PLASCOAT PPA 571 COATING POWDER

A GUIDE TO COATING PROCESS PROCEDURES

ISSUE: 5 - NOV 2015

(This guide contains our latest appendices and technical

data sheets which may post-date the above).

PLASCOAT SYSTEMS LIMITED

Farnham Trading Estate
Farnham
Surrey GU9 9NY, England

Tel: 01252 733777

Fax: 01252 721250
Web: www.plascoat.com

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 PLASCOAT PPA 571

A GUIDE TO COATING PROCESS PROCEDURES

TABLE OF CONTENTS

TABLE OF CONTENTS .................................................................................................................... 2

ABOUT THIS GUIDE ........................................................................................................................ 3
ABOUT PLASCOAT .......................................................................................................................... 3
IMPORTANT NOTE .......................................................................................................................... 3
A GUIDE TO COATING PROCESS PROCEDURES ........................................................................ 4
SECTION 1. INTRODUCTION ......................................................................................................... 4
SECTION 2. THE COATING PROCESS .......................................................................................... 5
2.1 Metalwork Preparation ........................................................................................................ 5
2.2 Metalwork Pre-treatment ..................................................................................................... 6
2.2.1 Degreasing ...................................................................................................................... 6
2.2.2 Mechanical Pre-treatment ................................................................................................ 7
2.2.3 Chemical Pre-Treatment of Steel ..................................................................................... 7
2.2.4 Pre-Treatment of Zinc Plated or Galvanised Steel ........................................................... 8
2.2.5 Pre-treatment of Cast Iron ............................................................................................... 8
2.2.6 Pre-treatment of Aluminium ................................................................................................ 8
2.3 Application and Fusion of the Coating Powder ......................................................................... 9
2.3.1 Fluidised-Bed Coating Process ........................................................................................ 9
2.3.2 Electrostatic Spraying Process ...................................................................................... 11
2.3.3 Flock Spraying ............................................................................................................... 11
2.4 Final Inspection for Acceptable Quality Standards.................................................................. 13
2.4.1 Testing the Coating Film Thickness ............................................................................... 13
2.4.2 Testing for Pinholes/Porosity ......................................................................................... 13
2.4.3 Testing the Adhesion of Plascoat PPA 571 - Knife Cut Method ..................................... 13
SECTION 3. REPAIRING DAMAGE COATINGS ........................................................................... 14
3.1 Repairing with Plascoat PPA 571 powder ......................................................................... 14
3.2 Repairing with Plascoat PPA 571 rod ................................................................................ 14
3.3 Repairing damaged coatings on site with proprietary liquid coating materials.................... 14
SECTION 4. PACKAGING ............................................................................................................. 16
SECTION 5. COLOUR AVAILABILITY ........................................................................................... 16
SECTION 6. PROBLEM SOLVING ................................................................................................ 17
SECTION 7. REMOVAL OF DEFECTIVE PLASCOAT PPA 571.................................................... 20
COATINGS ..................................................................................................................................... 20
SECTION 8. POTENTIAL APPLICATIONS FOR PLASCOAT PPA 571 ......................................... 20
SECTION 9. PLASCOAT PPA 571 PERFORMANCE LONGEVITY ............................................... 20
APPENDIX I.1 ................................................................................................................................. 22
APPENDIX I.2 ................................................................................................................................. 23
APPENDIX I.3 ................................................................................................................................. 24
APPENDIX II ................................................................................................................................... 25
APPENDIX III .................................................................................................................................. 26
APPENDIX IV.................................................................................................................................. 27
APPENDIX V................................................................................................................................... 32
APPENDIX VI .................................................................................................................................. 33
APPENDIX VII ................................................................................................................................. 35
Plascoat PPA 571 Technical Datasheet .......................................................................................... 36
Plascoat PPA 571 ES Technical Datasheet..................................................................................... 38
Plascoat PPA 571 / ES GHS-SDS ................................................................................................... 42

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 ABOUT THIS GUIDE

The objective of the Guide is to help the customer and user to gain the maximum possible
benefits when using Plascoat PPA 571, PPA 571ES, PPA 571H and PPA 571HES
protective materials. To avoid unnecessary duplication the term PPA 571 will be used to
encompass PPA 571, PPA 571ES, PPA 571H and PPA 571HES unless otherwise stated.

ABOUT PLASCOAT

With nearly 50 years experience, 35,000 tonnes per year of capacity and many factories in
Europe, Plascoat is the world leader in thermoplastic coating and powder technology.

Plascoat's expertise arises from its unique position as one of Europe's largest grinders of
thermoplastics and as Europe's largest custom coater of metal and plastic articles.

With this unparalleled understanding of both process and application technology Plascoat
has, over the last three decades, manufactured, marketed and developed the widest range
of thermoplastic powders and fluids for metal finishing in the world.

Plascoat now sells to most countries in the world through a network of representatives,
agents and distributors. There are three material manufacturing sites strategically located in
the UK, and the Netherlands.

The materials in powder or liquid form can provide durable coatings for corrosion protection,
impact resistance, chemical protection, electrical insulation or supply a high quality
decorative finish. Applications range from refrigerator shelves, dishwasher baskets and
fencing to pipe lining, street lighting columns and the internal lining of fire extinguishers.

Plascoat is committed to Quality Management and to exemplary service in accordance with

the requirements of ISO 9002, BS5750 Pt 2.

IMPORTANT NOTE

All of the information contained in this Guide is presented in good faith. It should be
appreciated that the information is, to the best of our knowledge and belief, true and
accurate. There is no guarantee as to its accuracy and no responsibility or liability, express
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or implied, can be accepted by Plascoat for any problems which may arise as a result of any
actions or decisions that may be taken by the coating applicator, or by any other party that
may be involved with specifying or using the product. Since the conditions under which our
materials and equipment may be used are beyond our control, recommendations are made
without any form of warranty or guarantee. It is the responsibility of the user to ensure that
the material is fit for the purpose for which it has been selected. This disclaimer does not
affect your statutory rights.

PLASCOAT PPA 571

A GUIDE TO COATING PROCESS PROCEDURES

SECTION 1. INTRODUCTION
Plascoat PPA 571 is a unique high-performance coating powder based on a blend of acid
modified polyolefins. It has been specifically designed by the Technical Centre of Plascoat
to provide a long-lasting, tough, vandal resistant thick film coating for exterior applications
on steel, galvanised steel and aluminium.

Plascoat PPA 571 is resistant to stress cracking, adverse weather conditions, detergents,
salt spray and typical airborne pollutants. The coating maintains excellent adhesion to the
metal substrate without the need of a primer or, in many circumstances, chemical pre-
treatment such as phosphating. It also provides a high degree of electrical insulation and
impact resistance particularly at low temperatures.

Plascoat PPA 571 is applied by dip-coating (fluidised bed), and PPA 571ES by electrostatic
spraying. Typically fluidised bed dipping will result in coating thickness of 300 to 700
microns whilst with electrostatic spraying thicknesses of 150 and 250 microns are common.

Plascoat PPA 571 was primarily developed for use over mild steel and aluminium. Some
substrates require special processing, therefore coating of galvanised steel is discussed in
Section 2.2.4, and coating of cast iron is discussed in Section 2.2.5.

Plascoat PPA 571 is suitable for applications requiring extended periods up to 65°C and for
applications in prolonged contact with alcohols, dilute acids or alkalis. A full chemical
resistance information is included with this guide. See Appendix IV.

Plascoat PPA 571 can withstand normal atmospheric or waterborne pollutants including
dilute acids and alkalis, and UV light. PPA 571 is approved for use in contact with most
foods at room temperatures and for use in contact with potable water. See Appendix V.

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SECTION 2. THE COATING PROCESS
The normal coating process for Plascoat PPA 571 can be divided into 4 stages.

2.1 Metalwork preparation.

2.2 Metalwork pre-treatment.

2.3 Application and fusion of the coating material.

2.4 Final inspection for acceptable quality standard.

2.1 Metalwork Preparation

Most well designed products take account of the required finish early in the design stage.
This is particularly important for metalwork that will need to be plastic coated later. It is not
possible in a general guide such as this to take account of all the potential applications,
which might occur. Therefore if you have a new item for coating in Plascoat PPA 571, about
whose design parameters you are unsure, seek advice at an early stage from Plascoat on
suitable metalwork design and preparation. In order to obtain the optimum quality standard
of protection or decoration of a metal substrate, the following basic guidelines should be
considered for every potential application.

 All sharp edges and corners should be rounded off or ground down to a minimum
of a 0.3 mm radius if possible.

 The metalwork should be clean, unpainted.

 All welds should be continuous, ground down smooth and free from flux and
porosity.

 Spot welding should be avoided.

 Weld spatter should be removed.

 All soldered joints should be avoided, since most solders tend to melt at
temperatures below those which will be required for the coating process. The one
exception might be the use of silver solder, but tests should be made before
production quantities are processed.

 At least one suspension point will be required during the coating process, for
which due allowance should be made.

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  For fabricated items, all joints should be designed so that they do not deform after
coating and during subsequent use.

2.2 Metalwork Pre-treatment

It cannot be stressed too highly that correct metal preparation and pre-treatment are
fundamental to all successful metal finishing operations, including plastic coating. In order
to achieve the optimum protective or decorative coating performance, all of the surfaces of
the metal parts to be coated must be free of rust, grease, mill scale and any other
contamination because these might inhibit the adhesion of the coating. This in turn can give
rise to a premature failure of the coating.

Several metal pre-treatment systems exist that are used prior to plastic coating applications.
The most commonly used methods are:-

2.2.1 Degreasing.

2.2.2 Mechanical pre-treatment.

2.2.3 Chemical pre-treatment of steel.

2.2.4 Pre-treatment of Zinc plated or galvanised steel.

2.2.5 Pre-treatment of cast iron.

2.2.6 Pre-treatment of Aluminium

More than one pre-treatment process may be necessary for some metal components. This
will depend on the design of the part, the application for which it is intended and the coating
performance specification that is agreed for the job. Typically, mechanical pre-treatment,
such as grit blasting, can follow degreasing.

2.2.1 Degreasing

The first stage of any metal work pre-treatment is the removal of oil and greases from the
metal surface. This is essential if the subsequent pre-treatment processes are not to be
contaminated and if the initial and long-term adhesion is to be optimal.

Degreasing can be done using either solvents or aqueous solutions.

The solvent degrease process is by immersion of the items into the hot vapour of a
chlorinated solvent. The vapours condense on the cold metal and so wash off the soluble
oils and greases, This process will not remove stearates, which may have been used in the
cold drawing process to produce metal sheets and in tube and pipe forming processes. This
solvent degrease process is usually used prior to mechanical pre-treatment.

The aqueous degreasing systems use either alkali or detergents or a combination of these.
The items are immersed in a hot bath of the solution. The solution reacts with the

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contaminants and dissolves them from the surface. It is usual to follow this by washing in
hot water prior to further aqueous chemical pre-treatments.

2.2.2 Mechanical Pre-treatment

The most commonly used method of mechanical pre-treatment for items that require to be
plastic coated is grit blasting. Sometimes this method is called shot blasting. The objective
of grit blasting is to clean the surface of the metal substrate and to leave a slightly
roughened surface, which allows the coating to adhere securely. If any grease or oil is
present on the metal surface, grit blasting alone is not sufficient as a pre-treatment. Any
such components should be degreased prior to grit blasting.

Various blasting media are available. The decision of which type to use will depend on the
metalwork that is to be cleaned. As a general rule, round shaped media should not be used.
It is better to use sharp edged media wherever possible. These will not only abrade the
surface better, but they will create a profile on the metal substrate containing undercuts.
These will generally enhance the level of adhesion achieved by the coating to the substrate.
Ensure that the grit media remain clean. Dirty or oily grit can deposit and leave dirt on the
metalwork being processed. Chilled iron shot leaves a deposit of graphite on the metal
surface and should not be used since this can interfere with the bond between the coating
and the metal.

For the majority of Plascoat PPA 571 external coating applications, the following pre-
treatment guideline is reasonable. The metal should have a visual surface cleanliness of
between Swedish Standard Sa 2.5 and 3, in accordance with ISO 8501 - 1, 1988, and a
surface profile of 30 microns or 10% of the required film thickness which ever is the lowest.

2.2.3 Chemical Pre-Treatment of Steel

The important aspect of chemical pre-treatment is that it leaves a thin film corrosion
resistant barrier layer on the metal surface. If this film is not damaged, it will aid the long-
term adhesion of the plastic coating.

Always apply chemical pre-treatments in accordance with the manufacturer's instructions.

Particular attention should be paid to details of the processing times and temperatures, as
well as to the recommended chemical solution strengths. Such a pre-treatment system will
include usually an appropriate degreasing stage.

Several chemical pre-treatment systems are available for use with plastic coating. These
include zinc phosphate, iron phosphate and chromate. Care must always be taken when
plastic coating any metalwork that has been chemically pre-treated, because the resulting
thin film layer is temperature sensitive and may be adversely affected by excessive oven
preheat temperatures. Zinc phosphate gives the best corrosion resistance but may be
damaged by the high pre-heat temperatures normally required for fluid bed applications.
Therefore Plascoat recommend the use of iron phosphate for fluid bed applied PPA 571 and
the use of Zinc phosphate for electrostatically applied PPA 571ES. Your pre-treatment
chemical supplier will be able to offer more details information for your specific requirement.
For suggested pre-treatment systems see Appendix VI.

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2.2.4 Pre-Treatment of Zinc Plated or Galvanised Steel

It is often difficult to achieve good coating adhesion on zinc, galvanised and other plated
surfaces. It is therefore recommended that a test coating be conducted on such surfaces in
order to ensure that the metal surface is suitable for coating.

When Plascoat PPA 571 is applied over a zinc or galvanised substrate, the following
guidelines may be helpful, in order to achieve a satisfactory coating:

Plascoat recommend a mechanical pre-treatment using a non-ferrous medium such as fine

copper slag, J Blast or Carborundum powder. A particle size of 0.2 to 0.5 mm would be
suitable. Do not use angular iron grit, which may cause premature failure due to bimetallic
corrosion. The blasting pressure should not exceed 0.3 Mpa (40 psi) and we would
recommend a nozzle diameter of about 6 mm and a nozzle to work piece distance of 300
mm.

If a chemical pre-treatment were felt to be necessary then we would recommend an acid

pickle followed by phosphating or chromating. See Appendix VI.

Where hot dip galvanising is being used under PPA 571ES it is essential to pre-bake the
metal at 30°C above the coating temperature for about 30 minutes to remove volatiles.

2.2.5 Pre-treatment of Cast Iron

There are several different qualities and types of cast iron and therefore the required pre-
treatment will vary. Therefore this information is for guidance only. The main problems
associated with any powder coating onto cast iron are poor adhesion and pinholes due to
gassing from the pores in the cast iron. These problems are overcome by pre-baking the
items at 30°C above the pre-heat temperature for one to two hours. When cool the items
are grit blasted and any large holes filled in using fire cement. During blasting graphite
powder dust may be released. This must be removed using an air blast and suitable dust
extraction system. The items can then be preheated and coated in the usual way.

2.2.6 Pre-treatment of Aluminium

A thin, dense invisible layer of oxide will form quickly on aluminium once exposed to the air
and this needs to be removed in order to ensure optimum adhesion. There are two methods
by which it can be done. Either by acid-pickling or by blasting the surface with a non-ferrous
medium.

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2.3 Application and Fusion of the Coating Powder
Plascoat PPA 571 materials can be applied by the following methods.

2.3.1 Fluidised-bed coating. (PPA 571).

2.3.2 Electrostatic spraying. (PPA 571ES).

2.3.3 Flock spraying. (PPA 571 and PPA 571ES).

2.3.1 Fluidised-Bed Coating Process

The fluidised bed coating process consists of:

2.3.1.1 Pre-heating.

2.3.1.2 Fluidised bed coating.

2.3.1.3 Post-heating (if necessary).

2.3.1.4 Cooling.

2.3.1.1 Pre-heating. A smooth, pinhole free coating on a given piece of metal requires the
metal to have a certain heat content. This depends on:-

(a) The oven temperature

(b) The time in the oven

(c) The metal thickness

The shape and construction of the item also plays an important role. Thin metal parts heat
up rapidly, but also lose heat quickly. Thick metal tends to take longer to heat up, but also
retains its heat for a longer time. Consequently, for plastic coating processes, thin walled
items usually require a higher oven temperature setting than thicker metalwork. When
metalwork contains several metal thicknesses it is best to preheat at a high temperature for
a short time. In this way the thin metal will heat up to near oven temperature and the thicker
metal will have a sufficient heat content to allow PPA 571 to melt without degrading.

Metalwork thinner than 1.5mm will not have sufficient heat capacity for this process and
should therefore be coated using PPA 571ES. Our suggested metal temperatures for other
metal thicknesses are:

(a) Mild steel sheet between 1.5 and 2 mm thick.

Between 320 and 400°C.

(b) Mild steel sheet between 3 and 5 mm thick.

Between 280 and 360°C.
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(c) Mild steel sheet over 6 mm thick.
Between 230 and 300°C.

These figures should be considered as a rough guide only. The preheating times can vary
enormously, from under 1 minute to 30 minutes or more. Every new piece of metal will need
to have its optimum process times and temperatures worked out, before production
quantities can be processed successfully. Overheating must be avoided since this can
cause lighter colours to yellow and will reduce the weather resistance of all shades.

2.3.1.2 Fluidised bed coating. After preheating, the item is dipped into a bed of fluidising
powder. Beds vary in size, hence a laboratory-sized powder bed may hold as little as a few
hundred grams of powder, whilst a large scale production model may hold several tonnes.
This bed consists of two compartments, one on top of the other. The upper, larger
compartment contains the coating powder. The lower compartment, or "plenum chamber",
is a reservoir for pressurised air. A porous membrane sometimes called a diffuser
separates the two compartments. Usually the membrane is made of canvas or a high
quality filter paper. The porosity of the membrane is critical to the quality of the fluidisation
of the powder. Compressed air is forced into the lower compartment. It diffuses through the
membrane and moving upwards, still under pressure. It moves between the fine powder
particles that are contained in the upper compartment. Hence the powder particles are
separated and the mass increases in volume, which can be up to 30%. As a result the bulk
density of the powder is reduced and this permits the preheated metal object to be lowered
easily, without any resistance, into the now "fluidising" bed of powder. The powder behaves
like a liquid and continues to do so, as long as the air is forced into the lower plenum
chamber.

By careful agitation or controlled movement of the hot metal object underneath the surface
of the "fluid" powder, the cold powder comes into contact with every point of the hot metal
and fuses onto it. Usually, after between 3 and 10 seconds, enough powder has fused onto
the metal to produce a satisfactory coating. A thickness of between 300 and 750 microns is
suggested for Plascoat PPA 571 in order to achieve the optimum potential of the coating
material.

The metal object is removed from the powder and any surplus powder is blown off, using an
airline nozzle at low pressure.

To calculate the specification for a blower to match a tank of PPA 571 see Appendix VII.

2.3.1.3 Post-heating. If the heat content of the metal is insufficient to effect complete fusion
of the powder particles a slightly grainy, gritty or powdery texture will remain on the surface
of the coating. In that case it is necessary to put the coated part back into an oven for a
short time at a temperature of around 200°C. This allows the fusion process to be
completed and a smooth coating to result.

2.3.1.4 Cooling. The part may then be allowed to cool in the air. However to reduce cycle
times the items can be quenched in water. One of the advantages of PPA 571 is that it is an
amorphous (non-crystalline) polymer and as such it has a relatively low thermal shrinkage.
Hence water quenching does not produce the severe pull back experienced with other
polymers.

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2.3.2 Electrostatic Spraying Process

Plascoat PPA 571ES was developed specifically to be applied by the electrostatic spray
process. This process is well known and well documented. However in very simple terms
powder is blown through a gun. It picks up an electrostatic charge and is attracted to the
object, to be coated, which is earthed. The electrostatic charge may be supplied either from
a charged point at the end of the gun barrel, this is called corona charging, or by friction
against the walls of the gun, this is called tribo charging. Because of the chemistry of
PPA571ES, tribo-guns do not create enough charge on PPA571ES particles. Therefore
Plascoat only recommend the use of corona charged guns.

The charge on the particles is sufficiently strong and long lasting that the powder coated
item can be moved into an oven set at 150 to 250°C where the powder fuses to produce a
smooth coating. Plascoat PPA 571 is a thermoplastic and as such does not need to
undergo the chemical cross-linking or curing process which is associated with thermosetting
systems. However experience has shown that the normal processing times and
temperatures used for conventional polyesters are a good starting point. If using these
conditions the coating is not sufficiently smooth, increase the temperature or time. If the
coating has sagged from the top edge, then reduce these times and temperatures.

When using the corona process the amps must be set to 5-15 µAmps and the voltage to
100kV if both settings are available. For Corona guns with voltage setting only, set voltage
at 30-50 kV. Failure to use the correct settings may result in coatings that are to thin or with
poor coverage.
If the voltage is too low or the amps too high, then the film thickness will be low and the
powder efficiency may be reduced. If the charge is too high the coating may suffer from
craters caused by "back-ionisation” and the coating of internal corners and the interstices of
wire parts will be poorer because of the Faraday cage effect.

PPA 571ES has a larger particle size than other conventional powder coatings and therefore
if the powder is fed from a fluidised bed hopper the amount of fluidising air must be
increased.

PPA571ES coatings are thermoplastic. Therefore if it is necessary or desirable to over spray

a PPA571ES coating with more PPA571ES then the two layers will melt and fuse together
so that the inter-coat adhesion is excellent. We have also found that PPA571ES can be
over-sprayed with most conventional polyesters. The polyester chemically reacts with the
acid groups in the PPA571ES and so gives excellent inter-coat adhesion. The use of zinc
rich epoxy primers under Plascoat PPA 571 is generally not recommended. If they are
required for specification purposes, then the primer should remain ‘green-cured’
(undercured) in order to ensure adequate inter-coat adhesion. Please refer to Plascoat for
more details.

For more detailed information on processing times and temperatures see PPA571ES data
sheet in Appendix VIII.Page 10

2.3.3 Flock Spraying

Flock spraying is sometimes called "powder spray coating". This method consists of
blowing powder through a suitable spray gun onto metal items that have been preheated to
a predetermined temperature. The powder hits the hot metal and sticks to it, where it
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gradually fuses to form a homogenous coating. This method of powder application is
particularly suited to processing large or awkward objects, which would otherwise be
impractical to process by the fluidised bed process. It should not be considered as a
commercially viable alternative to fluidised bed coating. Flock spraying has the added
benefit that more than one coat of powder can be applied, if the metal object is carefully re-
heated before re-spraying. This process can be repeated several times, if necessary, in
order to build up and achieve the desired coating film thickness.

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2.4 Final Inspection for Acceptable Quality Standards
Before any coating project is started, a mutually acceptable Quality Standard should be
agreed for the item that is to be coated. In such cases, due allowance should be made for
any repairs that might be necessary to the finished coating. See Section 3 for repair
methods. The quality standard will require some tests to be performed on some of the
coated items. The commonest of these tests are listed below.

2.4.1 Testing the Coating Film Thickness

It is normal to specify a minimum acceptable coating film thickness. This should be

sufficiently thick to ensure that there is no risk of pinholes. Any coating film of
Plascoat PPA 571 that is above 300 microns should ensure that this would not be a
problem. The maximum recommended film thickness is 800 microns. For PPA 571ES 150
microns is the very minimum recommended film thickness. Excessively thick coatings are
not recommended since stress cracking may occur. Various instruments are available for
checking the film thickness, depending on the metal item that is being coated. Consult
Plascoat if assistance is required.

2.4.2 Testing for Pinholes/Porosity

Most finished coatings can be checked for freedom from porosity by using a spark tester. If
a high-voltage pinhole detector is used, Plascoat recommends that a test voltage of 1000
volts per 100 microns of film thickness should be selected, up to a maximum voltage of
7,500 volts. If pinholes are discovered, check Section 6, Problem Solving, for possible
solutions, and section 3 for methods of repair.

2.4.3 Testing the Adhesion of Plascoat PPA 571 - Knife Cut Method

The following subjective method can be used to assess the adhesion of Plascoat PPA 571
coatings: A sharp, pointed knife is used to make two cuts into the coating, penetrating
through to the metal substrate and forming converging lines. These should make an angle
of 30 degrees. The tip where the two lines meet should be prized up with the point of the
knife. The force required to pull off the coating is indicative of the adhesion. If the metal
was properly pre-treated and coated, it should be impossible to prize off or lift up the coating
without the coating tearing.

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SECTION 3. REPAIRING DAMAGE COATINGS
Since Plascoat PPA 571 coatings are tough and elastic, the coating is capable of being
deformed considerably without exposing the metal surface underneath. Despite this
Plascoat PPA 571 coated surface may be damaged, either due to excessive mechanical
stresses or because of accidental damage immediately after coating, in transport or during
assembly. However the relatively low melting point and good melt viscosity properties of
Plascoat PPA 571 allow such damage to be repaired without too much difficulty. It is
important to effect the repair as soon as possible after the damage has occurred, so as to
eliminate the onset of corrosion. The area to be repaired should be clean and free from
grease. The following methods have proved successful in practice:

3.1 Repairing with Plascoat PPA 571 powder.

3.2 Repairing with Plascoat PPA 571 rod.

3.3 Repairing with proprietary liquid coating materials.

3.1 Repairing with Plascoat PPA 571 powder

If accidental damage occurs during or immediately after the coating process, Plascoat PPA
571 powder can be poured carefully onto the damaged area and fused with localised heat.
As long as the metal and surrounding coating area are hot enough, the fresh powder will
fuse with the existing coated film and cover the defect with a new, pinhole-free film. If the
metal temperature is no longer sufficient to allow this to happen, the part can be re-heated
with care.

If the damage occurs after the metal part is cold, or if the damage occurs much later, the
affected area must be warmed with a heat source, such as a naked gas flame or hot air gun.
The metal area to be repaired has to reach the fusion temperature of Plascoat PPA 571.
Some fresh powder can then be applied. If the residual heat is insufficient to fuse the new
powder completely, the item must be re-heated slightly and with care. It is important to
avoid overheating the fused coating around the repair point since a degradation of that
coating may occur.

3.2 Repairing with Plascoat PPA 571 rod

Small areas of damage can be repaired by using a specially extruded repair rod of Plascoat
571. The rod is melted with the aid of a gas-heated soldering iron, or hot air gun. Extruded
rods of Plascoat PPA 571 are used as the soldering material and applied in the same
manner as solder. The rods are available on request from Plascoat.

3.3 Repairing damaged coatings on site with proprietary liquid coating materials

Where such a repair procedure is necessary, Plascoat recommends that the metal should
be cleaned with a clean piece of emery cloth. This cleaning should be down to the bare

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metal and the resulting hollow should be filled with a proprietary brand of car body filler.
Once this has set, it should be smoothed down and then a suitable liquid coating such as
Thixothane may be applied to the damaged area.

Thixothane from H. Marcel Guest Ltd., Riverside Works, Collyhurst Road, Manchester M10
7RU England - Telephone: +44(0)161 205 7631, can be used as a repair material.

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SECTION 4. PACKAGING
Care should be taken with all plastic coated items. This is particularly important when
moving them from one place to another and when installing them as the final destination.
Common sense should alert installers to the fact that fabric or webbing slings should be
used for large or heavy items and steel hooks or chains should not be used because these
can damage the coating.

Small items need to be packaged in such a way that they arrive at their destination in the
same condition as they left the coating workplace. A few minutes care at this stage of the
proceedings can save a lot of anguish later. Plascoat recommends that the matter of
sensible packaging should form an integral part of any agreed Quality Plan that is drawn up
between the coater and the client.

SECTION 5. COLOUR AVAILABILITY

The colour range of both PPA 571 and PPA 571ES is available ex stock. Most other colours
can be produced for orders with a minimum quantity of 1 tonne.

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SECTION 6. PROBLEM SOLVING
It is inevitable that when plastic coating large volumes of metal parts, some problems are
likely to occur from time to time. The following list highlights some of the more commonly
experienced problems and their solutions.

Problem Cause and Remedy:

Orange-peel effect Cause 1:

Insufficient heat.
Remedy 1:
Increase either the temperature or the time the metalwork is in the
oven.
Cause 2:
Inadequate fluidisation of fluid bed PPA 571.
Remedy 2:
Check the Fluidaire tank diffuser is clean and has not been
damaged. Check the blower is operating correctly and its air
filter is clean.

Holes, pinholes Cause 1:

Insufficient powder pickup.
Remedy 1:
For PPA 571 check metal temperature is sufficiently high.
Increase oven pre-heat temperature.
Extend dipping time and agitate the part more vigorously in the
powder.
Cause 2:
For PPA 571 - Poor dipping technique.
Remedy 2:
Agitate the item in the powder for a longer period of time.
Reduce the time between the part leaving the preheat oven and
entering the powder to reduce heat loss.
Cause 3:
For PPA 571ES - Poor powder fed to gun.
Remedy 2:
Check all powder feed tubes are clean and not "kinked".
If using a fluid bed hopper, check the air is sufficient to fluidise
the powder. PPA 571ES requires a higher airflow than most
thermoset powders.
If feeding straight from a box ensure the fluidising air feed ports
are clean and the vibrator is working correctly.
Cause 4:
Incorrect charge on the powder.
Remedy 4:
For corona guns ensure the charge is between 30 and 50 kV and
fit a corona ring or bar to gun.
For tribo-charged systems ensure the powder feed is satisfactory
and that the guns are not blocked.

Page 17
"Fisheyes" Cause 1:
sometimes called Usually it is the presence of silicones somewhere in the factory.
craters. This is a major problem for plastic coaters and must be eradicated.
Alternatively the metal may not have been adequately pre-treated.
Remedy 1:
Check that no silicones are being used anywhere in the factory.
Silicones are found in certain polishes, mould release agents,
greases and acrylic powder paints. Degrease the metal surface
carefully (see sec. 2.2.1). Check that the powder has not been
contaminated. Keep a closed lid on the powder box, especially
when it is not in use.
Cause 2:
Degradation of the coating powder by excessively high processing
temperatures.
Remedy 2:
Reduce oven temperatures and/or times to the minimum to achieve
a satisfactory finish.
Cause 3:
Insufficient powder pickup of PPA 571.
Remedy 3:
Check metal skin temperature is sufficiently high.
Increase oven pre-heat temperature.
Extend dipping time and agitate the part more vigorously in the
powder.
Cause 4:
For PPA 571ES - Back ionisation.
Remedy 4:
The gun may be too close to the work piece.
For corona guns the charge should be reduced or a corona ring
or corona bar attached to the gun.

Coating will not Cause 1:

stick to the Inadequate metal pre-treatment (see section 2.2)
substrate Remedy 1a:
Check for grease or dust on the substrate. For optimum
results, pre-treatment should be undertaken immediately prior
to the coating process.
Remedy 1b:
If a chemical pre-treatment has been used, check the chemical
condition of the pre-treatment baths.
Cause 2:
For PPA 571 - Insufficient metal preheat temperature. Only valid
for sections thicker than 5mm.
Remedy 2a:
Increase the time or temperature in the preheat oven.

Coating too thin Cause 1:

at the edges. Sharp edges on the metalwork.
Metal "grins" Remedy 1:
through. Improve the metal pre-treatment standard and fettle all edges
to a minimum of 0.3 mm radius.
Page 18
 Cause 2:
Metal temperature is too high.
Remedy 2:
Lower the oven temperature.
Cause 3:
For PPA 571ES voltage too high
Remedy 3:
Lower voltage to 30 kV and fit corona ring or bar to gun.

Discolouration Cause 1:
of the coating. Degradation due to excessive pre-heat temperature.
Remedy 1a:
Lower the preheating temperature.
Remedy 1b:
Reduce the time metal spends in the preheat oven and record
the results.

This listing is by no means exhaustive, but it includes those problem areas that are most
often reported. All of the above problems have been reported by coaters when applying
Plascoat PPA 571 onto ferrous metal substrates. When other metal items are involved,
such as steel or aluminium castings, less common problems can occur. Because of the
wide experience that has been gained over many years in processing a variety of
thermoplastic coating materials, talk to Plascoat if problems arise that cannot be resolved
quickly and easily.

Page 19
SECTION 7. REMOVAL OF DEFECTIVE PLASCOAT PPA 571
COATINGS
Sometimes it is necessary to remove a coating from a metal substrate. In such cases,
because Plascoat PPA 571 adheres very well to the component, it is necessary to tackle the
task with care. The metal part must not be damaged and presumably will require to be re-
coated at a later date. The simplest way to remove unwanted coatings is to burn them off in
a hot oven, set at a temperature that will not cause any problems to the metalwork. Care
must be taken to ensure compliance with all the local regulations concerning the emission of
fumes. Fumes should be vented away safely. After burning off the coating, the metalwork
should be grit blasted clean.

A cleaner method of burning off coating is using the hot fluid bed technique. One
manufacturer is: Seghers, Gentsesteenweg 311, B-9240 Zele, Belgium.
Tel: +32(0) 9 367 9494.

SECTION 8. POTENTIAL APPLICATIONS FOR PLASCOAT PPA

571
Thick film Plascoat PPA 571 coatings are used wherever corrosion resistance, as well as
good resistance to weathering, chemicals or aggressive atmospheres is required in
decorative colours. Numerous applications exist where Plascoat PPA 571 has been used
successfully. Some typical uses are listed in Appendix II.

SECTION 9. PLASCOAT PPA 571 PERFORMANCE LONGEVITY

Plascoat has been producing and marketing coating powders for over 40 years and is the
world leader in its field. This unparalleled experience is derived from its unique position as
both a provider of subcontract thermoplastics grinding and compounding services and as an
applicator of a wide variety of coatings to both metal and plastic articles.

Its unrivalled combination of coatings production and application expertise has enabled
Plascoat to develop the widest range of thermoplastic metal finishing powders and promote
its own range of coating equipment.

PPA 571 is a thermoplastic powder developed specially to achieve long term adhesion to
both mild steel and aluminium substrates without the need for an adhesive primer. It is
especially recommended where there is a requirement for excellent resistance to
ultraviolet light, salt spray and atmospheric pollutants. Whilst not having been specially
formulated for use in aggressive chemical environments, or for applications requiring high
abrasion resistance, it has proved its suitability for contact with concentrated sulphuric acid
(traction battery boxes) and a number of other chemicals.

Page 20
Since PPA 571 was developed 10 years ago, PPA 571 has been subjected to thorough
laboratory testing, Salt spray to ASTM B117, QUV to ASTM G53-77 and Florida site
exposure at 45° from horizontal towards South. The results of these tests have proven PPA
571 to be superior to most, if not all, materials in this price range. From these test results,
using techniques developed over 40 years, Plascoat is able to estimate that PPA 571
coatings will continue to protect the metal for a minimum period of 30 years outside
exposure in northern Europe, 20 years in the south (northern Mediterranean region) and 10
years in more tropical areas. Provided that:

 The PPA 571 is applied in accordance with the conditions outlined on the material data
sheet.
 The coating is not in contact with abnormally aggressive chemicals or gases.
 The metal has been appropriately cleaned and is free from sharp corners or edges.
 The coating is continuous and free from exposed edges or pinholes.
 The coating has not been damaged through to bare metal, for example during transport,
site erection or subsequent use.
 The metal substrate has not been deformed after coating.
 The article/coating has not been exposed to continuous temperatures in excess of 50°C
or prolonged periods over 65°C.

PPA 571 is now used in many countries, including the Middle East and in the Arctic, for the
coating of fencing, connectors, cable trays, battery boxes, street furniture etc. In its history
not one instance has yet been reported of coating degradation in exterior use, even in the
most harsh of environments.

U.K. Registered Trade Names

Plascoat: Plascoat PPA and Fluidaire are all U.K. registered trade names.

Some useful addresses:

Plascoat Systems Limited

Farnham Trading Estate, Farnham, Surrey, GU9 9NY, England
Tel: +44(0) 1252 733777 Fax: +44(0) 1252 721250

Plascoat Europe BV
PO Box 9, 3214ZG Zuidland, The Netherlands

Tel: +31 181 458888 Fax: +31 181 458877

Plascoat Corp.
2700 Avenger Drive, Suite 108, Virginia Beach, VA 23452, USA

Tel: 001 844 752 7262 Email: [email protected]

Page 21
 APPENDIX I.1

PLASCOAT PPA571ES PROCESS CONDITIONS

CONDITIONS FOR 1.5 mm THICK STEEL PLATE

TEMPERATURE °C 160 190 220

TEMPERATURE °F 320 374 428

MAXIMUM TIME (mins) 60 25 13

MINIMUM TIME (mins) 20 13 5

PLASCOAT PPA 571ES

PROCESS TIME v TEMP FOR 1.5mm STEEL SHEET

70
60
TIME (mins)

50
40 MAXIMUM TIME"
30 MINIMUM TIME

20
10
0
160 180 200 220
TEMPERATURE °C

Page 22
 APPENDIX I.2

PLASCOAT PPA571ES PROCESS CONDITIONS

CONDITIONS FOR 2.0 mm THICK STEEL PLATE

TEMPERATURE °C 160 190 220

TEMPERATURE °F 320 374 428

MAXIMUM TIME (mins) 70 30 15

MINIMUM TIME (mins) 25 16 8

PLASCOAT PPA 571ES

PROCESS TIME v TEMP FOR 2.0mm STEEL SHEET

80
70
TIME (mins)

60
50
MAXIMUM TIME"
40
MINIMUM TIME
30
20
10
0
160 180 200 220
TEMPERATURE °C

Page 23
 APPENDIX I.3

PLASCOAT PPA571ES PROCESS CONDITIONS

CONDITIONS FOR 3.0 mm THICK STEEL PLATE

TEMPERATURE °C 160 190 220

TEMPERATURE °F 320 374 428

MAXIMUM TIME (mins) 80 40 17

MINIMUM TIME (mins) 30 17 9

PLASCOAT PPA 571ES

PROCESS TIME v TEMP FOR 3.0mm STEEL SHEET

100
80
TIME (mins)

60 MAXIMUM TIME"
MINIMUM TIME
40
20
0
160 180 200 220
TEMPERATURE °C

Page 24
 APPENDIX II

PLASCOAT PPA 571

Weathering Case History

Plascoat PPA571 has been sold since 1990. Below is listed just a few of the many
applications for which this coating has been used. According to our records all these
examples are performing well and look as good as new. Plascoat Systems has not
received any complaints of any in-service coating failure.

YEAR
COUNTRY CITY/TOWN DESCRIPTION OF COATED ITEM
INSTALLED
1992 SPAIN SAN SEBASTIAN SUPPORT STRUCTURE FOR
PASARELA FOOT BRIDGE
1992 BELGIUM/ VARIOUS GUTTER BRACKETS
HOLLAND
1993 SPAIN TRETO SUSPENSION CABLE COVERS ON
THE COLINDRES VIADUCT LINKING
SANTANDER AND BILBAO
1993 SWITZERLAND VARIOUS GUTTER BRACKETS AND DOWN
PIPES
1994 SAUDI ARABIA VARIOUS FENCING PANELS USED BECAUSE
PPA571 RESISTS SAND STORMS
1995 WEST INDIES POOL SIDE FURNITURE

1995 DUBAI PLAYGROUND FURNITURE AT

CHICAGO BEACH HOTEL
1995 SWEDEN STOCKHOLM GALVANISED STEEL LAMP POSTS

GOTTENBURG CITY DRINKING WATER PIPES

1995 ENGLAND NOTTINGHAM FENCE FRAMES AROUND TENNIS

CENTRE
1995 U.K. VARIOUS SEATING FOR RAILWAY AND
MOTORWAY SERVICE AREAS
1996 HONG KONG CABLE TRAYS ON BRIDGE
STRUCTURES LINKING ISLANDS TO
MAINLAND
1997 USA IDAHO ALUMINIUM DECORATIVE FENCING

W.G.O'DONNELL
TECHNICAL MANAGER
01 FEB 01

Page 25
 APPENDIX III

PLASCOAT PPA 571

FIRE TESTS AND FIRE FUME CERTIFICATES

UK - BS 476 Pt.5 - Test for Ignitability Class P

UK - BS 476 Pt.6 - Fire Propagation I = 0.2

UK - BS 476 Pt.7 - Spread of Flame Class 2

UK - NES 713 - Toxicity of Fume Index 1.76

USA - NFPA 258 - Smoke Generation - Flaming mode 110.06

- Non Flaming mode 27.84

France - NF P 92-501 - Fire Performance of Rigid Materials Class M1

France - NF C20-453 - Corrosiveness of Smoke pH = 4.46

France - NF C20-454 - Gases evolved during Pyrolysis:-

- Detected CO2 (34%), CO (7.5%),
Water and non-volatiles (58%)
- Not Detected HC1, HBr, HCN, HF, SO2

3 July 2000

Page 26
 APPENDIX IV

PLASCOAT PPA 571

CHEMICAL RESISTANCE

Prolonged Contact refers to where the coating material is immersed in the chemical permanently or
intermittently for long periods of time.
Occasional Short Term Contact refers to where the coating is exposed either once or intermittently for
short periods of time only.
Splash refers to where the coating is exposed to the chemical for a very short time only through accidental
contact.
NR = NOT RECOMMENDED.

Figures in table are maximum temperatures ⁰C for contact

Splash Occasional Short Prolonged Contact

Term Contact
Acetaldehyde ( 40% ) 20 20 20
Acetamide 20 20 NR
Acetic Acid ( 30% ) 60 20 20
Acetic Acid ( 80% ) 60 20 NR
Acetic Acid ( Glacial ) 20 NR NR
Acetic Anhydride 20 20 NR
Acetone 20 20 NR
Acetyl Chloride 20 20 NR
Adipic Acid ( 20% ) 60 60 60
Alcohols 20 20 NR
Allyl Chloride 20 NR NR
Aluminium Salts ( 15% soln.) 60 60 60
Ammonia (conc.soln.) 20 NR NR
Ammonia (dilute soln. ( 10% ) 20 20 20
Amyl Acetate 20 20 NR
Amyl Chloride 20 20 NR
Aniline 20 20 NR
Arklone 20 NR NR
Aviation Fuel 20 NR NR
Barium Salts ( 15% soln.) 60 60 60
Benzaldehyde 20 20 NR
Benzoic Acid (20%) 60 60 60
Bleach (Sodium Hypochlorite, 12%) 20 NR NR
Borax 60 60 60
Boric Acid 60 60 60
Brine (5%) 60 60 60
Brine (15%) 60 60 60
Bromine Water 20 NR NR
Butadiene 20 NR NR

Page 27
 Splash Occasional Short Prolonged Contact
Term Contact
Butane 20 20 20
Butanediol 20 20 20
Butyl Acetate 20 20 20
Butyl Chloride 20 20 NR
Calcium Salts ( 15% soln.) 60 60 60
Calcium Hydroxide ( 30% ) 20 20 NR
Calcium Hypochlorite ( 10% ) 20 NR NR
Carbon Disulphide 20 NR NR
Carbonic Acid 60 60 60
Caustic Soda (see Sodium Hydroxide) 20 NR NR
Carbon Tetrachloride 20 NR NR
Cellosolve Acetate 20 20 20
Chlorine in Sea Water ( 5 ppm) 20 20 20
Chlorine Water ( 0.7 g/l ) 20 NR NR
Chlorobenzene 20 NR NR
Chloroform 20 NR NR
Chromic Acid ( 15% ) 20 NR NR
Chromic Acid ( 25% ) 20 NR NR
Citric Acid ( 20% ) 60 60 60
Copper Salts (15% soln.) 60 60 60
Detergent ( 30% ) 60 60 60
Detergent ( 70% ) 20 20 20
Dibutylphthalate 20 20 20
Dichloroethylene 20 NR NR
Diethylamine 20 NR NR
Diethylene Glycol 20 20 20
Diethylether 20 NR NR
Dimethylamine ( 20% ) 20 NR NR
Dimethylformamide 20 20 20
Dioxane 1.4 20 NR NR
Ethane 20 - -
Ethers 20 NR NR
Ethyl Acetate 20 20 20
Ethyl Alcohol (Ethanol) 20 20 NR
Ethyl Chloride 20 NR NR
Ethylene Bromide 20 NR NR
Ethylene Chloride 20 NR NR
Ethylene Diamine 20 NR NR
Ethylene Glycol 20 NR NR
Fluorine NR NR NR
Formaldehyde ( 1% ) 20 20 20
Formaldehyde ( 20 w/w ) 20 20 20
Formaldehyde 10% (Formalin) 20 20 20
Formic Acid ( 20% ) 20 20 20

Page 28
 Splash Occasional Short Prolonged Contact
Term Contact
Glucose 60 60 60
Glycerol (Glycerine) 60 60 60
Genklene 20 NR NR
Heptane 20 20 20
Hexane 20 20 20
Hydrobromic Acid ( 5% ) 20 20 20
Hydrobromic Acid ( 30% ) 20 20 NR
Hydrochloric Acid 5% (SG 1.03) 60 60 60
Hydrochloric Acid ( 10% ) 20 20 20
Hydrochloric Acid ( 20% ) 20 20 NR
Hydrochloric Acid 37% (SG 1.18) 20 20 NR
Hydrocyanic Acid ( 5% ) 60 60 60
Hydrofluoric Acid ( 5% ) 20 20 20
Hydrofluoric Acid ( 40% ) 20 NR NR
Hydrofluoric Acid ( 70% ) NR NR NR
Hydrofluoric Acid ( 100% ) NR NR NR
Hydrogen Peroxide ( 10% ) 20 NR NR
Hydrogen Peroxide ( 90% ) NR NR NR
Hydrogen Sulphide ( 5% ) 60 60 60
Hypochlorous Acid 20 NR NR
Iodine soln. ( 0.7 g/l ) 20 NR NR
Isopropanol ( 70% ) 20 20 NR
Isopropylacetate 20 20 NR
Iron Salts ( 10% soln.) 60 60 60
Kerosene 20 20 20
Ketones 20 20 NR
Lactic Acid ( 20% ) 60 60 60
Linoleic Acid 20 20 20
Linseed Oil 20 20 20
Liquid Propane Gas 20 20 20
Machine Oil 20 20 20
Magnesium Salts ( 15% soln.) 60 60 60
Mercuric Salts ( 15% soln.) 60 60 60
Methanol 20 20 NR
Methyl Acetate 20 20 20
Methyl Bromide 20 20 NR
Methyl Cellosolve 20 20 20
Methyl Ethyl Ketone 20 20 NR
Methyl Isobutyl Ketone 20 20 NR
Methyl Dichloride 20 NR NR
Methylene Chloride ( 100% ) 20 NR NR
Mineral Oil 20 20 20
Naphthalene 20 20 NR

Page 29
 Splash Occasional Short Prolonged Contact
Term Contact
Nickel Salts ( 15% soln.) 60 60 60
Nitric Acid ( 5% ) 20 20 20
Nitric Acid 10% (SG 1.05) 20 20 NR
Nitric Acid ( 20% ) 20 20 NR
Nitric Acid 30% (SG 1.18) 20 NR NR
Nitric Acid ( 70% ) 20 NR NR
Nitric Acid fuming (SG 1.51) NR NR NR
Nitrobenzene 20 NR NR
Nitrous Acid 20 20 20
Octane 20 20 20
Oleic Acid 20 20 NR
Ozone 20 20 20
Paraffin 20 20 20
Peracetic Acid 20 20 NR
Petrol 20 20 20
Phenol ( 10% ) 20 20 NR
Phenol in Water ( 20 w/w ) 20 20 20
Phosphoric Acid 20% (SG 1.1) 60 60 60
Phosphoric Acid ( 30% ) 20 20 20
Phosphoric Acid ( 85% ) 20 NR NR
Phosphoric Acid conc. (SG 1.87) 20 NR NR
Polyglycol Ethers 20 NR NR
Potassium Salts ( 15% soln.) 60 60 60
(other than potassium permanganate)
Potassium Hypochlorite ( 15% ) 20 NR NR
Potassium Permanganate (15%) 20 NR NR
Potassium Hydroxide ( 5% ) 20 20 NR
Potassium Hydroxide ( 10% ) 20 20 NR
Potassium Hydroxide ( 30% ) 20 NR NR
Propylene Dichloride 20 NR NR
Rubber Latex 60 60 60
Silver Nitrate ( 15% ) 60 60 60
Slurry (cow, pig, poultry etc.) 30 30 30
Sodium Carbonate ( 2% ) 60 60 60
Sodium Carbonate ( 15% ) 60 60 60
Sodium Chloride ( 5% ) 60 60 60
Sodium Chloride ( 10% ) 60 60 60
Sodium Hydroxide ( 1% ) 20 20 20
Sodium Hydroxide ( 5% ) 20 20 NR
Sodium Hydroxide ( 10% ) 20 20 NR

Page 30
 Splash Occasional Short Prolonged Contact
Term Contact
Sodium Hydroxide ( 30% ) 20 20 NR
Sodium Hypochlorite 20 NR NR
Sodium Sulphate ( 15% ) 60 60 60
Starch 60 60 60
Sulphur Dioxide (wet grades,100%) 20 NR NR
Sulphur Dioxide (wet grades, 5%) 20 20 20
Sulphuric Acid ( 10% ) 20 20 20
Sulphuric Acid 34% (SG 1.25) 20 20 20
Sulphuric Acid ( 50% ) 20 20 20
Sulphuric Acid 100% (SG 1.83) 20 NR NR
Sulphurous Acid ( 15% ) 20 20 20
Tetrachloroethylene 20 20 NR
Tetrahydrofuran 20 NR NR
Toluene 20 NR NR
Trichloroacetic Acid ( 10% ) 20 20 NR
Trichloroacetic Acid ( 100% ) 20 NR NR
Trichloroethylene 20 20 NR
Trichlorophenol 20 20 NR
Turpentine ( White Spirit ) 20 20 20
Water 60 60 60
Xylene 20 NR NR
Zinc Chloride 60 60 60
Zinc Sulphate 60 60 60

Page 31
 APPENDIX V

PLASCOAT PPA 571

WATER AND FOOD CONTACT APPROVALS

BELGIUM - ORGANOLEPTIC, TOXICOLOGICAL AND

BACTERIOLOGICAL PROPERTIES - NBN
S-29-001

FRANCE - DRINKING WATER APPROVAL TO DIRECTIVE

DGS AND STANDARD AFNOR XP P 41-250-1/2/3

EC - DIRECTIVE 90/128/eec FOOD CONTACT PLASTICS

GERMANY - EU RULES 89/109/EWG AND BGA

RECOMMENDATIONS FOR CONTACT WITH
FOODSTUFFS

GERMANY - DOCUMENT W272 OF DVGW - REGARDING

INCREASE IN MICRO ORGANISMS ON MATERIAL
FOR THE DRINKING WATER SECTOR.

HONG KONG - OFFICE OF THE WATER AUTHORITY - POTABLE

WATER

JAPAN - JAPANESE FOOD AND SANITATION LAW - FOOD

CONTACT

UK - WRC WATER BYE LAWS SCHEME BS 6920

UK - DWI - COMMITTEE ON CHEMICALS AND

MATERIALS OF CONSTRUCTION FOR USE IN
PUBLIC WATER SUPPLY AND SWIMMING POOLS

24 July 2000

Page 32
 APPENDIX VI

PLASCOAT PPA 571

RECOMMENDED PRETREATMENT FOR GALVANISED STEEL

No matter what organic coating is being applied onto any galvanised surface good adhesion
is always difficult without the proper pretreatment. It is therefore recommended that a test
coating is conducted on a sample of the pretreated surface in order to ensure that it is
suitable for coating and that adhesion has been obtained.

When Plascoat PPA 571 is applied over a galvanised substrate, the following guidelines
may be helpful, in order to achieve a satisfactory coating:-

For fluidised bed coatings of PPA 571 Plascoat recommend a mechanical pretreatment
using a non ferrous medium such as fine copper slag, J Blast or Carborundum powder. A
particle size of 0.2 to 0.5 mm would be suitable. Do not use angular iron grit which may
cause premature failure due to bimetallic corrosion. The blasting pressure should not
exceed 0.3 Mpa (40 psi) and we would recommend a nozzle diameter of about 6 mm and a
nozzle to work piece distance of 300 mm. High pressures may damage the galvanised
surface by weakening the bond between the zinc and the iron/zinc alloy below.

Alternatively phosphating, chromating or Gardobond 4590 can be used for PPA 571 or
Plascoat PPA 571ES applications. For high stoving temperatures (i.e. in fluid-bed
application) Gardobond 4590 or calcium-modified zinc phosphates such as Bonder 25/1 can
be used. However if the galvanised surface has been treated at the galvanising plant with a
resin phosphate system it will be necessary to remove this treatment prior to the pre-
treatments recommended below. This can be done using a strong alkaline stripper such as
Stripalene 504 (25% at 85°C for 5 mins) obtainable from Henkel Metal Chemicals, England
(Phone +44 (0) 1753 811108, Fax +44 (0) 1753 811195). It is also possible to remove it
using a solvent stripper based on NMP obtainable from Brent Europe (see below for details).

Excellent initial adhesion and salt spray results have been obtained on galvanised steel
pretreated with the following systems:-

 Phosphoric acid based degrease-cleaner-etch e.g. Walterclean 6231

5 mins at 50°C
Cold water rinse X 2.Resin based phosphate coating e.g. Walterisation RCT101 1 min at
20°C
Dry at 120°C for 5 mins

With this system it is important that the conversion coating has not cross-linked too much
because adhesion to the PPA 571ES will be poor.

All these products are supplied by Walterisation (UK) Ltd.

Phone +44 (0) 181 688 2791, Fax +44 (0) 181 688 2727.

Page 33
APPENDIX VI contd..

 Acid based degrease-cleaner-etch e.g. Pyroclean 205 at 20°C for 2 mins

Cold water rinse X 2
Conditioning rinse based on Titanium salts to create fine phosphate crystals e.g.
Parcolene X for 1 min at 20°C
Zinc phosphate plus nickel salts to minimise build up e.g. Bonderite 35 Demineralised
water rinse
Dry at 150°C for 10 mins

These products are supplied by Brent Europe Ltd., England

Phone +44 (0) 1753 630200. Fax +44 (0) 1753 817775

 Acid based degrease-cleaner-etch e.g. Pyroclean 205 at 20°C for 2 mins

Cold water rinse X 2
Hexavalent Chromate e.g. Ardrox 160 at 20°C for 1 min and dry at 50°C for 10 mins

These products are supplied by Brent Europe Ltd., England

Phone +44 (0) 1753 630200. Fax +44 (0) 1753 817775

 Predegrease Gardolene 517 2% 45-50°C 55 secs

Degrease Gardolene 517 2% 45-50°C 1 min 50 secs
Wash Water Amb 55 secs
Activation Gardolene Z/1 1.5% Amb 55 secs
Phosphate Bonder 25/1 Form 4% 2 min 9 sec
Wash Water Amb 55 secs
Wash Water Amb 55 secs

 Gardobond 4590
These products are supplied by Chemetall Ltd., England
Phone +44 (0) 1296 399233

Page 34
 APPENDIX VII

BLOWER REQUIREMENTS FOR FLUID BED POWDERS

STANDARD 550 BOX CONTAINING PPA 571

AIRFLOW REQUIREMENT = 80 M3/Hr PER M2 SURFACE AREA OF BED

BED WIDTH LENGTH AREA AIR FLOW REQUIRED

METRES METRES M2 M3/Hr Ft3/Min

1.67 0.91 1.52 121.58 71.55

PRESSURE REQUIRED = 3 x HEIGHT x BULK DENSITY x 100 mbar

POWDER POWDER BULK DENSITY PRESSURE REQUIRED

HEIGHT TYPE g/cc = kg/L mbar ins water gauge
METRES

0.84 LDPE 0.38 95.76 38.45

W.G. O'Donnell

Page 35
 TECHNICAL DATA

PLASCOAT PPA 571

Performance Polymer Alloy Coating

GENERAL DESCRIPTION
Plascoat PPA 571 has been specifically designed to provide a long lasting, tough coating for exterior applications to mild steel, galvanised steel and
aluminium. It is based on an alloy of acid modified polyolefins. Therefore it is Halogen free and the combustion fumes are low in smoke and have a
low toxicity index.
Plascoat PPA 571 is resistant to stress cracking, adverse weather conditions, detergents, salt spray and typical airborne pollutants. The coating
maintains excellent adhesion to the metal substrate without the need for a separate primer. The material also provides a good degree of electrical
insulation, abrasion and impact resistance.

PPA571 is normally applied by the Fluidised Bed process, but it can also be applied by Flock Spray.

TYPICAL USES TYPICAL PROPERTIES OF THE POWDER

Fence posts, fencing panels, sign posts, street furniture, balustrading, Coverage (100% efficiency) 3m 2/Kg at 350 microns
stadium seating, pipes including potable water, cable tray and ducting. Particle Size 95% less than 250 microns
Garden furniture, gutter brackets and wirework. Bulk Density (at rest)* 0.40 g/cm3
Fluidising Characteristics Excellent
GUIDE TO TYPICAL COATING Packaging 20 kg cardboard boxes

CONDITIONS TYPICAL PROPERTIES OF THE MATERIAL

Recommended Pretreatment:
Specific Gravity* 0.93-0.96 g/cm3
Tensile Strength ISO 527 14 MPa
To get the full benefits of the material, mild steel should be blast
Elongation at Break ISO 527 800%
cleaned to Swedish standard SA 2½-3. The optimum profile is 30
Brittleness Temperature ASTM D-746 -78°C
microns. Alternatively degreasing and iron phosphating can be used.
Hardness Shore A 95
Shore D 44
For galvanised steel the surface should be grit blasted with a fine
Vicat Softening Point ISO 306 70°C
non-ferrous medium at a low pressure. For maximum long term
Melting Point 105 °C
adhesion, a suitable phosphate or chromate system should be
Tear Strength ASTM D1938 22 N.mm
used.
Environmental
Stress Cracking ASTM D1693 Greater than 1000 hrs
For both types of metal surface, ensure any previously applied resin
Toxicity Index NES 713 1.8
based pretreatment is removed before applying your own in-house
Flammability UL94 3.2mm moulding Unrated
pretreatment. Advice on this can be obtained from your pretreatment
(see also Properties of Coating)
supplier.
Dielectric Strength IEC 243 VDE 0303 47.8 KV/mm at
370 microns
Fluid Bed Batch Operation:
Volume Resistivity IEC 93 3 x 1017 Ohm.cm
Metal preheat temperature 220°C - 320°C, depending on metal
Surface Resistivity IEC 93 8 x 1017 Ohm
thickness. Dip for 3-5 seconds or as required to achieve the desired
at 350 microns
coating thickness. A post-heat cycle at 170°C may be required to
Water Absorption ASTM D570-81 <0.03%
develop fully the surface finish on thin items.
*These values may vary from colour to colour
The process temperatures used should only be the minimum to
achieve an acceptable surface finish. However to ensure optimum STORAGE
adhesion the metal temperature must exceed 150°C. Overheating may Stored in a clean dry area at 10-25°C and out of sunlight, the
cause the coating to discolour later in storage or in service. material should not deteriorate. However, in the interest of good
housekeeping, old stocks should be used first.
Thicknesses outside the recommended range may be detrimental to
the properties of the coating. HEALTH AND SAFETY
Plascoat PPA 571 is supplied as a finely divided powder. Whilst
Flock Spray method:
there are no known health hazards associated with PPA 571,
After pre-treating the metal as above the substrate should be preheated
normal handling precautions for dealing with fine organic powders
to a metal temperature of 180 to 220°C. To ensure optimum adhesion the
should be taken - i.e. excessive dust generation and inhaling of the
metal temperature must exceed 150°C. The PPA571 can then be sprayed
powder should be avoided. Facilities may be required for removing
onto the metal until the coating no longer melts. i.e. has a "sugar-like"
excess dust from the working area during the coating of certain
appearance. The item is then returned to the oven to fully melt the
difficult items.
coating. To obtain thicker coatings more powder can be sprayed onto the
molten first coat and reheated. This process can be repeated until the
As with all polymeric powders, the material can ignite if brought into
required thickness is achieved.
contact with a high temperature source or ignition - particularly in the
fluidised condition.

Reference should be made to the respective Plascoat Health and

Safety Data Sheet, available on request.
For typical properties of the coating see overleaf.
Should the coating be required for contact with food or potable water,
further details should be obtained from Plascoat.
 TECHNICAL DATA

PLASCOAT PPA 571

Performance Polymer Alloy Coating
TYPICAL PROPERTIES OF THE COATING
The following data applies to a 350 micron coating applied under standard conditions onto 3mm thick steel or aluminium. The pretreatment
consisted of degreasing and gritblasting unless otherwise stated.

Recommended Coating Thickness 300-750 microns

Appearance Smooth/Glossy
Gloss ISO 2813 70
Impact Strength Gardner (drop weight) ISO 6272
Direct 23°C (0.7mm plate) Greater than 27 Joules
Reverse 0°C (0.7mm plate) Greater than 27 Joules
Reverse 0°C (3mm plate) 18.0 Joules
Direct 23°C (3mm plate) 2.7 Joules
Abrasion Taber ASTM D4060/84
H18, 500g load, 1000 cycles 60 mg weight loss
CS17, 500g load, 1000 cycles 25 mg weight loss
Salt Spray ISO 7253 and NF 41-002 Results after 1000 hours
Steel - Scribed Loss of adhesion less than 10mm from scribe.
Under film corrosion 1mm
- Unscribed No blistering or corrosion after 10,000 hours

Aluminium - Scribed No loss of adhesion

- Unscribed No loss of adhesion
Chemical Resistance* - Dilute Acids 60°C Good
- Dilute Alkali 60°C Good
- Salts (except peroxides) 60°C Good
- Solvents 23°C Poor
Adhesion PSL, TM 19 A-1
Weathering QUV ASTM G53-77 2000 hrs - No significant change in colour or
loss of gloss.
Florida 45° facing South 3 years - No significant change in colour or
loss of gloss.
Burning Characteristics
Ignitability BS476: Pt5: 1979 P - not easily ignitable
500 micron coating
Surface spread of flame BS476: Pt7: 1979 Class 1
500 micron coating
Fire Propagation BS476: Pt6: 1989 I = 0.2
500 micron coating
Flammability UL94 Vo (see also Properties of Material)
Safe Working Temperature (Continuous in air) 60°C max
*The results given are for full immersion in the chemicals for a prolonged period of time. The coating is resistant to splashes and short term contact
of most chemicals. Further technical advice may be obtained from Plascoat concerning the effects of particular chemicals or mixtures.

QUALITY DISCLAIMER
Plascoat is committed to the manufacture and supply of a wide range The information given here is, to the best of our knowledge, true and
of thermoplastic coating powders. This service is backed by the accurate.
unrivalled experience of over 50 years of powder coating application.
With a policy of continuous improvement to its range of products, Product and item design, pre-treatment, coating conditions, quality
Plascoat reserves the right to alter or amend any item. Stringent assurance and conditions of product end use are among the factors
quality control procedures are carried out at every relevant stage of that affect performance of the coated products and are outside
manufacture and Plascoat operates a quality management system Plascoat’s control.
approved by BSI in accordance with ISO 9001:2008.
Conditions under which our materials may be used are beyond our
Plascoat can also offer, through its factories in Europe, specialist control. The suitability for application and performance of finished
plastic coating equipment, an extensive custom coating service and a goods coated with Plascoat material is the sole responsibility of the
size reduction service for plastics and other materials. customer and end user.

Plascoat is a subsidiary member of the IPT Group of companies. Plascoat expressly denies specific or implied warrantees including
Plascoat is an EU registered trade name. warrantees for fitness for a particular use or purpose.

Plascoat Systems Limited Plascoat Europe BV Plascoat Corp. Plascoat Corp.

Farnham Trading Estate, PO Box 9 2700 Avenger Drive Crown Center
Farnham, Surrey, 3214ZG Suite 108 Suite 600
GU9 9NY Zuidland Virginia Beach 5005 Rockside Road
United Kingdom The Netherlands VA 23452 Cleveland
Tel: +44(0)1252 733777 Tel:+31 (0) 181 458 888 USA OH44131
Fax: +44(0)1252 721250 Fax:+31 (0) 181 458 877 Tel: (844)-PLASCOAT U.S.A
Web site: www.plascoat.com [email protected] (844-752-7262)
[email protected] [email protected]
PPA571/ 05/07/2010 /HM
 TECHNICAL DATA

PLASCOAT PPA 571 ES

Performance Polymer Alloy Coating
GENERAL DESCRIPTION
Plascoat PPA 571 ES is a thermoplastic coating powder which has been specifically designed to provide a long lasting, tough coating for exterior
applications to mild steel, galvanized steel and aluminium. It is based on an alloy of acid modified polyolefins. Therefore it is Halogen free and the
combustion fumes are low in smoke and have a low toxicity index.
Plascoat PPA 571 ES is resistant to stress cracking, adverse weather TYPICAL PROPERTIES OF THE POWDER
conditions, detergents, salt spray and typical airborne pollutants. The coating
Coverage (100% efficiency) 5.2m 2/Kg at 200 microns
maintains excellent adhesion to the metal substrate without the need for a
Particle Size 95% less than 150 microns
separate primer. The material also provides good abrasion and impact
Bulk Density (at rest)* 0.40 g/cm3
resistance. If PPA571ES over-sprayed powder is to be recycled then blend a
Packaging 20 kg cardboard boxes
maximum of 25% of this over-sprayed powder with 75% of virgin powder.
TYPICAL USES TYPICAL PROPERTIES OF THE MATERIAL
Fencing, fan guards.
Specific Gravity* 0.93-1.06 g/cm3
SUMMARY OF ESSENTIAL COATING Tensile Strength ISO 527 14 MPa
Elongation at Break ISO 527 800%
REQUIREMENTS Brittleness Temperature ASTM D-746 -78°C
1. The metalwork must be either grit blasted or chemically Hardness Shore A 95
pretreated prior to coating. * Shore D 44
2. Set amps to 5 – 15 microAmps and voltage to 100kV if both Vicat Softening Point ISO 306 70°C
Melting Point 105 °C
settings are available.For Corona guns with voltage setting
Tear Strength ASTM D1938 22 N.mm
only, set voltage at 30-50 kV. Failure to use the correct Environmental
settings may result in coatings that are too thin or with Stress Cracking ASTM D1693 Greater than 1000 hrs
poor coverage. Toxicity Index NES 713 1.8
3. Heating schedule typically as polyester (See below). Flammability UL94 3.2mm moulding Unrated
Ensure metal temperature exceeds 150°C. * (see also Properties of Coating)
4. Thickness must be a minimum of 170 microns. (See note 2 Electrical
re voltage above). This may also require a longer spraying Dielectric Strength IEC243 VDE0303 47.8 KV/mm at
370 microns
time or increased powder supply. This thickness should
Volume Resistivity IEC 93 3 x 1017 Ohm.cm
be periodically checked. Surface Resistivity IEC 93 8 x 1017 Ohm
5. Galvanised substrates may need degassing. Preheat to at 200 microns
30°C higher than the postheat temperature for at least as Water Absorption ASTM D570-81 <0.03%
long as the postheat time.
6. Do not use cured resin based pretreatment systems, e.g. *These values may vary from colour to colour
acrylic based phosphates or chromates. If the metal-work
has been pretreated with these remove by gritblasting or STORAGE
strong alkaline rinse. Stored in a clean dry area at 10-25°C and out of sunlight, the
7. Adhesion checks should be carried out at regular material should not deteriorate. However, in the interest of good
intervals.* housekeeping, old stocks should be used first.
* See "PPA571 Process Guide"
HEALTH AND SAFETY
GUIDE TO TYPICAL COATING CONDITIONS Plascoat PPA 571 ES is supplied as a finely divided powder. Whilst
Recommended Pretreatment: there are no known health hazards associated with PPA 571 ES,
The metal must be degreased and all mill scale and corrosion products normal handling precautions for dealing with fine organic powders
removed. should be taken - i.e. excessive dust generation and inhaling of the
Mild steel should be solvent degreased then either grit blasted to Swedish powder should be avoided. Facilities may be required for removing
Standard SA 2½ to 3 or phosphated. Galvanised steel should be either grit excess dust from the working area during the coating of certain
blasted at 0.3MPa (40 psi) using a fine grit (0.2 to 0.5mm) or treated with a difficult items.
phosphate system. To achieve maximum long term adhesion, Plascoat
recommend the use of zinc phosphate systems on both steel and galvanised As with all polymeric powders, the material can ignite if brought into
steel. If chemical pretreatment is used it is essential to remove any previously contact with a high temperature source or ignition - particularly in the
applied resin based pretreatment systems. Discuss this with your fluidised condition.
pretreatment supplier.
Aluminium should be degreased to remove lubricants and processing soaps. Reference should be made to the relevant Plascoat Health and
For most purposes no further treatment is necessary. However for maximum Safety Data Sheet, available on request.
long term corrosion resistance chromate treatment is recommended.
Coating Conditions: Should the coating be required for contact with food or potable water,
The heating schedule should be 160°C to 220°C for 5-40 mins depending on further details should be obtained from Plascoat.
metal thickness. To ensure optimum adhesion, the metal temperature during
processing must exceed 150°C. Since Plascoat PPA 571 ES is a For typical properties of the coating see overleaf.
thermoplastic there is no crosslinking to take place. Therefore when the
powder has melted to form a smooth coating no further heating is required.
Overheating can cause craters to form in the coating, or the coating to reduce
in gloss. It may also cause the coating to discolour in storage or in service.
Thicknesses outside the recommended range may be detrimental to the
properties of the coating.
Do not cure thermosetting powder paints with PPA 571 ES. The fumes
from such systems can affect the surface of the PPA 571 ES coatings.
TECHNICAL DATA

PLASCOAT PPA 571 ES

Performance Polymer Alloy Coating
TYPICAL PROPERTIES OF THE COATING
The following data applies to a 200 micron coating applied under standard conditions onto 3mm thick steel or aluminium. The pretreatment
consisted of degreasing and gritblasting unless otherwise stated.

Recommended Coating Thickness 170-300 microns

Appearance Smooth/Glossy
Gloss ISO 2813 70
Impact Strength Gardner (drop weight) ISO 6272
Direct 23°C (0.7mm plate) Greater than 27 Joules
Reverse 0°C (0.7mm plate) Greater than 27 Joules
Reverse 0°C (3mm plate) 18.0 Joules
Direct 23°C (3mm plate) 2.7 Joules
Abrasion Taber ASTM D4060/84
H18, 500g load, 1000 cycles 60 mg weight loss
CS17, 500g load, 1000 cycles 25 mg weight loss
Salt Spray ISO 7253 and NF 41-002 Results after 1000 hours
Steel - Scribed Loss of adhesion less than 10mm from
scribe.
- Unscribed Under film corrosion 1mm
After 10,000 hrs - No blistering or
Aluminium - Scribed
corrosion.
- Unscribed
No loss of adhesion
No loss of adhesion
Chemical Resistance* - Dilute Acids 60°C Good
- Dilute Alkali 60°C Good
- Salts (except peroxides) 60°C Good
- Solvents 23°C Poor
Adhesion PSL, TM 19 A-1
Weathering QUV ASTM G53-77 2000 hrs - No significant change in
colour or
Florida 45° facing South loss of gloss.
3 years - No significant change in colour
or
loss of gloss.
Burning Characteristics
Ignitability BS476: Pt5: 1979 P - not easily ignitable
500 micron coating
Surface spread of flame BS476: Pt7: 1979 Class 1
500 micron coating
Fire propagation BS476: Pt6: 1989 I = 0.2
500 micron coating
Flammability UL94 Vo (see also Properties of Material)
Safe Working Temperature (Continuous in air) 60°C max
*The results given are for full immersion in the chemicals for a prolonged period of time. The coating is resistant to splashes and short term contact
of most chemicals. Further technical advice may be obtained from Plascoat concerning the effects of particular chemicals or
mixtures.

QUALITY DISCLAIMER
Plascoat is committed to the manufacture and supply of a wide range The information given here is, to the best of our knowledge, true and
of thermoplastic coating powders. This service is backed by the accurate.
unrivalled experience of over 50 years of powder coating application.
With a policy of continuous improvement to its range of products, Product and item design, pre-treatment, coating conditions, quality
Plascoat reserves the right to alter or amend any item. Stringent assurance and conditions of product end use are among the factors
quality control procedures are carried out at every relevant stage of that affect performance of the coated products and are outside
manufacture and Plascoat operates a quality management system Plascoat’s control.
approved by BSI in accordance with ISO 9001:2008. Conditions under which our materials may be used are beyond our
Plascoat can also offer, through its factories in Europe, specialist control. The suitability for application and performance of finished
plastic coating equipment, an extensive custom coating service and a goods coated with Plascoat material is the sole responsibility of the
size reduction service for plastics and other materials. customer and end user.

Plascoat is a subsidiary member of the IPT Group of companies. Plascoat expressly denies specific or implied warrantees including
Plascoat is an EU registered trade name. warrantees for fitness for a particular use or purpose.

Plascoat Systems Limited Plascoat Europe BV Plascoat Corp. Plascoat Corp.

Farnham Trading Estate, PO Box 9 2700 Avenger Drive Crown Center
Farnham, Surrey, 3214ZG Suite 108 Suite 600
GU9 9NY Zuidland Virginia Beach 5005 Rockside Road
United Kingdom The Netherlands VA 23452 Cleveland
Tel: +44(0)1252 733777 Tel:+31 (0) 181 458 888 USA OH44131
Fax: +44(0)1252 721250 Fax:+31 (0) 181 458 877 Tel: (844)-PLASCOAT U.S.A
Web site: www.plascoat.com [email protected] (844-752-7262)
[email protected] [email protected]
TECHNICAL DATA
PPA571ES/06/01/2012/SA
PPA571ES TIME TEMPERATURE CURVES

Time and Temperature Graphs Collated From

Post-heat Schedules for PPA571ES on
Empirical Test data
1.5 m m Steel Plate

Application settings :- 30 – 50 kV = 10 – 20
Microamps (depending on profile to be sprayed.)
70

60 1.5 mm 160°C 190°C 220°C

Min. Time mins 20 13 5
50 Max Time mins 60 25 13
Time in Minutes

40

30 2.0 mm 160°C 190°C 220°C

Min. Time mins 25 16 8
20 Max Time mins 70 30 15

10

0 3.0 mm 160°C 190°C 220°C

160°C 190°C 220°C Min. Time mins 30 17 9
Max Time mins 80 40 17
Min.Time Max.Time

Post-heat Schedules for PPA571ES on Post-heat Schedules for PPA571ES on

2.0 m m Steel Plate 3.0 m m Steel Plate

80 90

70 80

70
60

60
50
Time in Minutes
Time in Minutes

50
40
40
30
30

20
20

10 10

0 0
160°C 190°C 220°C 160°C 190°C 220°C

Min.Time Max.Time Min.Time Max.Time

TECHNICAL DATA

Post-heat Schedules for PPA571ES on Wires

of Various Diameters at 160°C

40
30
Max.Time
20
10 Min.Time
0

Post-heat Schedules for PPA571ES on

Wires of Various Diameters at 190°C
Time in Minutes

25
20
15 Max.Time
10 Min.Time
5
0
m

10 m
m
m

m
1

9
 SAFETY DATA SHEET
SECTION 1 Identification of the substance/mixture and of the
company/undertaking
1.1 Product identifier:
Substance Name: PPA 571, ES, H, HES, FS & AQUA
(Includes all Colours as Stated on Packing Product Label)

1.2 Relevant identified uses of the substance or mixture and uses advised against:
Relevant identified uses:
Thermoplastic coating powders for application by fluidised bed, electrostatic spray or flock
spraying.

Uses advised against:

Any process which would require the product to be at temperatures above 300C for prolonged
periods.

Reasons why used advised against:

The product will degrade in these conditions.

1.3 Details of the Supplier of the Safety Data Sheet:

Plascoat Systems Limited
Farnham Trading Estate
Farnham
Surrey
GU9 9NY
United Kingdom

Email address: [email protected]

(This email will only be checked during office hours Monday to Friday
08.30 to 17.00 GMT)

1.4 Emergency Telephone Number:

+44 (0)1252 733777
(Available during office hours Monday to Friday 08.30 to 17.00 GMT)

SECTION 2 Hazards identification

2.1 Classification of the substance or mixture:

2.1.1 Classification: According to Regulation (EC) No. 1272/2008 (CLP).

These mixtures are not classified.

2.2 Label elements

Not applicable.

2.3 Other hazards

Although these mixtures are not classified they can be considered as nuisance dusts.

Issue 1 Date 29/05/15 Ref: GHS- PPA 571, ES, H, HES, FS & AQUA Page 
SECTION 3. Composition / information on
ingredients
3.2 Mixtures:
A melt compounded matrix of functionalised polyolefins including pigments and additives.
This mixture does not contain (above relevant concentration limits) any substances presenting a
health or environmental hazard within the meaning of Regulation (EC) No. 1272/2008, assigned a
Community workplace exposure limit, classified as PBT/vPvB or included in the Candidate List.

SECTION 4 First aid measures

4.1 Description of first aid measures

Inhalation: In case of adverse exposure to vapours formed at elevated temperatures,

remove victim from exposure. Administer artificial respiration if breathing has
stopped. Call for medical attention.

Skin Contact: Powder should be washed off with soap and water.

Eye Contact: Product is an inert solid, wash with water. If required seek medical advice

Ingestion: For accidental ingestion of small quantities first aid is not normally required.
If large quantities are accidentally ingested, request medical advice.

4.2 Most important symptoms and effects, both acute and delayed
See section 11.

4.3 Indication of any immediate medical attention and special treatment needed
Not applicable.

SECTION 5 Firefighting measures

5.1 Extinguishing media:

Suitable extinguishing media: Low pressure systems such as foam (AFFF), powder, water
spray or mist.

Unsuitable extinguishing media: High pressure systems such as inert gas or water jets.

5.2 Special hazards arising from the substance or mixture:

Hazardous combustion products: May include carbon monoxide, carbon dioxide, hydrocarbons,
aldehydes, ketones, organic acids, smoke and fumes.

5.3 Advice for fire-fighters:

For large fires breathing apparatus is required.

Issue 1 Date 29/05/15 Ref: GHS- PPA 571, ES, H, HES, FS & AQUA Page 
SECTION 6 Accidental release measures
6.1 Personal precautions, protective equipment and emergency procedures
If spillage is large and dust levels are high, dust masks should be worn, and in enclosed spaces
take precautions against dust explosion hazards.

6.2 Environmental precautions:

No hazard involved but since powder floats on water and is unsightly, prevent from entering water
courses.

6.3 Method and materials for containment and cleaning up:

Vacuum up dust. The use of brushes may cause dust cloud formations and potential dust
explosion hazards.

6.4 Reference to other sections:

See section 8.

SECTION 7 Handling and storage

7.1 Precautions for safe handling:
When emptying bags avoid dust cloud formation and/or static build up to prevent potential dust
explosion hazards. In case of large amounts of dust, wear respiratory protection.
During processing provide adequate local exhaust ventilation (LEV).

7.2 Conditions for safe storage, including any incompatibilities:

Store in a well ventilated dry environment.

7.3 Specific end use(s)

See section 1.2.

SECTION 8 Exposure controls / personal protection

8.1 Control parameters:
Powder in air should be treated as a dust as recommended in HSE Publication EH40/2005. Thus
the “Time Weighted Average 8 hours” should be kept below 10 mg/m 3 of total inhalable dust, or 4
mg/m3 of respirable dust.

8.2 Exposure controls:

8.2.1 Appropriate engineering controls: LEV suitable for “Dust” and “Fume” extraction shall be
used. See section 8.1
8.2.2 Personal protection equipment:
8.2.2.1 Eyes and face protection: Not normally necessary but if very dusty wear safety goggles.
8.2.2.2 Skin protection: Hands protection: During processing heat resistant gloves should be worn.
8.2.2.3 Respiratory protection: If dusty wear dust masks. If local exhaust ventilation is inadequate
wear fume mask.

Issue 1 Date 29/05/15 Ref: GHS- PPA 571, ES, H, HES, FS & AQUA Page 
SECTION 9 Physical and chemical properties
9.1 Information on basic physical and chemical properties:
Appearance: Powder
Colour: Various : As stated on the Product Label
Odour: Waxy
Specific Gravity: 0.94 - 0.98
Melting Point: 90 - 130°C
Boiling Point: Not relevant
Solubility in Water: Not soluble
Vapour Pressure: Not relevant
Flammability: Only flammable at high temperatures (see 10.4)

9.2 Dust explosion data

Maximum Explosion Pressure: 6.2 bar g (BS EN 14034-1:2004)
Kst Value: 40-60 bar.m.s-1 (BS EN 14034-2:2006)
St Class: 1 (BS EN 14034-2:2006)
Minimum Ignition Energy: 100 - 500 mJ (BS EN 13821:2002)
Minimum Ignition Temperature: 300 to 400°C (BS EN 50281-2-1:1999)
Minimum Explosive Concentration (MEC)
PPA 571ES, PPA 571HES - 140 g/m3 * (BS EN 14034-3: 2006)
PPA 571, PPA 571H, PPA 571FS , AQUA - 200 g/m3 * (BS EN 14034-3: 2006)

*These figures are based on tests performed on a similar product.

SECTION 10 Stability and reactivity

10.1 Reactivity:
At ambient temperatures the substance is stable.

10.2 Chemical stability:

At ambient temperatures the substance is stable

10.3 Possibility of hazardous reactions:

At ambient temperatures the substance is stable

10.4 Conditions to avoid:

Prolonged exposure to temperatures in excess of 300ºC (See 10.1)

10.5 Incompatible materials:

Strong oxidising agents.

10.6 Hazardous decomposition products

From Processing: Fumes contain low molecular weight aliphatic hydrocarbons, fatty acids and
fatty acid esters and other organic acids.

Issue 1 Date 29/05/15 Ref: GHS- PPA 571, ES, H, HES, FS & AQUA Page 4
SECTION 11 Toxicological information
11.1 Information on toxicological effects

Ingestion: This powder is considered inert; it should therefore produce no significant

toxic response.

Skin Contact: May cause irritation if caught between skin and clothing.

Eye Contact: Like any inert dust will cause irritation.

Inhalation: Processing fumes may cause irritation, see 10.6. Excessive dust may cause
irritation to the respiratory tract, see 2.1.1 and 16 (III).

SECTION 12 Ecological information

12.1 Toxicity:
The powder will float on water and is unsightly.
Not expected to be harmful to aquatic organisms.
Not expected to be harmful to terrestrial organisms.

12.2. Persistence and degradability

Biodegradation:
Low biodegradability.

Hydrolysis:
Transformation due to hydrolysis not expected to be significant.

Photolysis:
Transformation due to photolysis not expected to be significant.

Atmospheric oxidation:
Transformation due to atmospheric oxidation not expected to be significant.

12.3. Bio-accumulative potential

Potential to bio-accumulate is low.

12.4. Mobility in soil

Low mobility in soil.

12.5. Results of PBT and vPvB Assessment

Does not contain any substances that are assessed to be a PBT or a vPvB.

12.6. Other adverse effects

No adverse effects are expected.

Issue 1 Date 29/05/15 Ref: GHS- PPA 571, ES, H, HES, FS & AQUA
SECTION 13 Disposal consideration

13.1. Waste treatment methods

The European Waste Catalogue classification of this product, when disposed of as waste, is 08 02
01 `Waste Coating Powders’. If this product is mixed with other wastes, the original waste product
code may no longer apply and the appropriate code should be assigned. For further information
contact your local waste authority.

13.1.1 Product / packaging disposal:

Product disposal:
Can be recycled or used for landfill dependent on local regulations.

Packaging disposal:
Pallets are recyclable. Cardboard boxes can be recycled, incinerated or used for landfill. The
inner liners and shrink wrap can be recycled, incinerated or used for landfill dependent on local
regulations.

SECTION 14 Transport
14.1. UN number
ADR/RID, ADN, IMDG & IATA: Not regulated

14.2. UN proper shipping name

ADR/RID, ADN, IMDG & IATA: Not applicable

14.3. Transport hazard class(es)

ADR/RID, ADN, IMDG & IATA: Not applicable

14.4. Packing group

Not applicable

14.5. Environmental hazards

Not applicable

14.6. Special precautions for user

Not applicable

14.7. Transport in bulk according to Annex II of MARPOL 73/78 and the IBC Code
Not applicable

SECTION 15 Regulatory information

15.1. Safety, health and environmental regulations/legislation specific for the substance or
mixture
There are no regulatory requirements for this product.
15.2. Chemical Safety Assessment
No Chemical Safety Assessment has been carried out for this mixture by the supplier.

Issue 1 Date 29/05/15 Ref: GHS- PPA 571, ES, H, HES, FS & AQUA Page 
SECTION 16 Other information
I. The issue number and Date compiled are indicated in the page footers.

II. Modifications to the previous issue of this SDS are indicated by””

III. The information presented here is given in good faith and to the best of our knowledge, true
and accurate.

IV. This information may be subject to modification from time to time in the light of: legislation,
our experience and our policy of continuous development.

V. It is the user’s responsibility to verify that they are using the latest issue of the SDS in
conjunction with the latest copy of our Technical Data Sheet.

VI. Conditions under which our materials may be used are beyond our control. Hence, no
responsibility or liability, expressed or implied, can be accepted by Plascoat for any
problems which may arise as a result of any actions or decisions that may be taken by the
coating applicator, or by any other party that may be involved with specifying or using the
material.

VII. The product should not be used for purposes other than those shown in Section 1 without
first referring to the supplier and obtaining written handling instructions. As the specific
conditions of use of the product are outside the supplier’s control, the user is responsible for
ensuring that the requirements of relevant legislation are complied with.

VIII. The information in this safety data sheet is based on the present state of knowledge and
current legislation. It provides guidance on health, safety and environmental aspects of the
product and should not be construed as any guarantee of technical performance or
suitability for particular applications.

Issue 1 Date 29/05/15 Ref: GHS- PPA 571, ES, H, HES, FS & AQUA