【AS澳大利亚标准】AS NZS 4158-2003 A1 Thermal-bonded polymeric coatings on valves and fittings for water industry purposes.doc

as/nzs 4158:2003(incorporating amendment no. 1)as/nzs 4158:2003australian/new zealand standardthermal-bonded polymeric coatings on valves and fittings for water industry purposesthe standard is downloaded from standard sharingas/nzs 4158:2003this joint australian/new zealand standard was prepared by joint technical committee ws-022, valves for water supply purposes. it was approved on behalf of the council of standards australia on 3 january 2003 and on behalf of the council of standards new zealand on 24 january 2003.this standard was published on 5 march 2003.the following are represented on committee ws-022:australian industry groupaustralian chamber of commerceaustralian valve manufacturers associationbusiness new zealandmaster plumbers australianew zealand metal casting industry associationnew zealand water and waste associationsociety of mechanical engineers australiaplastics pipe institute association of australiawater industry alliancewater services association of australiakeeping standards up-to-datestandards are living documents which reflect progress in science, technology and systems. to maintain their currency, all standards are periodically reviewed, and new editions are published. between editions, amendments may be issued. standards may also be withdrawn. it is important that readers assure themselves they are using a current standard, which should include any amendments which may have been published since the standard was purchased.detailed information about joint australian/new zealand standards can be found by visiting the standards web shop at .au or standards new zealand web site at www.standards.co.nz and looking up the relevant standard in the on-line catalogue.alternatively, both organizations publish an annual printed catalogue with full details of all current standards. for more frequent listings or notification of revisions, amendments and withdrawals, standards australia and standards new zealand offer a number of update options. for information about these services, users should contact their respective national standards organization.we also welcome suggestions for improvement in our standards, and especially encourage readers to notify us immediately of any apparent inaccuracies or ambiguities. please address your comments to the chief executive of either standards australia or standards new zealand at the address shown on the back cover.this standard was issued in draft form for comment as dr 02420.as/nzs 4158:2003(incorporating amendment no. 1)australian/new zealand standardthermal-bonded polymeric coatings on valves and fittings for water industry purposesoriginated as as/nzs 4158.1:1994. previous edition 1996.second edition 2003.reissued incorporating amendment no. 1 (september 2005).copyright standards australia/standards new zealandall rights are reserved. no part of this work may be reproduced or copied in any form or by any means, electronic or mechanical, including photocopying, without the written permission of the publisher.jointly published by standards australia, gpo box 476, sydney, nsw 2001 and standardsnew zealand, private bag 2439, wellington 6020isbn 0 7337 5033 83as/nzs 4158:2003the standard is downloaded from standard sharingprefacethis standard was prepared by the joint standards australia/standards new zealand committee ws-022, valves for water supply purposes, at the request of manufacturers and users of polymeric coatings for valves and fittings, to supersede as/nzs 4158:1996.this standard incorporates amendment no. 1 (september 2005). the changes required by the amendment are indicated in the text by a marginal bar and amendment number against the clause, note, table, figure or part thereof affected.the objective of this standard is to provide requirements and performance tests for coating systems for valves and fittings used in supply systems including potable water, recycled water and wastewater systems, together with default compliance requirements for the use of manufacturers and certification bodies.changes to the previous edition area as follows:(a) the previous edition of the standard covered fusion-bonded epoxies and polyamides which were typically used at that time. this edition encompasses both thermoplastic and thermosetting coating materials(b) the limiting temperature for use has been changed to 50c to be consistent with the hot water immersion test temperature, which was reduced to accommodate thermoplastic coatings.(c) limits on water absorption have been tightened to reflect current coating material performance.(d) continuity testing has been updated to a high voltage test suitable for the typical coating thicknesses and cast substrates used for valve bodies and fittings.(e) improvements have been made to other type tests, process verification tests and the batch release tests. batch release testing requirements have been placed on the coating material supplier.(f) methods for demonstrating compliance with the standard have been expanded and made mandatory.polymeric coatings referred to in this edition of the standard apply to both thermoplastic and thermosetting, factory-applied, thermal-bonded coatings used to prevent corrosion of the internal and external surfaces of metallic valves and fittings.the terms normative and informative have been used in this standard to define the application of the appendix to which they apply. a normative appendix is an integral part of a standard, whereas an informative appendix is only for information and guidance.contentspagesection 1 scope and general1.1scope . 41.2referenced documents . 41.3definitions . 4section 2 requirements of the coating system2.1scope of section . 62.2coating system specification . 62.3type tests . 62.4coating material supply requirements . 72.5effect on water quality . 8section 3 requirements for factory-applied coating3.1scope of section . 93.2coating system materials. 93.3process verification. 93.4coating application and batch release . 103.5rework. 11appendicesapurchasing guidelines. 12bmeans for demonstrating compliance with this standard . 13creferenced documents . 17dspecification of coating system . 18epenetration resistance test . 2019as/nzs 4158:2003the standard is downloaded from standard sharingstandards australia/standards new zealandaustralian/new zealand standardthermal-bonded polymeric coatings on valves and fittings for water industry purposess e c t i o n1s c o p ea n dg e n e r a l1.1 scopethis standard specifies the requirements for factory-applied thermal-bonded polymeric corrosion protective coatings (barrier coatings). for the purposes of this standard, the term polymeric coating is intended to encompass both thermoplastic and thermosetting coating materials, which are used to coat both the internal and external surfaces of valves and fittings.this standard covers the following service application areas:(a) factory-applied coatings and associated coatings used for repair.(b) ductile iron, grey cast iron, malleable iron, steel and copper alloy based substrates. (c)valves, fittings and their components and associated equipment.(d) contact with water, and wastewater up to 50c. (e)above and below ground exposure.notes:1some coatings may not be suitable for all wastewaters. compatibility should be checked with the manufacturer.2guidelines on requirements to be specified by the purchaser are given in appendix a.means of demonstrating compliance with this standard are given in appendix b.1.2 referenced documentsthe documents referred to in this standard are listed in appendix c.1.3 definitionsfor the purpose of this standard, the definitions given in as/nzs 3500.0 and those below apply.1.3.1 coatinga material, applied to a surface at a specified film thickness, that is intended to protect the surface from corrosive elements or conditions such as moisture, gases, and abrasion by windblown or waterborne particles.1.3.2 coated producta valve or fitting or part thereof that has a coating applied to it.1.3.3 coating defecta detectable weakness or discontinuity in a coating, which causes its ability to protect the substrate from corrosion to be suspect during the normal service life.copyright1.3.4 continuitythe quality of a coating determines its freedom from defects or holidays.1.3.5 holidaya discontinuity in the coating that exposes the substrate.s e c t i o n2r e q u i r e m e n t so ft h e c o a t i n g s y s t e m 2.1 scope of sectionthis section specifies coating system type tests that have to be met prior to using the coating system on valves and fittings. it also includes coating specification and coating material supply requirements.2.2 coating system specificationthe coating system shall be specified in accordance with appendix d.2.3 type tests2.3.1 generalcoated test pieces, applied in accordance with the system specification (see appendix d) shall meet the type test requirements specified in clauses 2.3.1 to 2.3.10 (summarized in table 2.1). these tests shall be undertaken on the coating system, in order to demonstrate the suitability of the coating for service. hot water immersion and repair coating material testing shall be undertaken to qualify each nominated substrate material. the remaining tests shall be undertaken using either steel, cast iron or copper alloy as the substrate.type testing shall be performed on samples with an average coating thickness within100 m of the specified minimum coating thickness.the tests shall be undertaken on flat plate of nominal size 200 150 6 to 10 mm, unless otherwise specified herein.2.3.2 hot water immersionexpose the test piece in accordance with as 3862 at 50 2c for 14 days. test in accordance with as 1580.408.2. the adhesion rating shall be less than or equal to one.2.3.3 water absorptionwhen tested in accordance with as 3862 for 100 days at 23 2c, the amount of absorbed water shall be less than or equal to 4.0% by weight. the coating test pieces shall be approximately 100 100 0.5 mm thick.2.3.4 flexibilitywhen tested in accordance with as 3862 at 0c, the coating shall not crack when strained at 1.0%, as calculated in the following equation:wherestrain =100c %2r + cthe standard is downloaded from standard sharingc=sample thickness (including coating)r=radius of mandrel2.3.5 impact resistancewhen tested in accordance with astm g14 at 23c, the impact resistance shall be equal to or greater than 2.0 j. the test shall be conducted on pipe with an outside diameter of 110 to125 mm and wall thickness from 5 to 7 mm, or on 6 mm thick flat plate. if cast plate is used, the side in contact with the anvil shall be machined flat prior to testing.2.3.6 penetration resistancewhen tested in accordance with appendix e, the penetration shall be less than or equal to10% of the specified minimum coating thickness. this test is not required for epoxy materials.2.3.7 abrasion resistancethe abrasion resistance test shall be in accordance with astm d4060 with cs17 wheel,1000 g load for 1000 cycles at 23 2. the weight loss shall be less than or equal to 40 mg.2.3.8 cathodic disbondmenta1the test shall be carried out either in accordance with as/nzs 4352, using test cell a or b, at 23 2c for 28 days, or in accordance with bs 3900 part f11at 23 2c for 28 days. the average radial disbonded length shall be less than or equal to 15 mm.2.3.9 thermal stability thermosetting materialsthree coated panels shall be prepared and tested in accordance with as 3862, flexibility test, at 1% strain and at ambient temperature. the panels shall then be exposed in air at100 2c for 100 days. there shall be no holidays in the tension face of the coated samples after the exposure period when holiday tested to as 3894.1 at 2400 v. thermoplastic materialssix films of coating shall be prepared by application onto silicone-release-coated, or teflon-coated steel panels, or by application onto other suitable panels. the films shall be produced by coating application at the maximum allowable application temperature. the thickness of the films shall be in the range 250 to 500 m. three of the films shall be exposed in air at 100 2c for 100 days. either melt flow rate (to iso 1133) or elongation at break (to as 1145.3) shall be measured on the films both prior to and after exposure. the average of the three results on the exposed films shall not vary by more than 35% for melt flow rate, or 50% for elongation at break, from the average of the three results on the unexposed films.note: the film may be removed from the substrate before or after exposure.2.3.10 ultraviolet radiationa1the coating shall be tested in accordance with astm d2565, type b, for 100 days. the coating preparation and test requirements shall be in accordance with clauses and.2.3.11 repair coating materialthe repair coating material shall be tested for adhesion to a metal substrate and water absorption, as follows:(a) the repair coating material shall be applied in accordance with appendix d to a flat plate. after any required curing period, the repair shall be tested for adhesion in accordance with as 1580.408.2. the adhesion rating shall be less than or equal to 2.a1(b) the repair coating material shall be tested in accordance with clause 2.3.3 for water absorption. the amount of water absorption shall be less than or equal to 5.0%.2.4 coating material supply requirementsthe coating material shall be tested to demonstrate/ensure consistency. a certificate of compliance (from the coating material manufacturer), stating that the coating material meets the manufacturers required internal batch release testing (to demonstrate consistency) shall be deemed sufficient evidence of the suitability of the coating material.the standard is downloaded from standard sharingthese tests shall include tests for melting parameters (for thermoplastic materials), cure (for thermosetting materials), and particle size distribution.2.5 effect on water qualityall coatings, including repair coatings used in applications where they are in contact with water intended for human consumption, shall comply with as/nzs 4020.propertytestrequirementhot water immersionas 3862/as 1580.408.2 1water absorptionas 3862 4.0%flexibilityas 3862no crack 1.0%impact resistanceastm g14 2.0 jpenetration resistancesee appendix e 10%abrasion resistanceastm d4060 40 mgcathodic disbondmentas/nzs 4352 orbs 3900, part f11 15 mmthermal stabilityas 3862/iso 1133 or as 1145.3no cracks 1.0% / 35% or 50% changeultraviolet radiationastm d2565/iso 1133 or as 1145.3no cracks 1.0% / 35% or 50% changeeffect on water qualityas/nzs 4020no effect when used to convey drinking watera scaling factor of 0.05 shall be applied.table 2.1summary of type test requirementsa1s e c t i o n 3r e q u i r e m e n t sf o rf a c t o r y - a p p l i e dc o a t i n g 3.1 scope of sectionthis section specifies the process verification tests and batch release tests for thermal- bonded polymeric coatings applied in the factory. the process verification tests aim at ensuring that a