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Ford Focus RS (2011 year). Instruction - part 134

Description

Item

Use a measuring rod

Addition of hardener

Addition of additives

Process

Description

Item

Flow-beaker spray gun

Suction-beaker spray gun

Spray passes

Filler

Coat

Underbody protection spray gun

Dry

Description

Item

Ventilate

Drying time

Drying time with infra-red dryer

Further processing

Description

Item

Hand abrade (wet)

Hand abrade (dry)

Eccentric sander (wet)

Eccentric sander (dry)

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Paint - General Information

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DESCRIPTION AND OPERATION

Description

Item

Oscillating sander (wet)

Oscillating sander (dry)

Store

Description

Item

Protect from moisture

Store in a frost-free environment

Store in a cool place

Close the container

Other

Description

Item

Stir by hand

Stir using a mixing machine

Polish

Roll

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Paint - General Information

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DESCRIPTION AND OPERATION

Health and Safety Precautions

General instructions for the paint shop
and handling paint materials

Hazardous areas in repair paint shops:

• Danger from fires, explosions and hot surfaces.

• Dangers to health and safety from the effects

of harmful substances because of their
absorption through the skin and/or inhalation.

• Dangers caused by electricity, compressed air,

power tools and noise.

WARNING: During painting work there is
an increased danger of fire or explosion.
Prevent any sparks being created. Fire,
naked lights and smoking are forbidden.

Measures:

• Wear protective footwear made from anti-static

material.

• Only use tools made of wood, brass or copper

to clean stands and extraction ducts. Do not use
tools made of steel.

Only fill or decant paint materials in a specially
marked area.

As well as these general instructions on the
dangers in repair paint shops, all national and
international regulations must be observed:

• Health and Safety at Work Act

• Ordinance on Hazardous Substances

• Technical Rules for Hazardous Substances

• Regulations for the Prevention of Industrial

Accidents

• EU Directive on Hazardous Substances,

98/24/EU

• EU Directive on Noise, 2003/10/EU

• EU Directive on Volatile Organic Compounds

(VOC), 1999/13/EU, 2001/81/EU, 2004/42/EU

• Safety instructions of equipment and tool

manufacturers

Personal protection

Besides the body and limbs, several organs vital
to life are in very particular danger. Because
damage is mostly irreparable, special attention and
comprehensive protection are necessary.

WARNING: Solvents cause damage to the
health through inhalation. Splashes in the

eyes or on the skin can cause bodily harm.
When working with solvents, always use
suitable means of protection.

Description

Item

Protective hood with fresh air supply

Protective clothing

Protective gloves

Protective footwear

Breathing protection

During painting work and in the preparations for
painting, gases, vapors, mists or dusts can appear
in dangerous concentrations in the areas where
fellow employees breath.

For short periods of work or minimal concentrations
of hazardous substances, breathing protection
devices with a combination filter are suitable as
breathing protection equipment.

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Paint - General Information

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DESCRIPTION AND OPERATION

Description

Item

Activated charcoal filter

Coarse filter

For higher concentrations of harmful substances,
breathing protection devices which are independent
of the local atmosphere are suitable.

In these types of isolation systems, a compressed
air hose carries natural air from the compressor
line into the protective mask. During supply, the
air undergoes pressure reduction, water removal,
fine filtration and usually warming to natural breath
temperature.

WARNING: Vapor or spray mist containing
isocyanate as a paint base or hardener can
cause toxic respiratory disease (conditions
similar to asthma) leading to permanent
damage, even when inhaled in the lowest
concentrations.

Filter masks with wadding, sponge or colloid filters
and also paper masks are all unsuitable for working
with coating materials because they do not stop
solvent vapors.

The instructions for use provided by the
manufacturer must be observed when working with
breathing protection equipment.

Skin protection

Spray painters who are subject to considerable
exposure to coating materials must wear suitable
protective work clothing (flame-proof and
anti-static).

NOTE: Also, when working with water based
materials, comprehensive skin protection must be
worn, because these materials are very easily
absorbed through the skin.

The protective clothing must be changed at the
proper intervals. Items of clothing which are
contaminated with coating materials can easily
catch fire.

When selecting protective clothing, it must be taken
into account that cloth containing a high proportion
of easily melted plastic thread considerably
increases the degree of burns injury (melted plastic
on the skin!). This must also be taken into account
in the choice of underwear.

For areas of skin which are not covered by
protective clothing, suitable skin protection, skin
cleaning and skin care agents must be used.

Eye protection

Working with portable hand sanding machines on
which the tools move unguarded, at speed and
with power is fundamentally dangerous.

Goggles must be worn not only when sanding, but
also when working with paints and their additives.
These contain substances which are harmful to
the eyes. Damage ranging from irritation of the
cornea to incurable illnesses are possible.

The protective goggles must be inert toward
splashes of solvent, and fully enclose the areas at
the side of the eyes on both sides. The best
protection during spray painting is offered by full
mask respirators or helmet respirators with a
built-in visor.

Ear protection

Noise disturbance in repair paint shops caused by
various sources is particularly high. Sanding and
compressed air machines, paint cabin extractor
fans (compressors) and extractor ducts in the work
rooms are the causes of the high levels of noise.

WARNING: Avoid damage to your hearing!
Wear ear protection.

Suitable ear protection is offered by ear plugs or
ear defenders.

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Paint - General Information

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DESCRIPTION AND OPERATION

Environmental Regulations

Waste disposal in the repair paint shop

More than ever before, since the introduction of
EU directives, rigorous attention is paid to the
avoidance of waste materials and to recycling in
repair paint shops. In this respect, repair paint
shops must take into account and comply with the
following requirements:

• Separate waste according to its recycling and

disposal methods.

• Produce evidence for the correct transport and

disposal of waste.

NOTE: The organization of disposal in the plant
must comply with the requirements of the Waste
Avoidance and Management Act: The avoidance
and recycling of waste must always take priority.

However, despite all measures which may be
taken, waste cannot be completely avoided.

NOTE: Waste which is not allowed in household
rubbish, and which can no longer be utilized, must
be disposed of as special waste.

Paint residues containing solvent, application
residues, sanding dust, waste containing peroxides,
solvents, soiled cleaning cloths and paint slurry all
count as special waste. Each of these must be
collected in a separate, sealed and suitably labeled
metal container and properly disposed of using a
specialist company.

Careful separation allows some waste to be
usefully re-used.

• Empty metal containers can be sent for scrap

instead of being disposed of as waste.

• Contaminated cleaning thinners can be

separated by distillation.

• Packing material and masking paper can be

added to the recycled paper collection.

Residues which cannot be used must be correctly
disposed of.

All remaining waste must be treated as commercial
waste and disposed of according to the local
regulations.

The new VOC (Volatile Organic
Compounds) solvent regulation

Keeping the air clean protects the environment and
the population from the heath-damaging effects of
air pollutants.

In certain atmospheric conditions, volatile organic
compounds contribute to summer smog.

NOTE: For comprehensive information, please

refer to the European VOC Directive, 1999/13/EU.

Furthermore, the effective national regulations must
be complied with.

The European VOC (Volatile Organic Compounds)
Directive has controlled the limits for such
compounds since August 2001. It applies to
production coating companies and those which
undertake repair painting of private and commercial
vehicles.

Not least because of the VOC legislation, modern,
low solvent and solvent-free lacquers and paints
are finding greatly increased distribution across
industry and the trade. Up to the year 2007,
emissions from painting work will drop by at least
40%.

At the same time, the paint manufacturers
guarantee for example that they will produce a
ready-to-spray product consisting of base paint +
hardener + thinners, with a permitted VOC level.

A company in business today can conform with the
stipulated requirements by introducing water-based
paints and using the other necessary products from
the relevant paint manufacturers.

For more detailed information, please

refer to the

EU VOC Directive.

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Paint - General Information

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DESCRIPTION AND OPERATION

Factory Paint Application

General fundamentals of paint
technology

Paint is a pigment-containing liquid which
undergoes chemical and/or physical processes
after it has been applied to a surface, so changing
into a solid film covering.

Repair paint consists of binder, pigments, filler and
solvent.

NOTE: Organic solvent is being replaced by
solvent based on water.

Constituents of paint

• Binder

– Mostly semi-fluid resins which bind together

the other components of the paint when it
dries.

– Makes the paint durable.

– Ensures good surface coverage.

• Pigments

– Fine, colored powders, which give color to

the paint.

– Cover the components below (covering

power).

• Additives

– Additives give the paint special properties.

– e.g. flow improver, softener, drying

accelerator, thickener.

• Solvent

– Thins the paint and allows it to flow more

freely.

– Evaporates during drying.

Painting process and corrosion
protection.

In production, painting consists of individual steps
which are optimally matched to each other.

Bodywork consists almost entirely of steel panels
which have been pre-coated with zinc. The zinc
layer is between 5-10 µm thick and acts as the first
corrosion protection layer of the steel panel.

Production sequence:

• Clean and de-grease

– In the first step, the bare bodywork is initially

dipped in a cleaning bath and cleaned with
a degreasing solution.

• Phosphatising

– The cleaned bodywork is dipped in a bath

containing various phosphate salt solutions.
This creates a crystalline metal-phosphate
layer which offers the optimal prepared
surface and also corrosion protection.

• CDP base

– The cataphoretic dip paint (CDP) base acts

as a further corrosion protection layer.

– In this process the bodywork is completely

immersed in a bath consisting of a paint and
electrolyte solution.

– By application of an electric voltage, an

electric field is created.

– Positively charged paint particles settle on

the negatively charged bodywork and form
a protective layer up to 20 µm thick.

– Next the bodywork is placed in a dryer, where

the CDP base is hardened at 180°C.

• Sealing, stone-chip protection

– Edges, seams and but joints are sealer with

a sealing compound.

– Vulnerable areas are coated with stone-chip

protection.

• Filler

– Filler protects the body panels from stone

impacts. Furthermore, any unevenness of
the metal surface is flattened out, in order to
create the most homogenous and fault-free
undersurface possible.

– Once the filler is dry, it serves as the base

on which paint is applied.

• Top coat

– The top coat is applied as a single layer or

two layers of paint.

– When working with two layer paint, in the first

job step the initial colored base paint is
applied. In the second job step, a clear
lacquer is applied, giving the base paint shine
and hardness.

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DESCRIPTION AND OPERATION

The structure of an original paint finish

During construction of the original paint, a total
surface thickness of between 120 and 130 µm is
achieved. The thicknesses of the layers may vary
however, because they are greater for horizontal
surfaces than vertical ones.

Paint layers

Description

Item

Steel panel

Phosphate layer 2.9 g/m², corresponding
to 2 µm.

Cathodic dip paint 30-35 µm

Filler 30-35 µm

Base paint 15-20 µm

Clear varnish 55 µm

Colored fillers applied in production

Filler which gives color is used in production. Its
use makes the base paint and clear varnish
unnecessary on certain vehicle interior surfaces
(engine, doors).

Not every exterior paint has its own matching filler.
It is more that the tones of the filler are color
compatible, i.e. they have similar intensity to the
top coat.

During repair painting the filler color tones must be
used according to the manufacturer's instructions.

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Paint - General Information

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DESCRIPTION AND OPERATION

Paintwork Defects and Damage

Diagnosis and Damage Assessment

Paint concerns, regardless of their causes, are part
of the everyday work in the paint shop. Correct
damage assessment and determination of the
cause are preconditions for a professional
resolution of a paint concern.

Paint concerns can still occur through a variety of
causes, despite improved paint materials and new
spray methods.

NOTE: A first appraisal of the paint damage should
be done before cleaning. External factors such as
rust, droppings, incorrect or insufficient paint care
can then be more easily detected.

Diagnosis is best done in daylight but not in direct
sunlight. Exact evaluation can also be done under
artificial light from special luminescent lamps.

Paint damage guide

The most important paint damage concerns which
make a paint repair necessary are:

• Damage from biological paint contamination

such as bird or insect droppings, tree resin and
aphids.

• Chemical paint damage caused by industrial

contaminants such as smoke, fuel, acids, oils.

• Mechanical damage caused by stone impact

during operation, scratches in the car wash and
parking.

• Damage caused by faults in treatment.

Application defects such as paint runs or orange
peel.

• Dirt inclusions in the paint layer, e.g. caused by

dust in top coat or textile lint.

• Damage due to corrosion.

Before repair of such paint concerns, exact
diagnosis must be performed to determine the
cause exactly. On the spot diagnoses using simple
aids and processes are often enough.

Diagnosis without disturbing the paint is done by:

• Optical inspection without visual aids, under

suitable light conditions from a suitable angle
and correct distance.

• Optical inspection with the help of a magnifying

glass.

• pH paper.

• Measurement of the thickness using FE / NFE

coating thickness meters for ferrous (FE) and
non-ferrous metals and non-magnetic steel
(NFE) - magnetic process on steel panels, eddy
current process on non-metals.

A test method where the traces of testing can be
easily removed again is the finger nail test. With
suitable experience the existing hardness of the
paint can be determined.

Test methods where the paint is partially destroyed
are:

• Pencil hardness test.

• Adhesion test using adhesive tape.

• Lattice cut test process to check the strength of

adhesion.

Under certain circumstances these test methods
are not enough for a certain diagnosis. In this case,
paint diagnosis under laboratory conditions must
be performed.

Measuring and testing equipment for
painted surfaces

Coating thickness measuring devices

Magnifying glass

pH paper (together with water)

Suitable photographic equipment with macro lens

Shine measuring equipment

Paint damage caused by environmental
factors

• Bee droppings

• Bird droppings

• Insects

• Tree resin and sap

• Aphid secretions

• Tar spots

• Cement, plaster and slaked lime

• Rust film/deposits from industrial fallout

• Battery acid

• Brake fluid

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Paint - General Information

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DESCRIPTION AND OPERATION

Content .. 132 133 134 135 ..