【AS澳大利亚标准】AS NZS 4158-2017 A1 Thermal-bonded polymeric coatings on valves and fittings for water industry purposes.doc

【AS澳大利亚 标准 excel标准偏差excel标准偏差函数exl标准差函数国标检验抽样标准表免费下载红头文件格式标准下载 】AS NZS 4158-2017 A1 Thermal-bonded polymeric coatings on valves and fittings for water industry purposes.doc AS/NZS 4158:2003 (Incorporating Amendment No. 1) A S/NZS 4158:2003 ?Australian/New Zealand Standard Thermal-bonded polymeric coatings on valves and fittings for water industry purposes AS/NZS 4158:2003 This Joint Australian/New Zealand Standard was prepared by Joint Technical Committee WS-022, Valves for Water Supply Purposes. It was approved on behalf of the Council of Standards Australia on 3 January 2003 and on behalf of the Council of Standards New Zealand on 24 January 2003. This Standard was published on 5 March 2003. The following are represented on Committee WS-022: Australian Industry Group Australian Chamber of Commerce Australian Valve Manufacturers Association Business New Zealand Master Plumbers Australia New Zealand Metal Casting Industry Association New Zealand Water and Waste Association Society of Mechanical Engineers Australia Plastics Pipe Institute Association of Australia Water Industry Alliance Water Services Association of Australia Keeping Standards up-to-date Standards are living documents which reflect progress in science, technology and systems. To maintain their currency, all Standards are periodically reviewed, and new editions are published. Between editions, amendments may be issued. Standards may also be withdrawn. It is important that readers assure themselves they are using a current Standard, which should include any amendments which may have been published since the Standard was purchased. Detailed information about joint Australian/New Zealand Standards can be found by visiting the Standards Web Shop at www.standards.com.au or Standards New Zealand web site at www.standards.co.nz and looking up the relevant Standard in the on-line catalogue. Alternatively, both organizations publish an annual printed Catalogue with full details of all current Standards. For more frequent listings or notification of revisions, amendments and withdrawals, Standards Australia and Standards New Zealand offer a number of update options. For information about these services, users should contact their respective national Standards organization. We also welcome suggestions for improvement in our Standards, and especially encourage readers to notify us immediately of any apparent inaccuracies or ambiguities. Please address your comments to the Chief Executive of either Standards Australia or Standards New Zealand at the address shown on the back cover. This Standard was issued in draft form for comment as DR 02420. The,Standard,is,downloaded,from,www.bzfxw.com,Standard,Sharing, AS/NZS 4158:2003 (Incorporating Amendment No. 1) ?Australian/New Zealand Standard Thermal-bonded polymeric coatings on valves and fittings for water industry purposes Originated as AS/NZS 4158.1:1994. Previous edition 1996. Second edition 2003. Reissued incorporating Amendment No. 1 (September 2005). COPYRIGHT ? Standards Australia/Standards New Zealand All rights are reserved. No part of this work may be reproduced or copied in any form or by any means, electronic or mechanical, including photocopying, without the written permission of the publisher. Jointly published by Standards Australia, GPO Box 476, Sydney, NSW 2001 and Standards New Zealand, Private Bag 2439, Wellington 6020 ISBN 0 7337 5033 8 AS/NZS 4158:20032 PREFACE This Standard was prepared by the Joint Standards Australia/Standards New Zealand Committee WS-022, Valves For Water Supply Purposes, at the request of manufacturers and users of polymeric coatings for valves and fittings, to supersede AS/NZS 4158:1996. This Standard incorporates Amendment No. 1 (September 2005). The changes required by the Amendment are indicated in the text by a marginal bar and amendment number against the clause, note, table, figure or part thereof affected. The objective of this Standard is to provide requirements and performance tests for coating systems for valves and fittings used in supply systems including potable water, recycled water and wastewater systems, together with default compliance requirements for the use of manufacturers and certification bodies. Changes to the previous edition area as follows: (a) The previous edition of the Standard covered fusion-bonded epoxies and polyamides which were typically used at that time. This edition encompasses both thermoplastic and thermosetting coating materials (b) The limiting temperature for use has been changed to 50?C to be consistent with the hot water immersion test temperature, which was reduced to accommodate thermoplastic coatings. (c) Limits on water absorption have been tightened to reflect current coating material performance. (d) Continuity testing has been updated to a high voltage test suitable for the typical coating thicknesses and cast substrates used for valve bodies and fittings. (e) Improvements have been made to other type tests, process verification tests and the batch release tests. Batch release testing requirements have been placed on the coating material supplier. (f) Methods for demonstrating compliance with the Standard have been expanded and made mandatory. Polymeric coatings referred to in this edition of the Standard apply to both thermoplastic and thermosetting, factory-applied, thermal-bonded coatings used to prevent corrosion of the internal and external surfaces of metallic valves and fittings. The terms ‘normative’ and ‘informative’ have been used in this Standard to define the application of the appendix to which they apply. A ‘normative’ appendix is an integral part of a Standard, whereas an ‘informative’ appendix is only for information and guidance. The,Standard,is,downloaded,from,www.bzfxw.com,Standard,Sharing, AS/NZS 4158:2003 3 CONTENTS Page SECTION 1 SCOPE AND GENERAL 1.1 SCOPE ........................................................................................................................ 4 1.2 REFERENCED DOCUMENTS .................................................................................. 4 1.3 DEFINITIONS ............................................................................................................ 4 SECTION 2 REQUIREMENTS OF THE COATING SYSTEM 2.1 SCOPE OF SECTION ................................................................................................ 6 2.2 COATING SYSTEM SPECIFICATION ..................................................................... 6 2.3 TYPE TESTS ............................................................................................................. 6 2.4 COATING MATERIAL SUPPLY REQUIREMENTS ................................................ 7 2.5 EFFECT ON WATER QUALITY ............................................................................... 8 SECTION 3 REQUIREMENTS FOR FACTORY-APPLIED COATING 3.1 SCOPE OF SECTION ................................................................................................. 9 3.2 COATING SYSTEM MATERIALS............................................................................ 9 3.3 PROCESS VERIFICATION........................................................................................ 9 3.4 COATING APPLICATION AND BATCH RELEASE ............................................. 10 3.5 REWORK.................................................................................................................. 11 APPENDICES A PURCHASING GUIDELINES.................................................................................. 12 B MEANS FOR DEMONSTRATING COMPLIANCE WITH THIS STANDARD ..... 13 C REFERENCED DOCUMENTS ................................................................................ 17 D SPECIFICATION OF COATING SYSTEM ............................................................. 18 E PENETRATION RESISTANCE TEST ..................................................................... 20 AS/NZS 4158:20034 STANDARDS AUSTRALIA/STANDARDS NEW ZEALAND Australian/New Zealand Standard Thermal-bonded polymeric coatings on valves and fittings for water industry purposes S E C T I O N 1 S C O P E A N D G E N E R A L 1.1 SCOPE This Standard specifies the requirements for factory-applied thermal-bonded polymeric corrosion protective coatings (barrier coatings). For the purposes of this Standard, the term polymeric coating is intended to encompass both thermoplastic and thermosetting coating materials, which are used to coat both the internal and external surfaces of valves and fittings. This Standard covers the following service application areas: (a) Factory-applied coatings and associated coatings used for repair. (b) Ductile iron, grey cast iron, malleable iron, steel and copper alloy based substrates. (c) Valves, fittings and their components and associated equipment. (d) Contact with water, and wastewater up to 50?C. (e) Above and below ground exposure. NOTES: 1 Some coatings may not be suitable for all wastewaters. Compatibility should be checked with the manufacturer. 2 Guidelines on requirements to be specified by the purchaser are given in Appendix A. Means of demonstrating compliance with this Standard are given in Appendix B. 1.2 REFERENCED DOCUMENTS The documents referred to in this Standard are listed in Appendix C. 1.3 DEFINITIONS For the purpose of this Standard, the definitions given in AS/NZS 3500.0 and those below apply. 1.3.1 Coating A material, applied to a surface at a specified film thickness, that is intended to protect the surface from corrosive elements or conditions such as moisture, gases, and abrasion by windblown or waterborne particles. 1.3.2 Coated product A valve or fitting or part thereof that has a coating applied to it. 1.3.3 Coating defect A detectable weakness or discontinuity in a coating, which causes its ability to protect the substrate from corrosion to be suspect during the normal service life. COPYRIGHT The,Standard,is,downloaded,from,www.bzfxw.com,Standard,Sharing, 5AS/NZS 4158:2003 1.3.4 Continuity The quality of a coating determines its freedom from defects or holidays. 1.3.5 Holiday A discontinuity in the coating that exposes the substrate. COPYRIGHT AS/NZS 4158:20036 S E C T I O N 2 R E Q U I R E M E N T S O F T H E C O A T I N G S Y S T E M 2.1 SCOPE OF SECTION This Section specifies coating system type tests that have to be met prior to using the coating system on valves and fittings. It also includes coating specification and coating material supply requirements. 2.2 COATING SYSTEM SPECIFICATION The coating system shall be specified in accordance with Appendix D. 2.3 TYPE TESTS 2.3.1 General Coated test pieces, applied in accordance with the system specification (see Appendix D) shall meet the type test requirements specified in Clauses 2.3.1 to 2.3.10 (summarized in Table 2.1). These tests shall be undertaken on the coating system, in order to demonstrate the suitability of the coating for service. Hot water immersion and repair coating material testing shall be undertaken to qualify each nominated substrate material. The remaining tests shall be undertaken using either steel, cast iron or copper alloy as the substrate. Type testing shall be performed on samples with an average coating thickness within 100 µm of the specified minimum coating thickness. The tests shall be undertaken on flat plate of nominal size 200 × 150 × 6 to 10 mm, unless otherwise specified herein. 2.3.2 Hot water immersion Expose the test piece in accordance with AS 3862 at 50 ?2?C for 14 days. Test in accordance with AS 1580.408.2. The adhesion rating shall be less than or equal to one. 2.3.3 Water absorption When tested in accordance with AS 3862 for 100 days at 23 ?2?C, the amount of absorbed water shall be less than or equal to 4.0% by weight. The coating test pieces shall be approximately 100 × 100 × 0.5 mm thick. 2.3.4 Flexibility When tested in accordance with AS 3862 at 0?C, the coating shall not crack when strained at 1.0%, as calculated in the following equation: 100C Strain ε = % 2R + C where C = sample thickness (including coating) R = radius of mandrel 2.3.5 Impact resistance When tested in accordance with ASTM G14 at 23?C, the impact resistance shall be equal to or greater than 2.0 J. The test shall be conducted on pipe with an outside diameter of 110 to 125 mm and wall thickness from 5 to 7 mm, or on 6 mm thick flat plate. If cast plate is used, the side in contact with the anvil shall be machined flat prior to testing. COPYRIGHT The,Standard,is,downloaded,from,www.bzfxw.com,Standard,Sharing, 7AS/NZS 4158:2003 2.3.6 Penetration resistance When tested in accordance with Appendix E, the penetration shall be less than or equal to 10% of the specified minimum coating thickness. This test is not required for epoxy materials. 2.3.7 Abrasion resistance The abrasion resistance test shall be in accordance with ASTM D4060 with CS17 wheel, 1000 g load for 1000 cycles at 23 ?2?. The weight loss shall be less than or equal to 40 mg. 2.3.8 Cathodic disbondment The test shall be carried out either in accordance with AS/NZS 4352, using Test Cell A or A1 B, at 23 ?2?C for 28 days, or in accordance with BS 3900 Part F11at 23 ?2?C for 28 days. The average radial disbonded length shall be less than or equal to 15 mm. 2.3.9 Thermal stability 2.3.9.1 Thermosetting materials Three coated panels shall be prepared and tested in accordance with AS 3862, flexibility test, at 1% strain and at ambient temperature. The panels shall then be exposed in air at 100 ?2?C for 100 days. There shall be no holidays in the tension face of the coated samples after the exposure period when holiday tested to AS 3894.1 at 2400 V. 2.3.9.2 Thermoplastic materials Six films of coating shall be prepared by application onto silicone-release-coated, or Teflon-coated steel panels, or by application onto other suitable panels. The films shall be produced by coating application at the maximum allowable application temperature. The thickness of the films shall be in the range 250 to 500 µm. Three of the films shall be exposed in air at 100 ?2?C for 100 days. Either melt flow rate (to ISO 1133) or elongation at break (to AS 1145.3) shall be measured on the films both prior to and after exposure. The average of the three results on the exposed films shall not vary by more than 35% for melt flow rate, or 50% for elongation at break, from the average of the three results on the unexposed films. NOTE: The film may be removed from the substrate before or after exposure. 2.3.10 Ultraviolet radiation A1 The coating shall be tested in accordance with ASTM D2565, Type B, for 100 days. The coating preparation and test requirements shall be in accordance with Clauses 2.3.9.1 and 2.3.9.2. 2.3.11 Repair Coating Material The repair coating material shall be tested for adhesion to a metal substrate and water absorption, as follows: (a) The repair coating material shall be applied in accordance with Appendix D to a flat plate. After any required curing period, the repair shall be tested for adhesion in accordance with AS 1580.408.2. The adhesion rating shall be less than or equal to 2. (b) The repair coating material shall be tested in accordance with Clause 2.3.3 for water A1 absorption. The amount of water absorption shall be less than or equal to 5.0%. 2.4 COATING MATERIAL SUPPLY REQUIREMENTS The coating material shall be tested to demonstrate/ensure consistency. A certificate of compliance (from the coating material manufacturer), stating that the coating material meets the manufacturer’s required internal batch release testing (to demonstrate consistency) shall be deemed sufficient evidence of the suitability of the coating material. COPYRIGHT AS/NZS 4158:20038 These tests shall include tests for melting parameters (for thermoplastic materials), cure (for thermosetting materials), and particle size distribution. 2.5 EFFECT ON WATER QUALITY All coatings, including repair coatings used in applications where they are in contact with water intended for human consumption, shall comply with AS/NZS 4020. A scaling factor of 0.05 shall be applied. TABLE 2.1 SUMMARY OF TYPE TEST REQUIREMENTS Property Test Requirement Hot water immersion AS 3862/AS 1580.408.2 ? 1 Water absorption AS 3862 ? 4.0% Flexibility AS 3862 No crack @ 1.0% Impact resistance ASTM G14 ? 2.0 J Penetration resistance See Appendix E ? 10% Abrasion resistance ASTM D4060 ? 40 mg Cathodic disbondment AS/NZS 4352 or ? 15 mm A1 BS 3900, Part F11 Thermal stability AS 3862/ No cracks @ 1.0% / ISO 1133 or AS 1145.3 ? 35% or ? 50% change Ultraviolet radiation ASTM D2565/ No cracks @ 1.0% / ISO 1133 or AS 1145.3 ? 35% or ? 50% change Effect on water quality AS/NZS 4020 No effect when used to convey drinking water COPYRIGHT The,Standard,is,downloaded,from,www.bzfxw.com,Standard,Sharing, 9AS/NZS 4158:2003 S E C T I O N 3 R E Q U I R E M E N T S F O R F A C T O R Y - A P P L I E D C O A T I N G 3.1 SCOPE OF SECTION This Section specifies the process verification tests and batch release tests for thermal- bonded polymeric coatings applied in the factory. The process verification tests aim at ensuring that adequate surface preparation and coating application procedures are used in production coating application. 3.2 COATING SYSTEM MATERIALS All coating system types selected for use in production shall comply with the type test requirements detailed in Section 2 and shall be applied in accordance with the system specification (see Appendix D). 3.3 PROCESS VERIFICATION 3.3.1 General The coating applicator shall have in place documented production procedures for all stages of the process (see Appendix D). A batch of coated products, which has been processed in accordance with these production procedures, shall then be tested in accordance with and meet, the requirements of Clause 3.3.2. The production process shall then be considered to be verified. The tests shall be carried out for each substrate material, with the exception of the foaming and degree of cure tests, which need only be undertaken on one substrate material. For the purposes of these tests, the following substrate material classifications apply: (a) Cast iron (includes ductile, grey and malleable irons). (b) Steel (includes low alloy, i.e. less than 5% alloy content, mild and plain carbon steels). (c) Copper (includes its alloys). 3.3.2 Process verification tests 3.3.2.1 General Coated products or sections of products shall be used as samples for the tests of Clause 3.3.2.2 to 3.3.2.9. 3.3.2.2 Thickness When tested in accordance with AS 3894.3, the coating thickness on each of two coated products shall fall within the thickness limits specified for the system (see Appendix D). 3.3.2.3 Coating continuity Coatings applied to the internal wetted surfaces of products shall be continuity tested on each of two coated products, in accordance with AS 3894.1, but with a test voltage of 5V per µm of the specified minimum thickness of the coating system. Acceptance shall be in accordance with Table 3.3. Discontinuities at bolt holes, other external edges, hook holes and scuff marks shall not be considered as coating defects. COPYRIGHT AS/NZS 4158:20031 0 3.3.2.4 Foaming Where thermosetting coatings are applied, a coating section from each of two coated products shall be tested for foaming in accordance with AS 3862. The rating of each coating sample shall be equal to or less than four. 3.3.2.5 Adhesion Each of two coated products shall be tested for coating adhesion on one randomly selected site. The adhesion shall have a rating equal to or less than one when tested in accordance with AS 1580.408.2 at temperature of 10–30?C. 3.3.2.6 Degree of cure Where thermosetting coatings have been applied, two coated products shall be tested in accordance with AS 3862 for the degree of coating cure; ?Tg shall be equal to or less than 4?C and the degree of cure shall be equal to or greater than 95%. Each coated product shall be tested for coating cure at the points of maximum and minimum coating thickness. 3.3.2.7 Hot water immersion Expose two coated products (or two representative sections removed from a large fitting) in accordance with AS 3862 at 50 ?2?C for 14 days. The coated products/sections shall be tested in accordance with AS 1580.408.2. The adhesion rating shall be less than or equal to one. 3.3.2.8 Visual appearance Each coated sample shall be visually examined. The appearance shall be smooth and uniform in colour, and shall not exhibit any evidence of blistering or excessive sagging (which would result in jointing/assembly problems). TABLE 3.1 SUMMARY OF PROCESS VERIFICATION TEST REQUIREMENTS Property Test Requirement Thickness AS 3894.3 Thickness to be within the thickness limits specified for the system (see Appendix D). Continuity AS 3894.1 at 5V per µm of the specified minimum thickness of the As shown in Table 3.3 coating system. Foaming AS 3862 ?4 for thermosetting coatings only Adhesion AS 1580.408.2 ?1 Degree of cure AS 3862 ?Tg shall be equal to or less than 4?C, for thermosetting coatings only Hot water AS 3862/AS 1580.408.2 ?1 immersion Coating to be smooth and uniform in Visual appearance Visual colour, and not exhibit any evidence of blistering or excessive sagging 3.4 COATING APPLICATION AND BATCH RELEASE When process verification testing has been successfully completed (see Clause 3.3), production coating may commence. Coating shall be in accordance with Appendix D. Variations in the thickness of the coating shall be controlled to ensure that jointing, mating, assembly and other dimensional service requirements are achieved. COPYRIGHT The,Standard,is,downloaded,from,www.bzfxw.com,Standard,Sharing, AS/NZS 4158:20031 1 Batch release testing shall be undertaken in accordance with Table 3.2 and Table 3.3 for thermally bonded coatings. The cure test shall only apply to thermosetting coatings. Repaired coatings shall be tested for thickness and continuity in accordance with Table 3.2 and Table 3.3. 3.5 REWORK Where non-conforming coated products are to be reworked, this shall be done in accordance with the prequalified procedures and the coating system specification (see Appendix D). All re-coated products shall meet the requirements of this Standard. TABLE 3.2 BATCH RELEASE TEST REQUIREMENTS Test Test method Requirement Frequency All readings shall be within the minimum and Thickness AS 3894.3 Method B Each component maximum limits specified in the coating system specification (see Appendix D) Continuity AS 3894.1/Visual As shown in Table 3.3 Each component Adhesion AS 1580.408.2 ?1 Twice per shift Cure AS 3894.4 Method C: Pass (for thermosetting coatings) Twice per shift MEK rub test TABLE 3.3 ACCEPTANCE LIMITS FOR CONTINUITY TESTING/VISUAL INSPECTION Region End result Repair limitations Test requirements 2Internal wetted No Maximum holiday area 25 mmAS 3894.1 at 5V per micrometre surface holidays per holiday, with a maximum of of the specified minimum thickness of the coating system. 3 repairs per coated product or 23 repairs per 100 000 mm of coated surface which ever is the greater. 2Extenral No visual Visual Maximum holiday area 1000 mm surface defects per holiday, with a maximum of 6 repairs per coated product or 26 repairs per 100 000 mm of coated surface which ever is the greater. COPYRIGHT AS/NZS 4158:20031 2 APPENDIX A PURCHASING GUIDELINES (Informative) A1 GENERAL Australian/New Zealand Standards are intended to include the technical provisions necessary for the supply of materials referred to in the particular Standard, but do not purport to comprise all the necessary provisions of a contract. In a number of cases, the purchaser is asked to state the requirements or is given a choice of optional requirements. These are contractual matters to be agreed upon between the purchaser and the coating applicator or supplier. This Appendix contains detailed explanations, advice, and recommendations on the information to be supplied by the purchaser at the time of enquiry and order. Its aims are to avoid misunderstandings and to result in the purchaser receiving satisfactory products and services. A2 INFORMATION TO BE SUPPLIED BY THE PURCHASER The purchaser should consider and supply information on the following at the time of enquiry and order, or agree with the coating applicator, as appropriate: (a) Details of the products to be coated. (b) Details of the type of environment the coated item will be exposed to, particularly for wastewaters. Some coatings may not be suitable for all wastewaters. (c) Coating thickness, if different from that specified in Appendix D. (d) Details of any areas not to be coated or where a specific maximum thickness may apply. (e) Whether a certificate of compliance is required. A3 INFORMATION TO BE SUPPLIED BY THE SUPPLIER Upon request the supplier should supply details of the coating system. COPYRIGHT The,Standard,is,downloaded,from,www.bzfxw.com,Standard,Sharing, AS/NZS 4158:20031 3 APPENDIX B MEANS FOR DEMONSTRATING COMPLIANCE WITH THIS STANDARD (Normative) B1 SCOPE This Appendix sets out two means by which compliance with this Standard shall be demonstrated by a manufacturer. (a) The use of a product certification scheme. (b) The use of a minimum sampling and testing frequency plan. B2 RELEVANCE The long-term performance of pipeline systems is critical to the operating efficiency of water agencies in terms of operating licences and customer contracts. The long-term performance of plumbing systems is similarly critical to the durability of building infrastructure, protection of public health and safety and protection of the environment. B3 DEFINITIONS B3.1 Acceptable quality level (AQL) When a continuous series of lots or batches is considered, the acceptable quality level which for the purpose of sampling inspection is the limit of a satisfactory process average (see ISO 2859-1 and ISO 3951) NOTE: The designation of an AQL does not imply that a manufacturer has the right knowingly to supply any non-conforming unit of product. B3.2 Batch release test (BRT) A test performed on a batch of coated valves or fittings, which has to be satisfactorily completed before the batch can be released. B3.3 Inspection level The relationship between the lot or batch size and the sample size (see ISO 2859-1). B3.4 Lot A clearly identifiable subdivision of a batch for inspection purposes. B3.5 Production batch A clearly identifiable collection of units, manufactured consecutively or continuously under the same conditions, to the same specification. B3.6 Process verification test (PVT) A test performed on a sample at specific intervals, to confirm that the coating process is capable of conformity to the requirements of the Standard. NOTE: Such tests are not required to release batches of components and are carried out as a measure of process control. B3.7 Sample One or more units of product drawn from a batch or lot, selected at random with regard to quality. NOTE: The number of units of product in the sample is the sample size. COPYRIGHT AS/NZS 4158:20031 4 B3.8 Sampling plan A specific plan that gives the number of samples and the frequency of inspection or testing. B3.9 Type test (TT) A test performed on a sample to confirm that a new formulation conforms to the requirements of the relevant Standard before any batches can be released. B3.10 New formulation A new formulation is defined as any change in coating type, any change in manufacturing location of the coating material, and any major change in the formulation of the coating material. A major change in the formulation is defined in terms of the three important ingredients in the coating, i.e., resin; pigments or fillers; and other additives to aid in dispersion, longevity and coating application. All changes in resin type and source are considered to be a major change. A change in pigment/filler source is not a major change. A change in pigment/filler concentration in excess of 3.0% is considered to be a major change. All changes to other additives are not considered to be a major change, with the exception of significant changes to additives required for the coating to meet the thermal stability and ultraviolet radiation requirements of this Standard. FCATON B4 PRODUCT CERTIII The purpose of product certification is to provide independent assurance of the claim by the manufacturer that products comply with this Standard. The certification scheme shall meet the criteria described in SAI HB18.28/SANZ HB 18.28 (ISO/IEC Guide 28) in that, as well as full type testing from independently sampled production and subsequent verification of conformance, it requires the manufacturer to maintain effective planning to control production. The certification scheme serves to indicate that the products consistently conform to the requirements of this Standard. Product certification shall be conducted by a certification body accredited by the Joint Accreditation System for Australia and New Zealand (JAS-ANZ) or by another certification body that is acceptable to JAS-ANZ. The frequency of the sampling and testing plan as detailed in Paragraph B5 shall be used by the certifying body for product compliance auditing. However, where the manufacturer can demonstrate adequate process control to the certifying body, the frequency of sampling and testing nominated in the manufacturer’s quality plan and/or documented procedures shall take precedence for the purpose of product certification. B5 MINIMUM SAMPLING AND TESTING FREQUENCY PLAN B5.1 General Table B1 sets out the minimum sampling and testing frequency plan for a manufacturer to demonstrate compliance of product(s) to this Standard. B5.2 Retesting In the event of a test failure, the products manufactured since the previous test(s) conforming to the requirements outlined in Table B1 shall be quarantined as a batch. A further set of samples shall be selected randomly from the quarantined batch using a sampling plan to AS 1199 for an acceptable quality level (AQL) of 2.5 and an inspection COPYRIGHT The,Standard,is,downloaded,from,www.bzfxw.com,Standard,Sharing, AS/NZS 4158:20031 5 level of S3, unless otherwise specified. If the retest requirements are met, the batch may be released and compliance with this Standard for the quarantined batch may be claimed. Should a failure occur on retesting, then the quarantined batch shall be rejected and claims and/or marking indicating compliance to this Standard shall be suspended until the cause of the failure has been identified and corrected. B5.3 Rejection after est ret In the event of a quarantined batch being rejected after retesting in accordance with the procedures set out in Paragraph B5.2, it may be subjected to 100% testing for the failed requirement(s), and only those items found to comply may be claimed and/or marked as complying with this Standard. B6 TEST REQUIREMENTS Testing shall be undertaken at a frequency not less than that specified in Table B1. However, for batch release testing, where process control has been demonstrated to a product certifying body, the frequency of testing specified by the coating applicator shall apply. COPYRIGHT AS/NZS 4158:20031 6 TABLE B1 MINIMUM SAMPLING AND TESTING FREQUENCY PLAN Characteristics Clause Test Test Method Frequency TYPE TEST (TT) Performance 2.3.2 Hot water immersion AS 3862/AS 1580.408.2 2.3.3 Water absorption AS 3862 2.3.4 Flexibility AS 3862 2.3.5 Impact resistance ASTM G14 2.3.6 Penetration resistance Appendix E 2.3.7 Abrasion resistance ASTM D4060 AS/NZS 4352 or A12.3.8 Cathodic disbondment BS 3900, Part F11 At any new formulation, or at a 2.3.9 Thermal stability AS 3862/ISO 1133 or change of supplier or once every AS 1145 5 years, whichever occurs first ASTM D2565/AS 3862/ 2.3.10 Ultraviolet radiation ISO 1133 2.3.11 Adhesion to substrate AS 1580.408.2 Adhesion to coating AS 1580.408.2 Water absorption AS 3862 2.5 Water contact AS/NZS 4020 PROCESS VERIFICATION TESTS (PVT) 3.3.2.2 Thickness AS 3894.3 3.3.2.3 Continuity AS 3894.1 3.3.2.4 Foaming AS 3862 (thermosetting materials only) At any new formulation or at a Performance change of supplier or once every 3.3.2.5 Adhesion AS 1580.408.2 2 years, whichever occurs first Degree of cure 3.3.2.6 AS 3862 (thermosetting materials only) 3.3.2.7 Hot water immersion AS 3862/AS 1580.408.2 3.3.2.8 Appearance Visual BATCH RELEASE TEST (BRT) Thickness AS 3894.3 Method B Each component Continuity AS 3894.1/Visual Performance Table 3.2 Adhesion AS 1580.408.2 Twice per shift Cure (thermosetting AS 3894.4 Method C materials only) COPYRIGHT The,Standard,is,downloaded,from,www.bzfxw.com,Standard,Sharing, AS/NZS 4158:20031 7 APPENDIX C REFERENCED DOCUMENTS (Normative) AS 1145 Determination of tensile properties of plastics materials 1145.3 Part 3: Test conditions for films and sheets 1199 Sampling procedures and tables for inspection by attributes 1580 Paints and related materials—Methods of test 1580.408.2 Method 408.2: Adhesion—Knife test 3862 External fusion-bonded epoxy coating for steel pipes 3894 Site testing of protective coatings 3894.1 Method 1: Non-conductive coatings—Continuity testing—High voltage (brush) method 3894.3 Method 3: Determination of dry film thickness 3894.4 Method 4: Assessment of degree of cure AS/NZS 3500 National Plumbing and Drainage Code 3500.0 Part 0: Glossary of terms 4020 Products for use in contact with drinking water 4352 Tests for coating resistance to cathodic disbonding ISO 1133 Plastics—determination of the melt mass-flow rate (MFR) and the melt- volume flow rate (MVR) of thermoplastics 2859 Sampling procedures for inspection by attributes 2859-1 Part 1: Sampling schemes indexed by acceptance quality limit (AQL) for lot-by-lot inspection 3951 Sampling procedures and charts for inspection by variables for percent non- conforming SAI/SANZ HB18 Guidelines for third-party certification and accreditation HB18.28 Guide 28—General rules for model third-party certification schemes for products ASTM D2565 Practice for operating xenon arc-type light exposure apparatus with and without water for exposure of plastics D4060 Test method for abrasion resistance of organic coatings by the taber abraser G14 Test method for impact resistance of pipeline coatings (Falling weight test) BS 3900 Part F11: Methods of test for paint. Durability tests on paint films.A1 Determination of resistance to cathodic disbonding of coatings for use on land-based buried structures COPYRIGHT AS/NZS 4158:20031 8 APPENDIX D SPECIFICATION OF COATING SYSTEM (Normative) D1 SCOPE This Appendix sets out requirements for the specification of the coating system, and the application procedures that are to be recorded. D2 COATING SYSTEM TYPE The product names for all the coating system components shall be listed together with a description of the generic material type and recommended, shelf life. These components shall include, but are not limited to the following: (a) Materials used in surface preparation. (b) Surface cleaning agents / techniques. (c) Phosphate, and similar surface preparation chemicals. (d) Primers. (e) Intermediate coats. (f) Final coat. (g) Repair materials. D3 THICKNESS The minimum and maximum thicknesses for each coating layer, as well as the complete coating system, shall be specified. In no case shall the specified minimum coating thicknesses be less than those specified in Table D1. Systems that specify minimum thicknesses less than those specified in Table D1 are not covered by this Standard. TABLE D1 SPECIFIED MINIMUM COATING THICKNESSES (µm) Coating type Internal surface External surface (in contact with water) Thermoplastic 250 200 Thermoset 350 300 NOTE: A coating manufacturer may specify higher minimum coating thicknesses than those shown in Table D1. D4 SUBSTRATE MATERIAL The substrate materials for which the coating system and procedures have been developed shall be defined. D5 PREPARATION PROCEDURE BY APPLICATOR Where the component requires preparation prior to pretreatment (e.g., fettling of castings, removal of surface scale or corrosion product, or removal of surface contamination) the level of preparation required shall be specified. COPYRIGHT The,Standard,is,downloaded,from,www.bzfxw.com,Standard,Sharing, AS/NZS 4158:20031 9 D6 SUBSTRATE PRETREATMENT PROCEDURE The pretreatment procedure shall include details of the following requirements, which shall take place prior to the application of primers, intermediate layers or coating materials: (a) Surface cleanliness. (b) Surface roughness. (c) Removal of dust, slivers and grit. (d) Type of finish. (e) Class of finish. (f) Maximum time between surface preparation and coating. (g) Any other surface pretreatment, e.g., phosphating. D7 APPLICATION PROCEDURES The critical parameters of the coating system application procedures shall be detailed together with general manufacturing tolerances of coated products. Coating temperatures, including those for the item and the coating material, application times, e.g. dip times, post- heating and curing requirements, and other specified procedures, shall be detailed. D8 COATING REPAIR PROCEDURE The repair procedure shall be detailed. The repair coating thickness shall be equal to or greater than that specified in Table D1. D9 STRIPPING PROCEDURE A procedure for stripping a nonconforming coating from a salvageable component shall be specified. This procedure shall not significantly alter the metallurgical and functional condition of the workpiece. D10 TOXICITY AND HANDLING Any toxic hazard associated with coating materials submitted shall be declared, together with recommendations for safe handling in accordance with the requirements of health and safety regulations. COPYRIGHT AS/NZS 4158:20032 0 APPENDIX E PENETRATION RESISTANCE TEST (Normative) E1 SCOPE This Appendix sets out the method for determination of the penetration resistance. E2 PRINCIPLE A circular flat-footed indentor imparts to the coating a 10 MPa compressive stress. The amount of deformation is a measure of the resistance to penetration. E3 APPARATUS The following apparatus is required: (a) A metal rod weighing approximately 250 ?25g (the indentor) with an additional weight. The total weight of the indentor plus the additional weight shall be 2595 ?25 g. At the bottom end of the rod, a metal pin with a flat end face of 21.8 ?0.02 mm diameter (2.54 mm indentor surface) is arranged centrally. (b) A penetrometer with an accuracy of 0.01 mm. E4 PROCEDURE The procedure shall be as follows: (c) The test is performed at a temperature of 23 ?2?C, if necessary, with the aid of a water bath. (d) After 1 h for temperature equalization, the indentor without the additional weight is slowly and carefully placed on the sample, and the zero value is determined within the next 5 s. (e) The additional weight is then placed on the indentor and, after a period of 24 h under load, the penetration depth is read from the graduated penetrometer scale, to the nearest 0.01 mm. Penetration (mm) The percentage penetration(%) = ×100 Specified minimum coating thickness (mm) E5 TEST REPORT The following shall be reported: (a) The percentage penetration. (b) Reference to this test method, i.e., Appendix E of AS/NZS 4158. COPYRIGHT The,Standard,is,downloaded,from,www.bzfxw.com,Standard,Sharing, 21AS/NZS 4158:2003 AMENDMENT CONTROL SHEET AS/NZS 4158:2003 Amendment No. 1 (2005) REVISED TEXT SUMMARY: This Amendment applies to Clauses 2.3.8, 2.3.10, 2.3.11, Tables 2.1, and Appendices B and C. Published on 30 September 2005. AS/NZS 4158:200322 NOTES The,Standard,is,downloaded,from,www.bzfxw.com,Standard,Sharing, 23AS/NZS 4158:2003 NOTES AS/NZS 4158:200324 NOTES The,Standard,is,downloaded,from,www.bzfxw.com,Standard,Sharing, Standards Australia Standards Australia is an independent company, limited by guarantee, which prepares and publishes most of the voluntary technical and commercial standards used in Australia. 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