Paint Specification - Stellar Industries

QC08.04 Paint Acceptance REV F

Paint Specification

Overview • This acceptance criteria covers all manufactured or purchased components or

assemblies that require finish paint. • Finish paint will be defined as a wet or powder coat process. Powder coat finish

paint is required for all components with the structural integrity to endure this process.

• Suppliers of Stellar Industries not capable of powder coat finishing may use a wet paint with the approval of Stellar Engineering Dept.

• Parts with paint specification defined on current drawings shall maintain the finish that is specified.

• MSDS sheets will be available on any chemical or surface treatment including rust proofing, brought into the facility.

1.0 Requirements of all surface finishes

1.1 All weld spatter, rust, loose mill scale and rough edges will be removed from surfaces as defined in QC08.05 Surface Definition.

1.2 All metal parts and fabrications must be thoroughly cleaned before painting. Chemical or mechanical etching is required on all surfaces that are to be painted.

1.3 Cleaning processes other than chemical or mechanical etching must be approved by the Stellar Engineering Dept.

1.4 All machined surfaces must be masked or otherwise protected from paint or other contaminants, during storage or shipment and also during the paint process. No grease shall be used to mask any surface on a painted product unless approved by Engineering.

1.5 All threaded holes and studs must be plugged or capped with appropriate masking materials to keep them free of paint or other contaminants.

1.6 All bushing housings shall be masked with appropriate size plastic plugs. 1.7 Where bushing housings must be used to hang weldments for painting,

appropriately designed sleeves shall be used to prevent paint from entering. 1.8 All metal parts and fabrications must be painted completely unless otherwise

specified by Engineering. 1.9 All finished components must be handled in such a manner that does not

produce chipping or scratching of the painted surface. 1.10 Welded joints produced during the assembly process must be cleaned,

primed and painted to all aspects of this acceptance criterion.

QC08.04 Paint Acceptance REV F

2.0 Primer Requirements

2.1 Minimum thickness of primer shall not be less than 2.0 mils (dry) on metal and 1.0 mils (dry) on aluminum surfaces.

2.2 Primer is to be gray metal primer suitable for outside storage as well as for finish painting.

3.0 Wet Finish Paint Requirements

3.1 All components will be prepared and primed before painted in accordance with sections 1 and 2

3.2 When applicable, all external surfaces will be sanded to remove prime paint irregularities such as “fisheyes”, runs, sags, drips, etc.

3.3 All external surfaces will be painted with Dupont Imron 5000 or equivalent. 3.4 Any alterations from color, finish and gloss requirements must have approval

from Stellar Engineering Dept. 3.5 Minimum thickness of paint shall be 2 mils (dry) 3.6 Overall thickness of primer + paint shall be 4 mils (+/-1 mil) absolute

minimum coverage shall be no less than 3 mils. 3.7 Finish paint must be free of irregularities such as “fisheyes”, runs, sags, drips,

per QC08.05 Surface Definition. 3.8 All finish paint areas are subject to rework under the direction of Quality

Control, Engineering and/or Product Managers. 3.9 Finish durability requirements include resistance to acetone wipe down.

4.0 Powder Coat Requirements

4.1 All components must be prepared before finish paint in accordance with section 1.1 through 1.4 of the criteria.

4.2 Average thickness of powder coated components, as determined by no less than four individual reading must be between 3.0 and 4.0 mils. No individual reading of thickness will be below 2.5 mils or above 6.0 mils.

4.3 Component finish will withstand an MEK rub test of 50 double rubs with no degradation of finish before 35 double rubs.

4.4 Finish adhesion will be sufficient to ensure the component meets the maximum 5% allowable finish flaking requirement observed from and ASTM D-3359 Adhesion test.

4.5 Component finish will be capable of performing a 500 hour salt spray test ASTM B117 scoring no less thank a 5 in reference to ASTM D1654-92 rating scale.

QC08.05 Surface Definition Rev D. 4/21/21

Surface Definition and Locations

Specific to Tire Service and Mechanics Bodies painted at Stellar Industries - Garner

• Surface A Definition: That surface which is exposed to view from all angles. Exterior surface of body or painted surface of parts, which can have no runs, sags, dry areas, grinding marks, weld debris, excessive dirt (limited amount of dirt is acceptable as defined below), bugs, or any other impurity in finish. Areas that require an automotive type finish.

o Dirt or foreign contaminant – § One particle ≤ 0.030” per square foot § affected area ≤ 0.050” around particle

• Surface B Definition: That surface that for the most part is hidden from view. Areas that are covered by other parts or equipment. Areas that are inside of compartments. These surfaces may have small imperfections in them such as runs, sags, grinding marks, dry areas, and some impurities in the finish. This may also cover surface areas that are exposed to view if they are not deemed as requiring an automotive finish.

o Dirt or foreign contaminant –

§ Three particles ≤ 0.040” per square foot § Affected area ≤ 0.060” around particle § Defect length can be no more than 4 times the width

• Surface C Definition: Examples include all parts and surfaces that are hidden from sight and any diamond plated surface. May have runs, sags, dry spots, and impurities in the paint. Complete paint coverage is required to prevent rust and corrosion.

o Dirt or foreign contaminant – Allowed o Assembly touch up with approved aerosol can primer and paint - Allowed


Definition of automotive finish in this context: Surface with smooth unblemished finish. Has high rate of shine and longevity of color. Similar to chassis body finish.

“A” Surfaces – Mechanics Bodies

Side Pack street/curb side vertical exterior surface

• Exterior surface of drip rail • Door Exterior • Side Pack Rear • Side Pack Front (except where covered by rock guard, this is a “B” surface) • Workbench bumper rear and side vertical surfaces • Workbench bumper doors • Sliding Top Exterior side and rear door (top to be “B” surface)

“B” Surfaces – Mechanics Bodies

• Compartment Interior • Interior surface of drip rail • Door Interior • Door Jambs • Workbench bumper horizontal surface • Bulkhead – Inside and outside • Bolt on options – Boom supports, stabilizers, tailgates, compressor shrouds etc.

(NOTE: Moving parts that cause paint damage is not regulated by this criteria)

“C” Surfaces – Mechanics Bodies

• Load Bed Floor • Load Bed Side Walls • Side Pack Top • Any painted diamond plate surface • Underside of body with Underpaint Process • Surfaces to receive Bedliner • Trailer hitches • Working surfaces, i.e., rollers, d-rings, hitches etc

All “A” Surfaces that have components (i.e. fender rubber, weather stripping, boom rests) that cover sections of their surface shall maintain a minimum of “B” Surface in that covered section.


“B” and “C” surfaces with sections of their surface covered by other components shall maintain their respective surface requirements.

“A” Surfaces – Tire Service

Door exterior

• All exterior body surfaces visible to user from ground with doors shut (except where covered by rock guard, this is a “B” surface)

• Body mounted sign panel

“B” Surfaces – Tire Service

• Compartment Interior • Door Interior • Door Jambs • Rear Bumper / Block boxes • Body racks • Bulkhead – Inside and outside • Load gates when painted in-house • Load gate sign panels

“C” Surfaces – Tire Service

• Underside of body • Surfaces to receive Bed liner • Steel Body interiors (load bed area)


“A” Surfaces – Mech and Tire Cranes and Manipulators Not

needed

“B” Surfaces – Mech and Tire Cranes and Manipulators

� All painted surfaces not outlined as a “C” surface

“C” Surfaces – Mech and Tire Cranes and Manipulators

• Surface that are around moving components / wear items. o Stabilizer pads o Stabilizer beams o Extension boom wear path area for boom overlap and wire rope. o Snatch Block o Load Hook

• Bolt on items (winch, protective plates)

“A” Surfaces – Demountables

• Not needed

“B” Surfaces – Demountables

• All painted surfaces not outlined as a “C” surface

“C” Surfaces – Demountables

• Cable hoist o All surface

• Hooklift load bearing surfaces o Rollers o Hook area o Saddles o Latches o Bumper

• Container carrier load bearing surfaces o Forks o Bumpers

• Tarpers o All components except for the arms (arms to be “B” surface)


AMERICAN EAGLE TRAILERS

“B” SURFACES- A/E TRAILER

• SIDES/ TOP OF FRAME OR BED • EXTERIOR SURFACE OF FENDERS • EXTERIOR OF HITCH AND COUPLER MOUNT • REAR BUMPER • NON-WORKING EXTERIOR SURFACES OF BULKHEAD OR BOLSTERS • FIXED, NON-WORKING VERTICAL MEMBERS • NON-WORKING AREAS OF JACK BODY • ANY OTHER AREAS NOT OUTLINED AS “C” SURFACE THAT ARE VISIBLE WHILE

WALKING AROUND TRAILER

“C” SURFACES- A/E TRAILER

• UNDERSIDE OF FRAME / BODY • UNDERSIDE OF FENDER • AREAS TO BE SECONDARILY COATED (BED LINER) • INTERIOR FRAME/ BODY OR LOAD BED AREA • WORKING SURFACES- I.E.; WINCHES, SPINDLE BARS, INTERIOR OF WHEEL CHOCK

HOLDERS, COUPLER, VERTICAL SPINDLE BAR LOCATORS, JACK HANDLE


Sure foot: • This is a B surface • Requires 2 uniform coats • Allow enough time between coats to flash off • No balls or clumps • Unmask immediately after 2nd coat is applied • Clean up around tape line if necessary

Hurculiner: • This is a B surface • Requires 3 uniform coats • Allow 6 hours between coats • There should not be any transparent surface. • Unmask immediately after the 3 coat is applied • Clean up around tape lines if necessary

Line-X: • This is a C surface • Apply as many passes as needed to achieve 80-100 mills of coverages on all surfaces. • Surfaces should look uniform • Minor blemishes are acceptable like small sags, heavy edges and slightly shiny spots that have

texture • No excessive runs, large sags, shiny spots, tape residue, loose edges, overspray or crooked lines

will be excepted. • Wire needs to be pulled at a 45-degree angle towards the bed liner that is to remains on the

unit after unmasking • Line X shall have 80-100 mills of coverage overall. Higher readings are expected on the load bed

floor and bumper, up to 120 mills thick. These readings need to be checked before unmasking.


Surface Requirements for Outsource Parts

All purchased components shall comply with the following rules:

1. No laser cutting residue or oxidation shall be present before paint or other paints are applied.

a. Part needs to use one of the following to ensure laser edge oxidation removal i. Shot blasted

ii. Edges sanded or other mechanical removal process iii. Part cut using nitrogen as gas for laser.

2. Caulk must be applied to all intersecting parts where the seams can’t be painted and there is no weld.

a. Caulk must meet these minimum standards: i. No silicone, solvents, or isocyanates

ii. Elongation >275% iii. Tensile Strength >225psi iv. Lap Shear >275psi v. Hardness Shore A >40

vi. Service temperature -50F to 200F b. Must wait for the recommended skin time before applying

primer or paint. c. Must not exceed recommended service temperature

during baking. d. Apply by tooling or finger.

NOTE: SUPPLIER MUST CONFIRM AND VALIDATE WITH STELLAR INDUSTRIES IN WRITING THE PROCESS USED

3. There must be one of the following metal treatment options applied to the parts for prior to paint/powdercoat: DIRECT TO METAL only acceptable on Amercian Eagle drawer fronts, compressor covers and compressor pumps.

a. Autophoretic® Paint b. Corsol® c. E-Coat d. 2 part epoxy primer

NOTE: SUPPLIER MUST CONFIRM AND VALIDATE WITH STELLAR INDUSTRIES IN WRITING THE PROCESS USED


Paint Adhesion Test ASTM Test Method D3359

1. Select an area free of blemishes and minor surface imperfections. For tests in the field, ensure that the surface is clean and dry. Extremes in temperature or relative humidity may affect the adhesion of the tape or the paint.

2. Using the GARDCO cutting tool make two cuts in the film each about 40 mm (1.5 in.) long that intersect near their middle with a smaller angle of between 30° and 45°.

3. Inspect the incisions for reflection of light from the metal substrate to establish that the paint film has been penetrated. If the substrate has not been reached make another X in a different location. Do not attempt to deepen a previous cut as this may affect adhesion along the incision.

4. Place the center of the tape at the intersection of the cuts with the tape running in the same direction as the smaller angles. Smooth the tape into place by finger and then rub firmly with the GARDCO cutting tool. The color under the tape is a useful indication of when good contact has been made.

5. Within 90 seconds +/- 30 seconds of application, remove tape by seizing the free end and pulling off rapidly (not jerked) back upon itself at as close to an angle of 180° as possible.

6. Inspect the grid area for removal of paint from the substrate using a magnifier if necessary.

Acceptable Not Acceptable

Bolt, Nut, & Washer Zinc Coating

Classification Code

Min. Coating Thickness

Supplemental Finish Designation

First Appearance of Zinc Alloy Corrosion Production (hours)

First Appearance of Red Rust (hours)

Fe/Zn 5 ANS 0.0002 ANS 96 120

Bolt, Nut, & Washer Magni 501 Coating

Coating Thickness

Coefficient of Friction Color

Salt Spray Rating (hours)

8‐10 microns 0.18+/‐0.03 Black/Gold/Silver 240+

Pin Zinc CoatingZinc plate per ASTM B633‐07, SC3 (Fe/Zn 12), Type II (Yellow)Thickness: 0.0007 +/‐0.0002Blind holes should be kept free of rust

Port Tube Zinc CoatingZinc plate per ASTM‐B 633.98, Class Fe/Zn 12, Clear ZincThickness: 0.0002 96hr salt

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Paint Specification - Stellar Industries