Ref. MCM-1706 Page1 of 12 Effective From 1-3-2006 Specification No.

M&C/ PCN/ 111 /2006

RDSO SPECIFICATION

N o. M&C/PCN/111-06

SPECIFICATION FOR HIGH BUILD

EPOXY PAINT (TWO PACK)

RESEARCH DESIGNS & STANDARDS ORGANISATION

MANAKNAGAR, LUCKNOW – 226 011

March : 2006 Price :

Ref. MCM-1706 Page 2 of 12 Effective From 1-3-2006 Specification No. M&C/ PCN/ 111 /2006

SPECIFICATION NO. M&C/PCN/111/2006

SPECIFICATION FOR HIGH BUILD EPOXY PAINT (Two Pack)

0. FOREWORD

0.1 This standard was originally adopted in the year 1988 and was subsequently
revised in the year 2000. In this revision, resistance to chemicals test, covering
capacity at 100 microns DFT/125microns Wet Film Thickness, Drying time for
surface dry have been incorporated. Limits of Flash point have been raised to 30
ºC as against 20 ºC and of Pot life has been raised to 4hrs as against 2 hrs.

1. SCOPE

1.1 This standard prescribes the requirements and methods of testing for two pack
High Build Epoxy Paint intended to be used on interior of coaches where grit
blasting is not practicable. The material shall be suitable for application on a
metal surface having surface finish equivalent to St2 by hand tool cleaning or St3
by power tool cleaning of IS:9954. It should be suitable for application by airless
spray, but by using thinner, it shall be suitable for brush application, for touching-
up small areas. The material is compatible with Acrylic Polysiloxane finish top
coat the use of which will enhance the life of this material.

2. TERMINOLOGY :

2.1 For the purpose of this standard apart from the glossary of terms given in
IS: 1303-63 and terminology as per clause 2 of IS: 9162-79 and IS: 9954, the
following shall also apply. Rounding off, of observed values on different tests
shall be in accordance with IS: 2-1960.

2.1.1 Pack : The term used to describe each of the two packs of the paint which when
mixed together, form High Build Epoxy Paint.

2.1.2 Paint : The mixture of the two packs in the proportion recommended by the
manufacturer.

2.1.3 High Build : The property of a coating material which permits the application of
a coat of greater thickness than usually considered as normal i.e. 80
microns and above.
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3. REQUIREMENTS :

3.1 The mixing ratio of the pack A and pack B shall be in a simple ratio by volume,
1:1, 1:2 or 1:3 max.

3.2 Composition : The paint shall consist essentially of two packs namely
pack A and pack B.

3.2.1 Pack A: (Normally referred to as Base) shall consist of epoxy resin

with or without diluents.)

In the formulation of paint, epoxy resin of the following grade shall be used.

Table – I Requirements for epoxy resin

S. No. Characteristics Requirements Method of test

1. Weight per epoxy equivalent on 180-260 Cl.4 of IS:9162-79
non-volatile content basis

3.2.2 Pack B : (Normally referred to as Hardener) shall consist of any liquid hardener.

3.2.3 Liquid Hardener : This shall be liquid type such as an aliphatic amine, an
aliphatic or aromatic amine adduct, a polyamide or amido polyamine or any other
suitable hardener. It shall react with epoxy resin at normal ambient temperature.

4. PROPERTIES :

4.1 General : The paint shall comply with the requirements specified in Table II
of this specification.

4.2 Unless otherwise specified the following testing conditions shall apply.

4.2.1 The preparation of steel, tinned and glass panels shall be in accordance with Cl. 2,
Cl.3 and Cl.5 respectively of IS: 101(Pt.1/ Sec.3)-87.

4.2.2 All the tests shall be conducted at room temperature (27± 20C) and a relative
humidity at 65 ± 5%, in a well ventilated chamber free from draughts and dust.
The temperature of the surface to be painted must be at least 30C above the dew
point to prevent moisture condensation. The minimum temperature for
satisfactory cure is 100C.
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4.2.3 The two components i.e. base and hardener shall be mixed in the ratio
recommended by the manufacturer before conducting the test or tests. Where the
paint is required to be applied on panels, it shall be done so by using suitable
airless spray/brush application.

4.2.4 For touch-up/patch painting, the material shall be supplied in one litre containers.

4.2.5 For the preparation of painted panels for conducting different tests mentioned in
Table II, the details given in Table III shall be followed.

TABLE-II : REQUIREMENTS FOR HIGH BUILD EPOXY PAINT

S.No. Characteristics Requirements Method of test

1. Drying time at 27±2oC
a) Surface dry ,max 4 hours IS:101(Pt.3 /Sec.1)-
b) Hard dry/ 8 hours 86
Recoating time, max.
2. Consistency Smooth and uniform and IS:101 (Pt.1/ Sec.5)-
suitable for air-less 89
spray/brush application
3. Finish Smooth – matt/semi-glossy, IS:101 (Pt.3/Sec.4)-
free from sagging & 87
wrinkling
4. Colour Buff to Grey/RAL colour IS:101(Pt.4/Sec.2)-
89
5. Dry film thickness per 100-125 microns By Elcometer /
coat, min., By brush or Thickness gauge
by airless spray meter
6. Volume solids, % min 80 See Appendix-I
7. Scratch hardness No such scratch as to show IS : 101(Pt.5/Sec.2)-
(at 1.5 Kg. load) bare metal 88
8. Flexibility & Adhesion No visible damage or IS:101(Pt.5/ Sec.2)-
detachment of film 88
9. Flash Point for both the Above 30oC IS:101( Pt.1/ Sec.6)-
packs 87
10. Resistance to salt No sign of corrosion & no ASTM: B-117
spray* sign of deterioration up to
3000 hours
11. Protection* against No sign of corrosion & no IS:101(Pt.6 /Sec.1)-
corrosion under sign of deterioration up to 88
condition of 3000 hours
condensation

12. Keeping Properties for Not less than 12 months IS:101(Pt.6/ Sec.2)-
both the packs 89
13. Covering Capacity, min. 8 sq. m./litre IS:101(Pt.4 /Sec.1)-
(at 125 microns WFT or 88
at 100 microns DFT)

14. Wet film thickness, min. 125 microns to ensure 100 By wet film
microns DFT thickness gauge
15. Resistance to chemicals * I)Shall not show any sign of Appendix -II
1) 25% caustic soda blistering, wrinkling & lifting
solution (w/v) of paint film up to 2000 hrs.
11) 30% sulphuric acid (II) -do-
solution (v/v)
111) 20% hydrochloric (III)-do-
acid (v/v)
IV) Resistance to tap IV)Shall not show any sign
Water of blistering, wrinkling &
lifting of paint film up
to3000 hrs
16. Pot life at 27± 2ºC min. 4 hours Appendix-III
17. Mass in kg/10 litres, min. 12.0 IS:101Pt.1 Sec.7- 87
18. Impact resistance test Shall be free from cracking ASTM:D 2794-93
at height 31 inch and in the deformed coating by
3.226 pound ) dropping the indenter on
(100 inch-pound load) coated side of test panel
19. Adhesion test Matches to 5B ASTM D:3359
20. Adhesion & compatibility test Shall be compatible with Acrylic
with Acrylic Polysiloxane Polysiloxane and matches to (5A) ASTM: D-3359
& Appendix-IV

*In case of approval and / or bulk supply, every 5th batch or the last batch if the batches
are less than 05 , the duration of the test shall be 2000 hrs. Edges of the test panels may be
resealed with wax if it gets damaged/thinned down during testing period.

Ref. MCM-1706 Page 5 of 12 Effective From 1-3-2006 Specification No. M&C/ PCN/ 111 /2006
Ref. MCM-1706 Page 6 of 12 Effective From 1-3-2006 Specification No. M&C/ PCN/ 111 /2006

TABLE-III : DETAILS OF PREPARING PAINTED PANELS FOR TESTING

OF HIGH BUILD EPOXY PAINT (TWO PACK)
S. Test Type of Size in Paint- DFT Method Duration Spe-
No Metal m.m. ing of of Air cial
. Panel Detail Applicat- Drying Instruct
ion before ion
comence
-ment of
test
1. Drying M.S. 150 x One 125-150 Brush/ - -
Time 100 x coat of microns Spray
1.25 H.B.
Epoxy
Paint
2. Finish -do- -do- -do- -do- -do- 48 Hours -
3. Colour -do- -do- -do- -do- -do- 24 Hours -
4. Dry Film
thickness
a)By -do- -do- -do- -do- Brush -do- -
brush -do- -do- -do- -do- Spray -do- -
b) By
airless
spray
5. Scratch Tinned 150 x -do- -do- Brush/ 7 days *
Hardness M.S. 50 x Spray
.315
6. Flexibility -do- -do- -do- -do- -do- -do- -
&
Adhesion
7. Resist- M.S. 150 x Two 200-250 -do- -do- Paint
ance to 100 x coats of microns both
Salt Spray 1.25 High sides of
Build panels
Epoxy and seal
Paint the
edges
with
wax.
8. Protectio -do- -do- -do- -do- -do- -do- -do-
n against
corrosion
under
condition
s of
condensa
tion
9. Resist- -do- -do- -do- -do- -do- -do- -do-
ance to
 chemicals
i) 25%
(w/v)
caustic
soda sol.
ii)30%
(v/v)
sulphuric
acid sol.
iii) 20%
(v/v)
hydro-
chloric
acid sol.
iv)
Resistan
ce to tap
Water
10 Impact -do- -do- -do- -do- -do- -do- Apply
resistanc two
e test coats
on one
side of
test
panel
11. Adhesio MS 150 x One 125- -do- -do- -
n test 100 coat of 150
x1.25 H.B. micron
Epoxy s
Paint
 Apply a load of 1.5 Kg. instead of 1.0 Kg.

Ref. MCM-1706 Page 7 of 12 Effective From 1-3-2006 Specification No. M&C/ PCN/ 111 /2006
Ref. MCM-1706 Page 8 of 12 Effective From 1-3-2006 Specification No. M&C/ PCN/ 111 /2006

5. MARKING AND PACKING

5.1 Each container shall be marked with the following :

a) Name of the material
b) Indication of the source of manufacture
c) Volume of the material
d) Batch No. or Lot No. in code or otherwise and
e) Month & year of manufacture
5.2 For touch up/patch painting, the material shall be supplied in one litre container.

6. INSPECTION
(a) Paint procured through Indian Railway store contract

6.1 At the time of initial approval, full testing shall be done.

6.2 Inspecting Authority shall draw the sample from eatch batch and test shall be done
as per Table II, except for long duration test as per S. No.10 &11.
6.3 For bulk supply, every fifth batch or last batch if the batch is less than 5 batches
shall be subjected for full testing.
6. (b) Paint procured through Supply-Apply and Maintenance contract:

The paint procured by Indian Railway through Supply–Apply and

maintenance contract, the contractor shall take responsibility of
adhesion, corrosion resistance, impact resistance and
mechanical damage for the entire warrantee period of the
product supplied. The painting defect arises during service and
warranty period shall be repaired by the contractor on their own
cost. Production units and other consignee shall frame their own
terms and conditions of supply-apply and maintenance contract
for procurement of this paint and the same shall be introduced
in P.O.
Ref. MCM-1706 Page 9 of 12 Effective From 1-3-2006 Specification No. M&C/ PCN/ 111 /2006

APPENDIX- I
PROCEDURE FOR DETEMINING VOLUME SOLIDS PERCENTAGE

1. SCOPE
This method is applicable to the determination of the volume of non volatile matter
of paint coatings.
2. SIGNIFICANCE
This method is intended to provide a measure of the volume of dry coating
obtainable from a given volume of liquid coating. This volume is considered to be
the most equitable means of comparing the coverage (sq.meter of surface covered
at a specific film thickness per unit volume) and also for calculating the wet film
thickness of the given paint.

3. APPARATUS
i) Analytical balance
ii) Steel disc – Preferably stainless steel, 60 mm dia and 0.70 mm thickness
with a small hole 2 to 3 mm from the edge. A fine wire such as chromel is
attached through the hole and made of the appropriate length for
suspending the disc in a liquid.
iii) Weight box
iv) Beaker 1 litre , for weighing the disc in liquid.
v) Weight per litre cup for determining the specific gravity of the paint
material and of the suspending liquid if not known.
vi) Oven.

4. PROCEDURE :
i) Dry the disc in an oven at 105oC for 10 minutes and cool.
ii) Weigh the disc in air. Let it be W1 grams.
iii) Suspend the disc in water and weight again.Let it be W2 grams.
iv) Calculate the volume of the disc V as follows :

W1 – W2
V = ---------------- where d is the density of the water at room temperature.
d
v) Determine the weight of nonvolatile content of the liquid coating material
by drying a known amount of paint at 105o C for 3 hours. Let it be
W grams.

vi) Determine the specific gravity of the paint to the nearest 0.001 g/ml by
using weight per gallon cup. Let it be P.

vii) Dip the disc in the paint sample for 10 minutes and take out the disc and
allow the excess coating material to drain off. Blot the coating material off
the bottom edge of the disc so that heads or drops do not dry on the bottom
edge of the disc.
Ref. MCM-1706 Page 10 of 12 Effective From 1-3-2006 Specification No. M&C/ PCN/ 111 /2006

viii) Dry the disc. in an oven for 3 hours at 105oC and cool.

ix) Weigh the coated disc in air. Let it be W3 grams.

x) Suspend the coated disc in water and weigh again. Let it be W4 grams.

xi) Calculate the volume of the coated disc as follows :

W3 – W4
V1= ---------------- where d is the density of the water at room temperature.
d

xii) Calculate the volume of the dried coating as follows :-

Volume of dried coating = V1 - V

(Vd)
xiii) Calculate the volume of wet coating as follows :

W3 – W1
V1= ---------------- where W = grams of nonvolatile matter.
WXP P = specific gravity of the paint.
xiv) Calculate the percentage volume solids of the paints as follows :
V1 – V Vd
---------------- X 100 OR . -------- X 100
Vw Vw

The volume of non-volatile matter or the percentage volume solids of a

paint is related to the covering capacity and thickness in the following
manner :
% Volume solids
a) ---------------------------------- X 10 = Covering Capacity
Dry film thickness (microns)

Dry film thickness (microns)

---------------------------------- X 100 = wet film thickness
% Volume solids
Ref. MCM-1706 Page 11 of 12 Effective From 1-3-2006 Specification No. M&C/ PCN/ 111 /2006

APPENDIX-II
Accelerated Tests: (Resistance to Chemicals ) :

The following short - term tests of chemical resistance, do not categorize the
type of service for which High build epoxy paint coatings are intended but are included
to assure the customer that the coating contains a sufficiently cured resin to exhibit the
long term requirements.
Prepare the panels as per clause 9 of Table -III. Allow the panels to air dry for
7 days and seal the edges with wax.
a) Resistance to 25% caustic soda solution: Immerse 3/4th of the panel in 25% (w/v)
caustic soda solution for 2000 hours. Remove the panel, wash in running water and
allow it to air dry for an hour and record the observations .
b) Resistance to 30% sulphuric acid solution : Immerse 3/4th of the panel in 30% (v/v)
sulphuric acid solution for 2000 hours. Remove the panel ,wash in running water and
allow it to air dry for an hour and record the observations .
c) Resistance to 20% hydrochloric acid solution : Immerse 3/4th of the panel in 20%
(v/v) hydrochloric acid for 2000 hours. Remove the panel, wash in running water and
allow it to air dry for an hour and record the observations.
d) Resistance to tap water: Immerse 3/4th of the panel in tap water for 3000 hours.
Remove the panel, wash in running water and allow it to air dry for an hour and record
the observations.
APPENDIX-III
PROCEDURE FOR DETERMINING THE POT LIFE

(AS PER U.S. DEPTT. OF TRANSPORT/FED. RAIL, ROAD ADMN. OFFICE OF SAFETY TEST METHOD 2.7.1)

Take the usable time as the pot life of paint. Condition the components of the
coating for one hour at 27± 20C and mix immediately in proper ratio to get approx. 200
ml. of paint in 250 ml. of container. The lid should be loosely placed on the container.

1. Measure the viscosity initially and every hour thereafter. However, the interval may
be shortened, if desired.
2. Near the end of the paint’s working life, the viscosity builds-up rapidly. During this
period, when it appears the paint may be too viscous to spray, remove a small
portion and add the appropriate thinner. If the paint can still be thinned, the end of
the working life has not been reached. The end of the working life is reached when
the paint gels, becomes stringy or cannot be thinned for application.
Ref. MCM-1706 Page 12 of 12 Effective From 1-3-2006 Specification No. M&C/ PCN/ 111 /2006

APPENDIX-IV

DETERMINATION OF ADHESION AND COMPATIBILITY

1. Outline of method:

The material is tested in a painting system comprising of high build

epoxy and Acrylic Polysiloxane and schedule simulating actual use. Satisfactory
adhesion and compatibility between the coats is taken as criteria for having passed
the test.

2. Procedure:

A panel 300x150x0.9 mm, mild steel, with high build epoxy and Acrylic Polysiloxane
paint system shall be prepared as described below:

a) Clean the surface either by shot or grit blast and wipe this with petroleum
hydrocarbon solvent, 145/205 (low aromatic) (see IS: 1745- 1978) and allow to
dry.

b) Apply one coat of high build epoxy (two pack), 100-125 microns, DFT as per the
specification and allow to air dry for at least 8 hours, minimum. Dry rub with
emery paper no. 400 and wipe clean with a dry soft cloth.

c) Spray/apply one coat of Acrylic Polysiloxane (two pack), 45 microns, minimum

DFT, as per the specification. Allow to air dry for 5 hours, minimum. Allow to
air dry for at least 7 days before assessing the performance.

The material shall be deemed to have passed the test, if the material shows good
adhesion and compatibility over substrate and between high build epoxy and
Acrylic Polysiloxane.

This is assessed as per Test Method A-Cross Cut Tape Test of ASTM D 3359-
97 by making grid and placing 25 mm wide adhesive tape, semi transparent,
pressure sensitive, Parmacel 99 make or equivalent. The adhesive tape is then
pulled away with a jerk. The material shall be deemed to have passed the test, if the
edges of the cuts are completely smooth i e. it matches to 5A class of the above
mentioned specification.
N.B.
“All the provisions contained in RDSO’s procedures laid down in Document
No.QOD-7.1-11 dated 19.07.2016 (titled “vendor –changes in approved
status”) and subsequent versions/amendments thereof, shall be binding and
applicable on the successful vendor/vendors in the contracts floated by
Railways to maintain quality of products supplied to Railways.”
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