EUROCOUSTIC PRODUCTS LIMITEI)

KACHTGAM- DAMAN (UT )396210

MANUFACTURING PROCEDURE
FOR
FUSIOI{ BONDED EPOXY COATING
ON REBARS

Document No. : EPL/DMN/OI

Issue No./ Rev : 1/ Rev. 0

Effective date. : 01.09.2018

EUROCOUSTIC PRODUCTS LIMITED

POST BOX NO.25 VILLAGE KACHIGAM
DAMAN-(m)
PIN CODE - 396210
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Approved By:
ffi
MANUFACTING
EUROCOUSTIC PROCEDURE $tSo---"'-"
PRODUCTS LIMITED FOR
( UNIT HEAD )
KACHIGAM (DAMAN )
Sheet No. : 1 of 6 Issued By
Rev. No. :00 FUSION BONDED
Date : OL l09l18 EPOXY COATING OF
REBARS
(MR)

1.0 PROCEDURE

1.1 Raw Materials

The basic materials i.e. Epoxy powder shall meet the requirement of the
specifications given under reference 3.0.

I.2 BARE BARS _

I.2.I RECEIPT
All steel to be used shall be high yield strength deformed bars
conforming to IS L786 : 1985/ ASTM - A 615M/A706M or A 996 M I
150-6935-1/ISO 6935-2 /ISO-10544 or ISO 6935-3.

Bare bars received shall be checked for bar diameter, weight difference,
& surface defect. In case of any problem this shall be intimated to the
client concerned or shall be dealt according to the ordering information.
(Bare bars Inspection Report QR/QAQC/051)

1.2.2 STACKING

A11bare bars shall be stacked client wise/size wise above ground level
duly identified and record shall be maintained such as clients name,
challan number, diameter, quantity & status of the material (bars).
Approved By:
ffie
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'ffis* MANUFACTING
EUROCOUSTIC
PROCEDURE
PRODUCTS LIMITED FOR
KACHIGAM (DAMAN )
SheetNo. :2 of 6 Issued By
Rev No. : OO FUSION BONDED
:
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Date : Ol l09l18 EPOXY COATING OF .[t'*&-
REBARS (MR)

1.3 SURFACE PREPARATION

The blasting & coating operations are conducted under covered area.
Visual inspection is performed on each bar so that steel surface shall be
free of water, oil, grease and other kind of contamination on the bare bar
rack. Any bar found with any contaminant shall be cleaned with suitable
solvent and dried prior to blast cleaning according to SSPC-SP10
Specification or as per standards referred in reference 3.0.
Coating operation shall be completed within stipulated time as per
specification.
Tkre b\astkrg operatiorrs skra\\ rrot be Set(orrt\sd. rn the telative hulcrt(it5
exceed 95 percentage.
Every bar is conveyed to shot blaster where the bars are cleaned by
impact of steel shots/grits during the shot blasting operation.
Grade of cleaning shall be checked for every hour to conforming to SA21/z
as per pictorial representation of ISO-8501-1.

Roughness sha-ll be checked by Press-o-film and shall be recorded in In-

process Quality report (Blasting station QR/QAQC lO52Al in case of
ASTM 775A1775M-01& it
shall be between 40 to 100 microns per
specification

I.4 HEATING

The blast-cleaned bars shall be conveyed through conveyor and shall be

heated prior to Epoxy Powder application. Induction heater shall be used
for heating the blasted bars. A uniform temperature shall be maintained
along the total length of the bar.
The bar shall be heated as recommended by epoxy powder manufacturer.
The specified temperature shall be carefully maintained and checked by
Infra Red camera after coating booth & recorded in In-process Quality
Report Coating station (QR/QAQC I O52B).
& Approved By:
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MANUFACTING
EUROCOUSTIC PROCEDURE n'Yt-
PRODUCTS LIMITED FOR \.),.,
KACHIGAM (DAMAN ) r TTNTT HIIAD )

Sheet No. : 3 of 6 Issued By :

Rev No. : 00 FUSION BONDED

Date : Ol l09 I 18 EPOXY COATING OF
REBARS J"--p
(MR)

1.5 EPOXY POWDER APPLICATION

The heated bars shall pass through epoxy cabin where electro statically
charged epoxy powder is applied through spraying guns to get desired
coating thickness.
A11 the parameters vise line speed, air pressure and rate of charging
necessarJr to control the coating application of fusion bonded epo>ry shall
be established during the regular production and shall be recorded in
report QR/QAQC lo52B.
I.6 COOLING OF REBARS
After coating and proper curing the bars will be conveyed through the
cooling tunnel for quenching. The water shall be re-circulated through
cooling towers to maintain temperature at desired level.
I.7 INSPECTION AND TESTING
1.7 .l Thickness Inspection

After cooling, coated bars shall route stringent quality checks for visual
inspection and thickness as per customer requirement/ specification.
The thickness range and acceptance criteria shall be either per
specification or as per customer requirement.
The coating thickness limits do not apply to the patching work or repair
work.
Thickness status shall be recorded in Thickness sheet.
(QR/ QAQ c I o52cl .
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Approved BY:

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-ffi* MANUFACTING ,,,

EUROCOUSTIC
PROCEDURB
FOR
U""-
PRODUCTS LIMITED
( UNIT HEAD )
KACHIGAM (DAMAN )
SheetNo.:4of6 Issued By I r.
RevNo. : 0O FUSION BONDED l' -'V
Date : OL l09l18 EPOXY COATING OF JlLn'"
REBARS (MR)

1.7.2 ContinuitY of Coating.

The coating shall be visually inspected after curing for continuity of the
ani shall be free from holes, voids, contamination, and crack &
damag"ed area discernible to unaided eye. The holiday detection
"or.tirrg shall be
carried out using 67.5V DC holiday detectors'

Record no of holidays in In-process Quality control holiday sheet

(QR/QAQClo52 El

The acceptance criteria for the holiday test shall be as per specification'

1.7.3 Adhesion of Coating / Flexibility of Coating

The adhesion / flexibility of coating shall be evaluated a bend test on a

representative number of bars as per the specification.

No visible cracks and d.isbonding in the coating on the outer radius shall
be allowed.

The results shall be recorded in In-process Quality bend test report'

(QR/QAQC los2Dl.

1.8 Retest

If the specimen for coating thickness or for adhesion of coating fails to

meet tkre specified requirements, twice the number 6f samples originally
selected. shall be tested for each failure test. If the results of these retests
meet the specified requirements, the coated bar represented :by the
sample shall be accePted.
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Approved By:
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/ re: MANUFACTING
PROCEDURE D./
EUROCOUSTIC
PRODUCTS LIMITED FOR UNIT HEAD )
KACHIGAM (DAMAN )
SheetNo. :5 of 6 lssued - :
By
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No. : 00
Rev
Date : Ol l09l18
FUSION BONDED
EPOXY COATING OF 1JLV -*.Y
REBARS
(MR)

1.9 REMOVAL OF NON-CONFORMING PRODUCT

Coated bars represented by the samples that do not meet the

requirements of this specification shall be rejected. Such bar may be
stripped of coating, re-cleaned, re-coated and resubmitted for acceptance
test in accordance with the requirements.

2.O REPAIR PROCEDURE

A11damaged areas shall be repaired with patching material. Maxirnum

amount of damage shall not exceed 2 percent of the surface area of each
bar. Patching shall be done to the satisfaction of customer requirement.

3.0 MATERIAL HANDLING

The coated bars shall be handled under effective supervision. Wooden

packing batons shall be used while lifting & stacking. Bundles'of coated
bars shall be tied with PVC binding material.

The bundles of coated bars shall be stacked properly and each row of
coated bars shall have gap between ground and bars with wooden
batons. A11 bundles of coated bar shall be lifted with a strong back,
spreader bar, multiple supports or a platform bridge to prevent bar-to-
bar abrasion from sags.
Approved By:
ffi*
/ MANUFACTING -''
PROCEDURE a\ $lr-
EUROCOUSTIC
PRODUCTS LIMITED FOR u'
KACHIGAM (DAMAN ) ( UNIT HEAD )

Sheet No. :6 of 6 Issued By : f

Rev No.
Date
:00
: OL l09l18
FUSION BONDED
EPOXY COATING OF
1{t}" .;-Y
"
I

REBARS (MR )

4.O IDENTIFICATION & TRACE ABILITY:

Bare and coated bars shall be stacked separately customer wise, Project wise/
coating wise and identified from the tags recording
system/method. Each bundle shall have tag with following information.

Yellow coloured tag shall be used for bare bar receipt record and the information
such as Client narne, challan number, date of receipt, size of bars, type of bar,
quantity and status of the bars at the time of receipt shall be recorded.

Green coloured tag shall be used for coated bar record and the information such as
Client narne, challan number, date of coating, size of bars, quantity and status of the
bars at the time of coating shall be recorded.