23270 (23/50) the samples are assessed
for the degree of rusting in accordance with
DIN EN ISO 4628-3, cracking in accordance with
DIN EN ISO 4628-4, flaking in accordance with
DIN EN ISO 4628-5,
cross-cut
values
in
accordance with DIN EN ISO 16276-2 and pull-off
strength in accordance with DIN EN ISO 4624.
Version: 15 July 2014
(1) The samples are stored in the test liquid at
23 °C using the immersion method in accordance
with DIN EN ISO 2812-1. The duration of the test
is 168 h.
(2) The test liquids are petrol or mineral oil (e.g.
test petrol with 18 % aromatics content or 15 W 40
engine oil).
5.2.14.3 Testing
(1) After stressing, a visual assessment is made of
visible
changes
in
accordance
with
DIN EN ISO 4628.
9
TP KOR-VVS
(2) The pull-off strength is determined
accordance with DIN EN ISO 4624.
in
5.2.16.2 Stress
Stressing is applied through natural weathering in
accordance with DIN EN ISO 2810 in an urban or
industrial atmosphere. The duration of the
weathering is 60 months.
5.2.15 Short weathering
5.2.15.1 Test specimen
The coating substance in the colours RAL 3031
and RAL 5015 is applied with a dry layer thickness
of 100 µm to a slightly polished sheet of stainless
steel provided with a priming coat for galvanised
steel (sheet dimensions according to type of
weathering device). The samples are conditioned
for 7 d in a standard atmosphere 23/50.
5.2.15.2 Stress
The stress conditions in accordance
DIN EN ISO 11341 are as follows:
—
with
cycle A, synchronised with xenon-arc lamps,
5.2.16.3 Testing
(1) As soon as the stress ceases, the degree of
blistering is determined in accordance with
DIN EN ISO 4628-2.
(2) After 24 h of conditioning in a standard
atmosphere
in
accordance
with
DIN EN 23270 (23/50), the samples are assessed
for the degree of rusting in accordance with
DIN EN ISO 4628-3, cracking in accordance with
DIN EN ISO 4628-4, flaking in accordance with
DIN EN ISO 4628-5,
cross-cut
values
in
accordance with DIN EN ISO 16276-2 and pull-off
strength in accordance with DIN EN ISO 4624.
— irradiance 550 W/m² in a wave-length range
between 290 and 800 nm, of which 11 % is
between 290 and 400 nm,
5.2.17 Compatibility with rope filler
— black standard temperature (55 ± 2) °C and
5.2.17.1 Test specimen
— length of weathering 2 000 h.
Galvanised steel sheet (batch-galvanised in
accordance with DIN EN ISO 1461, dimensions
min. 150 x 100 mm, min. 3 mm thick) is degreased
and prepared by sweep blasting in accordance
with DIN EN ISO 12944-4. The rope filler is then
applied with, for example, the help of a spatula.
Surplus rope filler on the surface must be removed
as far as possible using the spatula. After a
storage period of 14 d in a standard atmosphere in
accordance with DIN EN 23270 (23/50) the panel
with rope filler is coated using the following coating
system:
5.2.15.3 Testing
(1) The colour difference between two samples is
to be measured spectro-photometrically in
accordance
with
DIN EN ISO 11664-4
and
DIN EN 5033-4 using the following measuring
parameters:
— illuminant D 65,
— measurement geometry diffuse/8°,
1 x 50 µm
priming coating (for galvanised
surfaces)
— 10° standard photometric observer.
1 x 150 µm
intermediate coat
(2) The colour difference (E*ab) is to be calculated
in accordance with DIN 11664-4.
1 x 60 µm
top coat
(3) The colour difference is to be determined
between the unweathered sample and the RAL
colour card (colour register RAL 840 HR) and
between weathered and unweathered samples.
5.2.17.2 Testing
— measurement
included and
with
specular
components
5.2.16 Long-term resistance
5.2.16.1 Test specimen
Test specimens are to be used in accordance with
No. 5.2.13.1.
After a curing period of 20 d under standard
atmospheric conditions in accordance with
DIN EN 23270 (23/50) the cross-cut test in
accordance with DIN EN ISO 16276-2 and the pulloff
strength
test
in
accordance
with
DIN EN ISO 4624 are performed.
5.2.18 Compatibility with sealants
5.2.18.1 Test specimen
(1) Galvanised steel sheets (batch-galvanised in
accordance with DIN EN ISO 1461, dimensions
min. 150 x 100 mm, thickness min. 3 mm) are
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degreased and prepared by sweep blasting in
accordance with DIN EN ISO 12944-4. The sealant
is applied in a thickness of 1 to 2 mm using a
spatula, for example, and conditioned for 14 d in a
standard atmosphere in accordance with
DIN EN 23270 (23/50).
(3) After cooling to room temperature in the
dessicator, the residue is weighed (weight-out "A").
The volatile matter content (mass-%) is the
difference between the weight-in "E" and the
weight-out "A" and is referenced to the weightin "E".
(2) Subsequently panels coated with sealant are
each provided with a single layer of the following
coatings:
5.3.3
— Sample 1: 1 x 50 µm
priming coat for
galvanised surfaces,
— Sample 2: 1 x 50 µm
steel,
priming coat for
— Sample 3: 1 x 150 µm
and
intermediate coat
— Sample 4: 1 x 60 µm
top coat.
(1) The ash content is determined in accordance
with DIN EN ISO 14680-2. This involves weighing
approx. 2 g (in the case of reaction resins of the
sealant blended from resin and hardener) into a
porcelain crucible.
(2) The sample is reduced to ashes for 3 h at
800 °C in order to determine the ash content
(residue from ignition).
5.3.4
5.2.18.2 Testing
There should be no incompatibility between the
coating and sealant, e.g. wrinkling, ripples etc.
Testing sealants
5.3.1
Identity of the binding agent
(1) During the test, the main component of the
sealant is diluted with a suitable solvent and the
pigments and filler materials are separated out by
centrifuge. Part of the centrifuged material is
carefully placed on a sodium-bromide platelet and
the solvent gently heated to evaporate it
completely. With the unpigmented hardener
component a capillary film forms between two
sodium-bromide
discs
without
previous
centrifuging. Infrared spectra are absorbed with the
binder or hardener films obtained in this way.
(2) IR spectra are to be absorbed for all the
sealants to be tested by the ATR method on the
cured film after a curing period of 7 d in standard
atmospheric conditions.
5.3.2
Non-volatile matter content
(1) The non-volatile matter content is determined in
accordance with DIN EN ISO 3251. For this
approx. 2 g (in the case of reaction resins of the
sealant mixed from resin and hardener) is weighed
into a flat dish (75 mm) (weight-in "E") and
spread evenly over the entire surface.
(2) The sealant cures initially under standard
atmospheric conditions 23/50 in accordance with
DIN EN 23270 for 24 h and is then placed in a
warming cabinet for 3 h at a temperature of
105 °C.
Version: 15 July 2014
Shore hardness A
The test is carried out in accordance with
DIN ISO 7619-1.
5.3.5
5.3
Ash content
Volume change
(1) The test is carried out in accordance with
DIN 52451-1.
(2) At least three samples are to be used in order
to determine the volume (liquid). For each sample
a plastic dish, e.g. a Petri dish of polystyrene with
dimensions of 51 mm x 15 mm, is filled with the
sealant mixture. The plastic dish must allow
complete, non-destructive removal of the cured
sealant. The mass of the sealant is found by
weighing it and the quotient of mass (liquid) and
density (liquid) equals volume (liquid) is calculated.
(3) After 7 d of curing, the test specimen is
removed from the plastic dish without destruction
or loss and its volume determined by weighing in
air and water (dipping and weighing method). The
dipping and weighing method involves fully
immersing a support device (consisting of wire, for
example) hanging from a thin plastic thread in
water and bringing it into equilibrium. Subsequently
the test specimen is placed on the support device
and the mass determined in the immersed state.
The volume (solid) is the difference between the
masses in air and water.
(4) From this the change in volume is determined:
ΔV =
5.3.6
volume (solid) - volume (liquid)
volume (liquid)
*100 [%]
Water absorption capacity
(1) To test for water absorption capacity three
aluminium dishes (minimum diameter 60 mm,
height 15 mm) are filled with sealant and the
surface skimmed smooth.
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(2) After curing for 14 d in a standard
atmosphere 23/50
in
accordance
with
DIN EN 23270, the water absorption is determined
daily in fully desalted water with a total test
duration of 8 d.
(3) The individual values for water absorption of
the sealant surface are stated in mg/cm² x d.
5.3.7
Resistance to flow
The test is performed in accordance with
DIN EN ISO 7390 after 1 h storage in a standard
atmosphere in a vertical position with a U-section
20 x 10 mm (method A).
pigments and filler materials are separated out by
centrifuge. Part of the centrifuged material is
carefully placed on a sodium-bromide platelet and
the solvent gently heated to evaporate it
completely. With the unpigmented hardener
component a capillary film forms without previous
centrifuging between two sodium-bromide discs.
Infrared spectra are absorbed with the binder or
hardener films obtained in this way.
(2) IR spectra are to be absorbed for all the
grouting substances to be tested by the
ATR method on the cured film after a curing period
of 7 d in standard atmospheric conditions.
5.4.3
5.3.8
Elastic recovery
The form, dimensions and manufacture of the
three test specimens must correspond to
DIN EN ISO 8340. The contact material consists of
a deflection-resistant steel sheet blasted in
accordance with Sa 2½. The pre-storage,
performance of the test and analysis take place in
accordance with DIN EN ISO 7389. The extension
value is 20 %, the duration of extension is 24 h and
the test is performed after 1 h relaxation.
5.3.9
Resistance to ageing
The form, dimensions and manufacture of the six
test
specimens
must
correspond
to
DIN EN ISO 8340. The contact material consists of
a deflection-resistant galvanised steel sheet with a
slightly roughened surface, e.g. through light
blasting. After a 14-day curing period in a standard
atmosphere 23/50
in
accordance
with
DIN EN 23270, three test specimens are stretched
by 2.4 mm (20 %). In the stretched state (by
means of inserting spacers), storage alternates for
1 h at - 25 °C and 1 h at 50 °C (= 1 cycle). A total
of 36 cycles is performed. After the alternating
storage, the test specimens are examined for
formation of cracks and flaking and are stressed
until fracture in a tensile testing machine.
Simultaneously the three unstressed comparison
test specimens are also subjected to similar tensile
stress until they fracture.
5.4
5.4.1
Testing grouting substances
Density
Non-volatile matter content
(1) The non-volatile matter content is determined in
accordance with DIN EN ISO 3251. For this
approx. 2 g (in the case of reaction resins of the
grouting substance mixed from resin and
hardener) is weighed into a flat dish (75 mm)
(weight-in "E") and spread evenly over the entire
surface.
(2) The grouting substance cures initially under
standard
atmospheric
conditions 23/50
in
accordance with DIN EN 23270 for 24 h and is
then placed in a warming cabinet for 3 h at a
temperature of 105 °C.
(3) After cooling to room temperature in the
dessicator, the residue is weighed (weight-out "A").
The volatile matter content (mass-%) is the
difference between the weight-in "E" and the
weight-out "A" and is referenced to the weightin "E".
5.4.4
Ash content
(1) The ash content is determined in accordance
with DIN EN ISO 14680-2. This involves weighing
approx. 2 g (in the case of reaction resins of the
grouting substance blended from resin and
hardener) into a porcelain crucible.
(2) The sample is reduced to ashes for 3 h at
800 °C in order to determine the ash content
(residue from ignition).
5.4.5
Shore hardness A
The test is carried out in accordance with
DIN ISO 7619-1.
The density of the grouting substance is tested on
individual components in accordance with
DIN EN ISO 2811.
5.4.6
5.4.2
(2) At least three samples are to be used in order
to determine the volume (liquid). For each sample
a plastic dish, e.g. a Petri dish of polystyrene with
dimensions of 51 mm x 15 mm, is filled with the
Identity of the binder
(1) During the test, the main component of the
grouting is diluted with a suitable solvent and the
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Volume change
(1) The test is carried out in accordance with
DIN 52451.
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grouting substance mixture. The plastic dish must
allow complete, non-destructive removal of the
cured grouting substance. The mass of the
grouting substance is found by weighing it and the
quotient of mass (liquid) and density (liquid) equals
volume (liquid) is calculated.
(3) After 7 d of curing, the test specimen is
removed from the plastic dish without destruction
or loss and its volume determined by weighing it in
air and water (dipping and weighing method). The
dipping and weighing method involves fully
immersing a support device (consisting of wire, for
example) hanging from a thin plastic thread in
water and bringing it into equilibrium. Subsequently
the test specimen is placed on the support device
and the mass determined in the immersed state.
The volume (solid) is the difference between the
masses in air and water.
(4) This then shows the change in volume
ΔV =
5.4.7
volume (solid) - volume (liquid)
volume (liquid)
*100 [%]
Water absorption capacity
(1) To test for water absorption capacity three
aluminium dishes (minimum diameter 60 mm,
height 15 mm) are filled with grouting substance
and the surface skimmed smooth.
(2) After curing for 14 d in a standard
atmosphere 23/50
in
accordance
with
DIN EN 23270, the water absorption is determined
daily in fully desalted water with a total test
duration of 8 d.
(3) The individual values for water absorption of
the grouting substance surface are stated in
mg/cm²/d.
5.4.8
Resistance to moisture
5.4.8.1 Test specimen
(1) The substrate used is blasted steel sheets with
a priming coat for steel of 2 x 50 µm thickness.
After conditioning, the grouting substance is
applied with a dry layer thickness of 500 to
550 µm.
(2) The samples are conditioned for 7 d in a
standard atmosphere 23/50.
5.4.8.2 Stress
Stress is applied through continuous condensation
in accordance with DIN EN ISO 6270-1. The
duration of the stress is 720 h.
5.4.8.3 Testing
(1) As soon as the stress ceases, the degree of
blistering is determined in accordance with
DIN EN ISO 4628-2.
(2) After 24 h of conditioning the samples in a
standard atmosphere in accordance with
DIN EN 23270 (23/50) the degree of rusting in
accordance with DIN EN ISO 4628-3, cracking in
accordance with DIN EN ISO 4628-4, flaking in
accordance with DIN EN ISO 4628-5 and pull-off
strength in accordance with DIN EN ISO 4624 are
assessed.
6
Standards and other
technical regulations
DIN EN ISO 1461: Hot-dip galvanised coatings on
fabricated iron and steel articles – Specifications
and test methods (ISO 1461:2009); German
version EN ISO 1461:2009
DIN EN ISO 1513: Paints and varnishes
Examination and preparation of test samples
(ISO 1513:2010);
German
version
EN ISO 1513:2010
DIN EN ISO 1514: Paints and varnishes
Standard panels for testing (ISO 1514:2004);
German version EN ISO 1514:2004
DIN EN ISO 1519: Paints and varnishes - Bend
test
(cylindrical
mandrel)
(ISO 1519:2011);
German version EN ISO 1519:2011
DIN EN ISO 2178: Non-magnetic coatings on
magnetic substrates - Measurement of coating
thickness - Magnetic method (ISO 2178:1982);
German version EN ISO 2178:1995
DIN EN ISO 2808: Paints and varnishes
Determination of film thickness (ISO 2808:2007);
German version EN ISO 2808:2007
DIN EN ISO 2811-1: Paints and varnishes Determination of density - Part 1: Pyknometer
method (ISO 2811-1:2011); German version
EN ISO 2811-1 2011
DIN EN ISO 2812-1: Paints and varnishes Determination of resistance to liquids - Part 1:
Immersion in liquids other than water (ISO 2812-1:
2007), German version EN ISO 2812-1: 2007
DIN EN ISO 3251: Paints, varnishes and plastics Determination of non-volatile matter content
(ISO 3251:2008);
German
version
EN ISO 3251: 2008
DIN EN ISO 4624: Paints and varnishes - Pull-off
test for adhesion (ISO 4624:2002); German
version EN ISO 4624:2003
DIN EN ISO 4628: Paints and varnishes Evaluation of degradation of coatings - Designation
Version: 15 July 2014
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TP KOR-VVS
of quantity and size of defects, and of intensity of
uniform changes in appearance
(ISO 11341: 2004);
EN ISO 11341: 2004
Part 1: General introduction
system (ISO 4628-1: 2003);
EN ISO 4628-1: 2003
DIN EN ISO 11664-4:
Colorimetry
Part 4: CIE 1976 L*a*b* Colour space (ISO 116644:2008); German version EN ISO 11664-4: 2011
Part 2: Assessment of
(ISO 4628-2:
2003);
EN ISO 4628-2: 2003
Part 3: Assessment of
(ISO 4628-3:
2003);
EN ISO 4628-3: 2003
and designation
German version
degree of
German
degree of
German
blistering
version
rusting
version
Part 4: Assessment of degree of cracking
(ISO 4628-4:2003); German version EN ISO 46284: 2003
Part 5: Assessment of degree of flaking (ISO 46285: 2003); German version EN ISO 4628-5: 2003
DIN EN ISO 6270-1:
Paints
and
varnishes:
Determination
of
resistance
to
humidity:
Continuous
condensation
(ISO 6270-1:1998);
German version EN ISO 6270-1: 2001
DIN EN ISO 7389: Building construction – Jointing
products - Determination of elastic recovery of
sealants (ISO 7389: 2002); German version
EN ISO 7389: 2003
DIN EN ISO 7390: Building construction – Jointing
products – Determination of resistance to flow of
sealants (ISO 7390: 2002) German version
EN ISO 7390: 2003
DIN ISO 7619-1:
Rubber,
vulcanised
or
thermoplastic - Determination of indentation
hardness - Part 1: Durometer method (Shore
hardness); (ISO 7619-1: 2010)
DIN EN ISO 8340:
Building
construction
–
Sealants – Determination of tensile properties at
maintained extension (ISO 8340: 2005); German
version EN ISO 8340: 2005
DIN EN ISO 8503-1:
Preparation
of
steel
substrates before application of paints and related
products - Surface roughness characteristics of
blast-cleaned
steel
substrates
Part 1:
Specifications and definitions for ISO surface
profile comparators for the assessment of abrasive
blast-cleaned
surfaces
(ISO 8503-1:2012);
German version EN ISO 8503-1:2012
DIN EN ISO 9227: Corrosion tests in artificial
atmospheres - Salt spray tests (ISO 9227:2012);
German version EN ISO 9227:2012
DIN EN 10346: Continuously hot-dip coated steel
flat products - Technical delivery conditions;
German version; EN 10346: 2009
DIN EN ISO 11341: Paints and varnishes -Artificial weathering and exposure to artificial
radiation; Exposure to filtered xenon-arc radiation
14
German
version
DIN EN ISO 12944: Corrosion protection of steel
structures by protective paint systems:
Part 2: Classification of environments (ISO 129442: 1998); German version EN ISO 12944-2: 1998
Part 4: Types of surface and surface preparation
(ISO 12944-4: 1998);
German
version
EN ISO 12944-4: 1998
Part 6: Laboratory performance test methods
(ISO 12944-6: 1998);
German
version
EN ISO 12944-6: 1998
DIN EN ISO 14680-2: Paints and varnishes Determination of pigment content - Part 2: Ashing
method (ISO 14680-2: 2000); German version
EN ISO 14680-2: 2006
DIN EN ISO 15528: Paints, varnishes and raw
materials for paints and varnishes - Sampling
(ISO 15528:2000);
German
version
EN ISO 15528:2000
DIN EN ISO 16276-2: Corrosion protection of steel
structures by protective paint systems Assessment of, and acceptance criteria for, the
adhesion/cohesion (fracture strength) of a coating Part 2: Cross-cut testing and X-cut testing
(ISO 16276-2:2007);
German
version
EN ISO 16276-2:2007
DIN 16945: Testing of resins, hardeners and
accelerators, and catalysed resins; 03.1989
DIN EN 23270: Paints, varnishes and their raw
materials; temperatures and humidities for
conditioning and testing (ISO 3270: 1984); German
version EN 23270: 1991
DIN 51451: Testing of petroleum products and
related
products;
Analysis
by
infrared
spectrometry; General working principles, 09.2004
DIN 52451-1: Testing of sealing in building
construction - Part 1: Determination of change in
mass and volume of self-levelling sealants,
01.2007
DIN 53122-1: Determination of the water vapour
transmission rate of plastic film, rubber sheeting,
paper, board and other sheet materials; Part 1 By
gravimetry, 08.2001
DIN 53150: Paints and varnishes - Drying tests
(Modified Bandow-wolff Test), 09.2002
DIN 53019-1: Viscosimetry - Measurement of
viscosities and flow curves by means of rotational
viscosimeters - Part 1: Principles and geometry of
measuring system
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DIN 53019-2: Viscosimetry - Determination of
viscosity and flow curves with rotational
viscosimeters - Part 2: Viscosimeter calibration and
determination of the uncertainty of measurement
DIN 53019-3: Viscosimetry – measurement of
viscosities and flow curves with rotation
viscosimeters – Part 3: Measurement errors and
corrections
DIN EN ISO 4618: Paints and varnishes - Terms
and definitions (ISO 4618:2006); three-language
version EN ISO 4618:2006
DIN 55945: Paints And Varnishes - Additional
terms and definitions to DIN EN ISO 4618,
03.2007
DIN EN ISO 9117-3: Paints and varnishes - Drying
tests - Part 3: Surface-drying test using ballotini
(ISO 9117-3:2010)
EN ISO 8394: Building construction - Sealants
DIN 53229: Paints, varnishes and similar coating
materials; Determination of viscosity at high shear
rates using rotational viscosimeters
DIN EN 5033-4: Colorimetry; Spectrophotometric
method
Version: 15 July 2014
15