Paint Specifications

Document: SF-ENG-SPEC - 001

Revision: A
Date: 08/02/2021

Owner Approval Approval Date

Jeff Stabell 08/02/2021

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1.0 PURPOSE
1.1 This document is to quantify and standardize the communication of paint system
performance requirements and the means to determine conformance. Many of the
conformance/validation tests rely on the appropriate ASTM standard to guide the testing.
2.0 DEFINITIONS:
2.1 Category Detail: A specific chosen category in a performance requirement i.e. performance
requirement = UV Resistance and category detail = High.
2.2 Delta E: The difference between two L.A.B color readings

2.3 Normal Sightline: Roughly considered to be above the knees and below the head of an
average height person (~5’9” tall).
2.4 Paint Performance: The appearance and protective capabilities of a paint system.
2.5 Paint Performance Requirements: The requirements that ensure the painted part will meet
the Safe Fleet required paint performance for the required amount of time. The
communication of these requirements is detailed in this document.
2.6 Paint System: This system contains the paint itself as well as the means and method of
applying the paint to the part substrate. The paint system is required to successfully meet all
of the Safe Fleet identified paint performance requirements. Each particular paint system will
have its own requirements but these may vary between suppliers of the paint and the
different substrates and parts that are painted.
2.7 Paint System Requirements: The paint system application and pretreatment requirements
dictated by the paint system supplier. These can include specifics such as cure
time/temperature, drying time/temperature, line speed, needed pretreatments, priming,
surface conditioning, cleaning solutions, paint thickness, and other requirements needed to
ensure paint performance.
2.8 Performance Requirement: A specification category. i.e. UV Resistance, Gloss, Texture, or
Impact Resistance.
2.9 Safe Fleet: This includes Safe Fleet as a whole and any of its divisions known by other
names (FRC, SMI, ROM, Prime Design, Randall, Roll Rite, American Van, etc…)
2.10 Substrate: The base material that is to be painted before any pretreatment or primer.
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3.0 RESPONSIBILITIES:
3.1 The Paint System supplier is responsible for meeting the required paint performance
specifications as outlined in this document. They must also communicate any
application/paint system requirements needed to satisfy the required paint performance as
outlined under section 2.1/2.2.
3.2 Safe Fleet Quality is responsible for determining conformance to the required paint
performance specifications.
3.3 Safe Fleet Engineering is responsible for specifying the required paint performance in
accordance with this document. They must also update and maintain the individual Safe
Fleet Plant color reference chart detailed in section 6.1 and designate all surface classes on
the part drawing as needed. All new painted part drawings after September 2021 will comply,
and where possible any older drawings that are being revised should also have this
information captured on the drawing.
3.4 Safe Fleet Program/Project/Sales departments are responsible for determining colors and/or
finding and communicating the customer paint color and system performance requirements
to Safe Fleet Engineering.
3.5 It is the ultimate responsibility of the Plant Manager to see that this procedure is understood
and followed.
3.6 It is the responsibility of all affected Safe Fleet Employees to understand and know how to
use the standards out lined in this work instruction.
4.0 GENERAL APPLICATION
4.1 This is for all paint systems used in the painting of parts in all of Safe Fleet’s products.
4.2 Suppliers of products covered in this specification shall not deviate from the paint
performance requirements outlined, unless prior written approval is provided by Safe Fleet
through the Supplier ECN process or Supplier Deviation process as defined in the Safe Fleet
Supplier Quality Manual. Safe Fleet may request evidence of compliance at any time.
4.3 This specification is not intended to limit the paint system, but for parts that are painted by
Safe Fleet, awareness needs to be maintained of individual plant process limitations. These
limitations may restrict the kinds of pretreatment, washing, cure timing/temperature, and
other paint system needs.
5.0 TECHNICAL GUIDELINES
5.1 Basic Requirements: Unless otherwise specified by Safe Fleet, painted parts and paint
systems used in Safe Fleet products shall meet the paint performance specifications stated.
5.2 Hazardous Requirements: Coatings cannot contain or be manufactured with any heavy
metals (i.e. Cadmium, Mercury, Lead), Hexavalent Chrome or any other material that in itself
or as a result of the manufacturing process is considered hazardous or creates a byproduct
that is considered hazardous.
5.3 Determining Basic Requirements: Requirements are chosen by the Safe Fleet engineering
group from each requirement’s detailed categories using specific part application knowledge.
Every effort should be made to use the categories as detailed in this standard, but Customer
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specified paint performance might supersede any specific detail category. There may be
parts that are not required to meet a particular performance requirement and will be noted as
N/A for that particular requirement.
5.4 Paint Performance Requirements: Each performance requirement below is detailed below
with several categories.
5.4.1 UV Resistance:
Table 1 UV Resistance Standards

UV Resistance Warranty Use Test Time Measurement for

Conformance

Standard 18 Months Internal/Light Duty 500 Hours <=3 Delta E

High 36 Month External/Heavy 1000 Hours <=3 Delta E

Duty

5.4.1.1 Validation based on ASTM D45878.

5.4.1.1.1 Validation to be conducted on a minimum of four paint coupons
made of the same substrate material and painted with the same
specified paint system.
5.4.1.1.2 Paint coupons to be roughly 3”x6” in dimensions
5.4.1.1.3 Delta E to be judged using a L.A.B. Delta E comparison between ½
of the coupons being unexposed to UV and ½ of the coupons
going through the UV testing cycle. The two results are averaged
for review.
5.4.2 Adhesion
5.4.2.1 Validation of Paint Adhesion to be judged for conformance using the ASTM D
3359 Test Method B – Cross Hatch
5.4.2.2 All Painted parts must be =>4B
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Table 2 Crosscut Reference Chart

5.4.3 Impact Resistance

Table 3 Impact Resistance

Impact Resistance Impact Force Conformance Criteria

Low Up to 50 lb-in Up to 57 kg-cm No Cracking Observed

Standard 50-140 lb-in 57 – 161 kg-cm No Cracking Observed

High >140 lb-in >161 kg-cm No Cracking Observed

5.4.3.1 Validation of impact resistance is to be performed per ASTM D2794

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5.4.4 Flexibility
5.4.4.1 Validation to be performed per ASTM D522-D522M Mandrel Bend test
5.4.4.1.1 Conformance to be judged based on the test being performed and
the sample shows no cracking or tearing.
5.4.5 Paint Curing/MEK Test:Test for under cured powder coating.
5.4.5.1 Equipment required:
 Reagent B (a solution mix of 10% MEK and 90% Xylene by volume). Store
solution in a MEK squeeze bottle (make sure it is properly labelled).
 2 lb. ball peen hammer.
 Soft cloth or folded into a 3" x 3" pad, 1/2" thick.
 Fastening device to attach pad to ball end of hammer.
 Painted test samples.

5.4.5.2 MEK Process

5.4.5.2.1 Fold the cloth into a 3" x 3" approximately 1/2" thick.
(Approximately 4 - 6 layers of folded cloth.)
5.4.5.2.2 Attach the 3" x 3" cloth to the ball end of the ball peen hammer
using an O-ring or wire to secure it. - this cloth should be changed
with each test, as paint build-up will affect the test
5.4.5.2.3 Saturate the pad in Reagent B. Caution: Reagent B is flammable -
use with adequate ventilation.
5.4.5.2.4 Select a test area that is flat and free of blemishes.
5.4.5.2.5 Holding the handle of the hammer parallel to the test piece,
stroke/slide the saturated pad approximately 1 ½” on the test piece
using only the weight of the hammer as pressure. Look for obvious
signs of fatigue. Do 100 double rubs (i.e.: forward and back equals
1 rub). Warning: Do not rub too hard or too quickly as this will
result in an inaccurate rub.
5.4.5.3 Rate as follows:
 Dissolve to metal: No cure. (NC)
 Some film removal and softening: Partial cure. (PC)
 Gloss reduction only with no or minimal effect on the paint: Cure. (C) (As
per known cure sample)

5.4.5.4 A rating of anything less than "Cure" is an indication of under-cured

powder coat and as such is a non-conformance and the appropriate
corrective action needs to be taken. All parts must "Cure" before being
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released into production.

5.4.6 Corrosion Resistance
Table 4 Corrosion Resistance

Hours of Salt
Corrosion Conformance
Spray Use
Resistance Criteria
Testing

Light Duty 100 Hours Internal <= 1/8” Creep

Standard Duty 500 Hours External <= 1/8” Creep

Heavy Duty 1000 Hours Salt Belt/Coastal <= 1/8” Creep

Extreme Duty >2000 Hours Marine <= 1/8” Creep

5.4.6.1 Validation testing to be performed according to ASTM B117 using a minimum

of two samples.
5.4.6.2 Use the actual part substrate material in a 3”x 6” coupon with one ¼” hanging
hole and coat according to the paint system being evaluated.
5.4.6.3 No scoring of paint is to be used
5.4.6.4 At the end of the salt spray testing, corrosion creep from hanging hole must be
less than 1/8” to conform.
5.4.7 Rework Criticality
5.4.7.1 The part must be identified as either being rework critical (Yes) or not (No).
5.4.7.2 A non-critical part will be able to tolerate up to 200% of the nominal paint
system thickness without out negatively affecting part function or fitment.
5.4.7.3 A Rework Critical part will not tolerate paint thickness being 200% of nominal.
Fitment and as a result function maybe negatively affected.
5.4.8 Color
5.4.8.1 Paint color will be identified by name, L.A.B., Pantone, and RAL
5.4.8.1.1 L.A.B to be identified by a colorimeter/spectrophotometer on an
approved sample paint coupon.
5.4.8.1.2 Pantone and RAL can be found by using an online web based
conversion tool to convert from the L.A.B. reading. (Example:
https://www.e-paint.co.uk/convert-lab.asp)
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5.4.9 Color Conformance

Table 5 Color Conformance

Conformance Level Delta E Allowed

Relaxed <=3

Close <=2

Exact <=1

5.4.9.1 Color Conformance will be judged based on the above chart using the
previously identified color L.A.B. and new L.A.B. readings from the suspected
part.
5.4.9.1.1 The Delta E will be calculated using the formula in Section 2.2.
5.4.10 Texture
5.4.10.1 Paint texture must be identified
5.4.10.1.1 The part will either have an intended texture (Yes) or not (No).
5.4.10.1.2 Conformance will be based on comparing the suspected finish vs.
the approved sample coupon from the paint system supplier with
the correct color and texture applied.
5.4.10.1.3 Texture sample coupons to be inventoried and maintained by the
plant personnel responsible for determining conformance. Care
should be taken to prevent damage, fading from UV, and oxidation
of the approved sample coupons.
5.4.10.1.4 Viewing practices will be the same as those required for cosmetic
acceptance (Figure 1).
5.4.11 Gloss Level
Table 6 Gloss Level

Gloss Level Angle of Incidence Gloss Meter Reading

Low 85 3-40

Medium 60 50-90

High 20 90-100

5.4.11.1 Conformance to be performed using a gloss meter and comparing the

readings to the chart above.
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6.0 Documentation of Requirements

6.1 Color Reference Chart
6.1.1 The color reference chart is created and maintained by engineering at each Safe
Fleet location. (See form Safe Fleet Corporate Color Chart SF-ENG-SPEC-002.xlsx)
6.1.2 Suppliers must contact the local Safe Fleet Plant for latest released Color Chart for
that plant location. Each plant location will have a different Color Chart.
6.1.3 The color reference chart will have the Color Name, LAB/CEILAB numbers, RAL,
Pantone, Gloss, Texture, and approved supplier’s names with paint system part
number.
Table 7 Safe Fleet Color Reference Chart Example

6.1.4 The Spec Matrix tab within the color reference chart file will be used to create the
Required Paint System table (Table 8).
6.1.4.1 This will document the Color Name (can be more than one), Impact
Resistance, Color Delta E Allowance, Default Surface Classification, UV
Resistance, Corrosion Resistance, and Rework Critical designation.
NOTE: Some of the requirements can/must be labeled “N/A” should the plant
engineering team decide that conformance to that specification is not needed
in that particular application.
6.1.4.2 Once the Required Paint System Specification table (Table 8) is filled out, it will
be copied into the appropriate note section of the part drawing. Part drawing
revision control will control any release or modification of this information
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Table 8 Required Paint System Specification Record Example

Required Paint System Specifications

Color Ultramarine Impact

Standard
Name Blue Resistance

Color Default
Delta E Close Surface B
Allowance Classification

UV Corrosion Standard
High
Resistance Resistance Duty

Rework
No/200% ok
Critical

7.0 Recommended Tool list

7.1 The following tools are recommended for implementing this specification.
Approximate cost
Related Specification Tool Type Tool Name Implementation
as of July 2021
Color/Color Color
Color Muse $59.99/Amazon All Plants
Conformance Photospectrometer
$138 -
Gloss Gloss Meter Glossmeter All Plants
$184/Amazon
Adhesion Cross Hatch Tester Adhesion tester $45/Amazon All Plants
ZQ-II Bending
Flexibility Mandrel Bend Tester $230/Amazon All Plants
Tester
UV Resistance UV Cabinet N/A N/A SMI/External Lab
Corrosion Resistance Salt Spray Chamber N/A N/A SMI/External Lab
Heavy Duty
$2196/Gardco.co TBD/External
Impact Resistance Impact Tester Impact Tester
m Lab
IM-IG-1120

8.0 Cosmetic Acceptance Criteria for Painted Parts

8.1 General Inspection Requirements:
8.1.1 Cosmetic inspection for painted parts from Safe Fleet or it suppliers shall use the
following time, distance and angle method to inspect as described in different section
of this document.
8.1.2 The cosmetic standards defined in this Workmanship Standard shall be used for
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training personal, checking surface quality produced by any process and used in
making “Accept/Reject“ decisions.
8.2 Viewing Conditions:
8.2.1 All Inspections will be made under normal artificial lighting as typically found in an
office-working environment. During cosmetic inspection, only visual (appearance) of
the part surface shall be considered.
8.2.2 Light source shall be typical of office lighting and intensity; the light shall be
positioned generally overhead and distanced to provide optimal viewing and minimize
glare and shadowing of the sample.
8.2.3 Viewing distance shall be 36”.
8.2.4 Viewing angle shall be approx. 45° to the inspected surface and manipulation of the
part during surface inspection should be avoided.
8.3 The following are Inspection criteria:
8.3.1 Inspection shall be conducted using the unaided eye and limited to the amount of
inspection time specified for each class of surface being inspected.
8.3.2 Where subjectiveness intervenes in the assessment, form/fit/function shall take
precedent. If uncertainty is still present, a quality team member or other management
team members should be consulted.
8.4 General Guidelines: (surface classifications)
8.4.1 Surface classes are identified on the production released part print. Some older prints
may not have been updated yet to contain this information. If this is the case contact
a designated Engineering team member for definition prior to inspection.
8.4.2 The Surface Class identified is a “Default” class for the part. Default is considered the
majority of part surfaces.
NOTE: For all parts, some judgement will need to be used in interpreting what
surfaces carry what Surface Classes. i.e. The inside of a small hole or internal facing
and non-customer facing mounting surface may relax to a “D” surface class, while
threaded portions of the part (whether internal or external) may not be coated at all.
8.4.3 Drawings may include exceptions with a higher Class than the default Surface Class.
These shall be designated with a text box that include the words “Surface Class X”
(with X being the exception surface class) and arrows pointing to the affected
surfaces.
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Table 9 Surface Class Definitions

Inspection
Classes Typical Description
Time
Very 15
Highly decorative surface in constant view and in the normal sightline of
A High Seconds
the customer.
Visibility
Moderately decorative surface in occasional view or outside the normal
High sightline of the customer. Surface must be visible without the unit being 10
B
Visibility removed or disassembled. May also apply to parts that are packaged Seconds
and seen up close by the customer only upon installation.
Non-decorative surface not readily visible to the customer. The
Moderate
C underside of parts, recessed areas, or areas visible only when a unit is 5 Seconds
Visibility
briefly opened as part of its normal function.
Any area of a painted surface that is normally covered by another part
and not visible unless disassembled. Could also be the backside of a
Low
D part not normally seen by the customer – Must be coated effectively to 5 Seconds
Visibility
prevent corrosion and in a way that does not impede part assembly or
functionality.
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Figure 1 Viewing Conditions

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8.5 Defects Definition: The following table will set the standard for acceptance and non-
acceptance criteria.
Table 10 Defect Definitions

Defect Code/Name Sample Description Acceptance limits

Class A/B Not

allowed.

Class C – ¼” in
diameter, 6” apart
no more than 3
Paint that
per part
appears to be
running/wavy Class D – allowed
C01-Heavy
or have a – as long as it does
Paint\Runs
non-intended not impede part
orange peel function
look

Class A/B Not

allowed

Class C - ½” in
diameter, 6”
apart, no more
Substrate than 4 per part –
(part base as long as
C02-Light Paint material) corrosion
shows protection is
through maintained

Class D – allowed -
corrosion
protection is
maintained
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Class A – none
allowed

Class B ¼” allowed
6” apart limit 3
per part
C03-Chipped Paint Paint missing
Class C – same as
B

Class D - allowed -
corrosion
protection is
maintained

Class A -none
allowed

Class B Hair line

no longer than ½”
6” apart no more
than 3 allowed.
Hair lines that
C04-Scratches are felt with
the fingernail
Class C - Hairline
no longer than 1”
6” apart no more
than 5 allowed.

Class D- Allowed,
but no substrate
showing -
corrosion
protection is
maintained
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Class A – none
allowed

Class B 6 allowed
in a 2” diameter.
Defects no more
than 1/16”
diameter. No large
clusters.
Also called
graters, or Class C-Surface: 4
C05-Out allowed in a 1”
looking like
Gassing\Bubbles diameter circle.
blisters/fish
eyes Defects no more
than 1/8”. No
large clusters.

Class D – Allowed.
No substrate
showing -
corrosion
protection is
maintained

A Surface: None
allowed

B-Surface no
longer than
½´long, 10” apart,
no more than 3
Paint is per part.
marred or
has Class C - : no
C06-Scuffed/Marred longer than 3/4”
unintended
texture – long, 10” apart, no
(non-scratch) more than 3 per
part.

Class D - No
substrate showing
- corrosion
protection is
maintained
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Class A– None
allowed

Class B – no larger
than ¼” in
diameter, 6” apart
no more than 3
per part
Dirt or other
C07-Contamination substance in Class C – no larger
the coating than 3/8” in
diameter, 6” apart
no more than 3
per part

Class D – Some –
as long as it does
not impede part
function

No/missing Not allowed – All

C08-Voids
paint classes

Paint
C09- Not allowed – All
falling/peelin
Adhesion/Peeling classes
g off part

Wrong color of type of paint used or the result Wrong Not allowed – All
C10-Wrong Coating is off color more than the specified paint delta color/type of classes
E detailed on the part print. powder used

9.0 Quality
9.1 General: All product supplied shall be clean and free from dirt, oils, or defects harmful to
product performance. Color and texture shall be uniform and consistent with the samples,
which were originally approved.
9.2 Qualification: Engineering qualification of painting sources is required in advance of
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production shipments. Suppliers shall submit PPAP/First Article/samples and documentation

for approval of finish, color and appearance, and performance as appropriate. Samples shall
be accompanied by test data certifying that all requirements of the specification have been
met.
9.3 Control Plan: A Quality Control Plan for products supplied to the requirements of this
specification will be established by mutual agreement between Safe Fleet and the supplier.
10.0 Supply Requirements
10.1 Components: Parts supplied against contracts or purchase orders citing this specification
shall be equivalent in all respects to those samples, which were approved by the purchaser.
No changes in formulation or processing practices are permitted without approval. In the
event that changes in material, properties, processing practices, construction, color, or
labeling of the product are required, the supplier shall notify Safe Fleet as indicated in
Section 3.2. Test data indicating conformance to all requirements of this specification, test
samples, and new, amended, or updated Material Safety Data Sheet(s) (MSDS), in
accordance with CFR Title 29, Part 1910 shall be submitted with the request for change.
10.2 Shipping and Packaging: Shipping, packing, and identification shall be in accordance with
Safe Fleet requirements. Parts shall be packaged to avoid any damage in shipment
detrimental to the appearance of the part.

11.0 REFERENCES
11.1 W-PR-30 SMI Supplier Quality Manual
11.2 ASTM D523 Standard Test Method for Specular Gloss
11.3 ASTM B117 Standard Practice for Operating Salt Spray (Fog)
Apparatus
11.4 SAE J2334 Laboratory Cyclic Corrosion Test
11.5 ASTM D1735 Standard Practice for Testing Water Resistance of
Coatings Using Water Fog Apparatus
11.6 ASTM D3359 Standard Test Methods for Measuring Adhesion by
Tape Test
11.7 ASTM D1729 Standard Practice for Visual Appraisal of Colors and
Color Differences of Diffusely-Illuminated Opaque
Materials
11.8 ASTM D552 Standard Test Methods for Mandrel Bend Test of
Attached Organic Coatings
11.9 CFR Title 29, Part 1910 Occupational Safety and Health Standards
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REVISION

REV REV DETAILS

DESCRIPTION OF CHANGE
LEVEL DATE Page Para.

A 8/2021 Initial release of specification

 End of Document 