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: Eab 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: Eab 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 10 Version 15 July 2014 TP KOR-VVS 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. 11 TP KOR-VVS (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 12 Volume change (1) The test is carried out in accordance with DIN 52451. Version 15 July 2014 TP KOR-VVS 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 13 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 Version 15 July 2014 TP KOR-VVS 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
