Electro™

Pre-treatment of Aluminium

The pre-treatment process must be capable of meeting the performance outputs as described in AS3715 and AAMA-2604.
Compliance to appropriate process parameters is essential in ensuring compliance to etch, conversion coating weights (time/concentration) and conductivity of the final rinse.

Etch

The etch process is a very important stage of pre-treatment and close consultation with your pre-treatment supplier is strongly recommended to ensure optimum adhesion & corrosion resistance is obtained. As an approximate guide:

• An etch rate of >1gm/m2 , is recommended for Electro projects greater than 100 metres from the coastline, but etch rate advice from pre-treatment suppliers should be taken into consideration.
• An etch rate of >2gm/m2 is recommended for all Electro projects between 10 and 100 metres from the coastline, but etch rate advice from pre-treatment suppliers should be taken into consideration.

Conversion Coatings

This is the next pre-treatment process for aluminium to ensure that it is suitably prepared for coating. It is recommended that Chrome conversion weights shall be a minimum of 431mg/m2, but advice from pre-treatment suppliers should be taken into consideration.

• For Chrome pre-treatment a Supplier ‘Certificate of Analysis’ should be provided by the customer and attached to Self-Assessment Declaration.
• Non Chrome conversion coatings should be applied and maintained in accordance with the manufacturer’s instructions.
• When changing from chrome to non-chrome your accreditation will require reapplication immediately. Warranty applications through this period will need to be monitored, tested and approved individually.

Final Rinse

Final rinse is to ensure optimum surface preparation prior to coating.

• Final rinse water run-off from the extrusion shall have conductivity of less than 30 micro Siemens/cm.
• The maximum time between pre-treatment and the application of the powder coating is 24 hours.
• The entire area of the aluminium shall be properly pre-treated, appropriate spacing devices should be used.

Handling

Care should be taken with handling to ensure health and safety measures are met and that the substrate is not contaminated.

• Pre-treated sections must never be handled with bare hands. Clean and lint free cotton gloves must be worn at all times when handling pre-treated sections.

Dry Off Oven (if applicable)

If your site uses a dry off oven to assist in the pre-treatment process please ensure:

• The temperature of the dry off oven must be such that the temperature of the sections does not exceed 75˚C unless advised by pretreatment supplier specifications. Applicators must be able to demonstrate compliance with this specification.

Pretreatment Standards

The pre-treatment process must be capable of meeting the performance outputs as described in AS3715 and AAMA-2604

Pre-treatment of Steel

Steel substrates shall be prepared as follows:
1. Wash and degrease all surfaces to be coated in accordance with AS1627.1 with a free-rinsing, alkaline detergent, in strict accordance with the manufacturer’s written instructions and all safety warnings.

2. Wash with fresh potable water and ensure that all soluble salts are removed in accordance with AS 3894.6 methods A&D.
3. Grind all sharp edges with a power tool to a minimum radius of 2mm.
4. Power tool clean welds to AS1627.2 Class 2 to remove roughness. Remove filings, preferably by vacuum or compressed air.
5. Abrasive blast clean all steel surfaces to be painted in accordance with AS1627.4 to visual standard AS1627.9 Class 2.5 (equivalent to ISO8501-1, Sa 2.5: Very Thorough Blast-Cleaning). Use a medium that will generate a surface profile of 35 to 65 microns (as tested to AS3894.5 Method A.) In situations where it is not possible to prepare your item on all surfaces as described above, for long term protection against corrosion it is strongly recommended whenever possible, that an alternative substrate such as, aluminium be considered.
6. The steel to be stored in an area which is clean and dry
7. The steel must be coated within 4 hours of blasting.

Application

Application Method

Electrostatic Spray

Cure Schedule

200° for 10 mins minimum

Packaging Pre Installation

Attention to packing is essential for powder coaters and fabricators to ensure that all powder coated sections are received in good condition.

When packing powder coated assets, it is recommended that:

• Sections must be adequately cooled prior to packing; the metal temperature must not exceed 40˚C on packing.
• Appropriate protective wrapping is recommended prior to packing to avoid damage during transport.
• If protective tapes are used, ensure that the tape will remain removable following transport, fabrication and installation and not irreversibly mark or damage the coating. Tapes should be used in accordance with the manufacturer’s instructions and only remain in contact for the minimum amount of time.
• Packed metal should be kept away from sunlight or moisture to avoid coating defects.

Care & Maintenance post installation

It is recommended in environments with low salt, low pollutants and in urban areas that cleaning should take place at a minimum of every twelve months. In areas where salts, pollutants and high corrosivity levels are prevalent, e.g. beachfront houses or industrial areas, it is recommended a cleaning program should be carried out more frequently at a minimum of every six months.

Sheltered areas can have a higher risk of coating degradation as wind-blown salt and other debris or pollutants may adhere to the surface and not be removed when it rains. These areas may require more frequent cleaning.

Use the following table to identify the recommended minimum cleaning and maintenance schedule for your project. The table references AS4312 and ISO12944 Atmospheric corrosivity zones in Australia to define the environmental conditions.

1. Geothermal environments with a PH>5 and <9. For PH outside this consult DGL.
2. Offshore islands that are not tropical include Waiheke, Stewart Island, Fraser Island etc.
3. Tropical islands include Australian Islands north of Mackay and Pacific islands such as PNG, Fiji, Samoa, Tonga.

Three steps to cleaning powder coated surfaces

Care and maintenance schedules are essential to ensure that the life of your asset is maximised whether the project be a residential, commercial or non-habitable project. Simply follow 3 important steps:

1. Carefully remove any loose surface deposits with a wet sponge by gently rubbing.
2. Clean by gently rubbing the surface with a soft brush (non-abrasive) and a dilute solution of a mild detergent, e.g. pH-neutral liquid hand or dishwashing detergent in warm water to remove dust, salt and other deposits. For stubborn stains use only recommended solvents on the affected area, e.g. Isopropyl alcohol (IPA) or methylated spirits and rinse off with clean water. Do not use other aggressive solvents.
3. Rinse the surfaces with clean fresh water after cleaning to remove all residues.

Warning

Aggressive solvents such as turpentine, white spirits, thinners, citrus based cleaners and other aggressive solvents are harmful to the extended life of the powder coated surface. These solvents should not be used for cleaning purposes and will render a warranty void if used.

If paint splashes, sealants/mastics or stubborn stains need to be removed use only Isopropyl alcohol (IPA) or methylated spirits and rinse off with clean fresh water.

In some cases, strong solvents recommended for thinning various types of paints and also for cleaning up mastics/sealants are harmful to the extended life of the powder coated surface. These solvents should not be used for cleaning purposes and will render the warranty void if used. If paint splashes or sealants/mastics need to be removed then the following solvents can be used safely: Methylated Spirits, Ethyl Alcohol, Isopropanol.

For more information about care and maintenance click here.

Project Suitability – Aluminium

Use the following table to help identify where Electro can be applied on aluminium projects, the system required and the DGL Alumi Shield™ warranty level available. Refer to the conditions information to determine the environment that your project will be exposed to.

Project Advice – Steel

The appropriate coating system on steel is largely driven by the corrosive environment of the coated item. This can be determined in accordance with AS4312 Atmospheric corrosivity zones in Australia.

Conditions

Use the following table which references AS4312 and ISO12944 Atmospheric corrosivity zones in Australia to define the environmental conditions and product is suitable for.

Interior & exterior environments close to liquids other than coastal, river and lake salt water environments

Please refer to the guidance below for:

• Any interior application of powder coating close to liquids, eg swimming pools, fountains, bathrooms, showers, sinks etc
• Buildings that have exterior facilities close to liquids other than the sea, eg outdoor swimming pools, fountains, outdoor bathrooms

1. Please note chemically treated water includes antimicrobial treatments, e.g. in pools, anti-corrosive chemicals, and soapy water in bathrooms and showers.
● Where indicated Alumi Shield™ warranties are available on areas >than 2m from the liquid (ie outside the splash zone).
 Where indicated and Alumi Shield™ warranties are available any distance from the liquid.
Alumi Shield™ warranties are only available when applied by a DGL Accredited Powder Coater to the warranty specification on recommended project types and conditions.
All DGL powder products are NOT suitable in strongly acidic or caustic environments so pH must be >5 and <9.
Alumi Shield™ warranties are not available if the powder coating is immersed in any liquid.

Advice Line

To send an enquiry to our Advice Line, please visit the Contact Us page

DGL Alumi Shield™ warranty performance on aluminium:

• 25 Year Durability warranty
• 15 Year Chalk and Colour Fade warranty

On pre-treated architectural aluminium when applied by a DGL Accredited Powder Coater to the warranty specification on recommended project types and conditions.
For more information on our DGL Alumi Shield™ warranty program click here.

Key Limitations for Alumi Shield warranties

Environments must be:

• Greater than 10m from the high tide mark
• Greater than 2m (ie outside the splash zone) for interior/exterior warranty in environments where liquids are 1. Chemically treated or 2. Salt Water
• Electro is NOT suitable in strongly acidic environments so PH must be >5.1

DGL Accredited Powder Coaters

Only DGL Accredited Powder Coaters are able to issue our DGL Alumi Shield™ warranties after demonstrating their capability to meet stringent quality conditions and international standards.

For more information click here.