MAN Truck & Bus AG WORKS STANDARD June 2013
2K base coating materials
Primer M 3162
Technical terms of delivery
Dimensions in mm
This English version is a translation. In case of doubt or conflict the valid German-language original will govern.
Contents
1 Scope and purpose
2 Release conditions
3 Item designation
4 Types/application
5 Delivery condition
6 Test specimens, coating, general
7 Basic properties of the coatings
8 Recoatability
9 Adhesion
10 Corrosion resistance
11 Resistance to media
12 Compatibility with elastomers/plastics
13 Identity test
14 General conditions
1 Scope and purpose
This standard applies for chromate-free (Types A and C) 2K base coating materials with standard
(Type A) or increased (Type C) corrosion protection which are used as a primer for 1K top coating
materials according to M 3031 and 2K top coating materials according to M 3094.
The standard only defines the requirements that have to be satisfied for the application described in
Section 4 and the material base; the selection of the suitable chemical composition is at the
manufacturer's discretion taking into account the specifications in Section 2.
2 Release conditions
All parts of the standards series MAN 239 apply. In these standards, the release conditions and
procedures, as well as the general terms of delivery for purchased parts, are laid down.
Further details, advice, sample plates and coating materials can be obtained from the department EMTA,
Nuremburg works.
3 Item designation
2K primer M 3162 - x - xxx
Type as per Table 1
Colour (only if required)
(Wherever possible, only colours that conform to colour chart RAL 840 HR or RAL F9 in the case
of military vehicles are to be used)
In addition to the item designation, the item master data must contain the SDV code of the supplier
concerned and the material and/or formula no. used by the supplier (supplier-based item numbering).
Continued on Page 2 to 12
Co-sponsors of the standard: EMTAC,
Nuremberg works
Prepared by: Kluger, EAS Release EAS: Replaces: 2012-07 Material group no.:
2013-06, english
MAN Truck & Bus Aktiengesellschaft, Munich works - Dept. Standardization (EAS) All rights reserved according to ISO 16016.
Distribution and use of the contents are not allowed without written permission from MAN Truck & Bus Aktiengesellschaft.
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4 Types/application
Table 1
Type Application Drying Application Material basis
2K primer In accordance with
for top coating materials in manufacturer's Air and airless 2K epoxy resin
A specifications spraying
accordance with M 3094-3/-7, chromate-free
1
series-production trucks )
2K primer
B Replaced by M 3162 Type C
- containing chromate -
2K primer
for top coats In accordance with
in accordance with M 3094-3/-7 2K epoxy resin
C manufacturer's Air and airless
and M 3031-1/-2 (series-production specifications spraying
trucks) chromate-free
1
as well as M 3094-5 (military )
vehicles)
1
) The manufacturer guarantees a consistently high quality of material characteristics within the temperature range
specified by the manufacturer
5 Delivery condition
Table 2
Requirements
Properties Test to
Type A Type C
Flash point °C DIN EN ISO 1523 21
Hazard class VbF (Regulation on to be specified
flammable liquids)
Runout time s DIN EN ISO 2431
3
Density of coating material g/cm DIN EN ISO 2811-1
2
Theoretical consumption m /kg DIN 53220
Binder base
Binder content g/100 g to be specified
Pigment base
---
Pigment content g/100 g
Pigment volume concentration (PVC)
Critical pigment volume concentration (CPVC)
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6 Test specimens, coating, general
The test plates according to Table 3 are to be coated as per Table 4.
Table 3 Test plates to DIN EN ISO 1514
Test plate Dimensions
Plate quality and surface Edge type
No. (mm)
Pickled deep-drawn plate
1 ST 1405 m according to DIN 1623 or DC04B 200 x 100 x 1
according to DIN EN 10130
or
Pickled deep-drawn plate 1
190 x 65 x 1 )
ST 1405 m to DIN 1623 or DC04B to DIN
EN 10130, or
2 2
blasted Sa 2 1/2 to SS 055900, 300 x 150 x 1 )
Surface roughness Rz 30 – 40 m
Pickled deep-drawn plate 200 x 100 x 1
3 ST 1203 m to DIN 1623 Punched with standard tool
or DC01A to DIN EN 10130
4 Aluminium plate Al Mg 3 F 26 minimum 2 edges with burr 200 x 100 x 1
Hot galvanised deep-drawn plate (no de-burring)
ST E 280-3 Z 200 SC
5 200 x 100 x 1
to M01.010 OV
chromated
Test plates No. 3, 4 and 5 in composite each
metal. The galvanised steel plate is spot- 1
welded to the steel plate and the Al plate 80 x 65 x 1 )
6 riveted using Al rivets to A 21 M7.242.19 or
(rivet head on aluminium side), 25 mm
overlap in each case each
2
see diagram in Section 10 300 x 150 x 1 )
1
) Only for MAN weathering simulation test to MAN 365
2
) Only for natural weathering test to ISO 2810-1974
Table 4 Test coating
Coating system System 1 System 3
Cleaning Degrease to M 3161 with solvent to M 3106
Pre-treatment Start-grind aluminium
Priming 2K primer to M 3162
Type A Type C
25 – 35 30 – 40
1 1
Layer thickness m or 40 – 50 ) or 70 – 80 )
1
)
For testing corrosion resistance according to Section 10.1 and compatibility with elastomers/plastics
according to Section 12
Important: The coating is applied to the side of the test plate without de-burred edges. These edges must
also be coated.
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Storage and regeneration periods
Unless otherwise specified in individual cases, the test samples must be stored for 7 days at room temperature
(RT) after the respective coating before the start of testing and must be allowed to regenerate for 1 hour at RT
after the test loads before the requirements are determined (evaluations).
7 Basic properties of the coatings
Test samples: System 1 on test plates No. 1 and 2
System 3 on test plates No. 3, 4 and 5
Table 5 Basic properties, requirements
Requirements
Properties Tests according to
System 1 System 3
Colour --- to be specified
Cross-cut DIN EN ISO 2409 max. Gt 1 max. Gt 1
Adhesion (scratch test) MAN 277 max. K 1 max. K 1
1
Mandrel bending test ) DIN EN ISO 1519 4 without crack
2 2
Cupping mm DIN EN ISO 1520 3 ) 3 )
Resistance to steam jet see Section 7.1 No signs of detachment;
to be submitted by the supplier
3
Bondability ) MAN 262-1 Requirements to MAN 262-1
Degree of drying
for drying according to Table 1 DIN EN ISO 9117-5 5 5
or for 3 h at RT
Thermomechanical analysis
e.g. torsional vibration test DIN EN ISO 6721 ff. to be specified
1
) Test plate to DIN EN ISO 1519
2
) Evaluation with 10x magnifying glass
3
) The bondability test is to be carried out with series adhesives for bus and truck
7.1 Resistance to steam jet
Test samples: Coating system on test plate No. 1
Test medium: Steam with 3 - 5 % detergent Erwa 2000 at 60 bar
Test temperature and test duration: 60 sec steam jet / 60 °C at jet distance of 10 cm
Requirements: No signs of detachment on any system
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8 Recoatability according to DIN 53221
Test samples: Systems 1 and 3 on test plates No. 1 and 2, overpainted with following coating systems:
Table 6 Recoatability, coating systems
Systems to Table 4 Overpainting with coating
Drying
Top coat
Time at temperature Pre-treatment
Systems 1 and 3 (coating thickness in m)
1K – M 3031-1
x
Acc. to manufacturer's in acc. with DIN 53221 (40 – 50)
specifications unground and ground 2K – M 3094-3, -3A, -3B, -5
x
(40 – 50)
1K – M 3031-1
x
in acc. with DIN 53221 (40 – 50)
"wet in wet"
unground 2K – M 3094-3, -3A, -3B, -5
x
(40 – 50)
Table 7 Recoatability, tests and requirements
Properties and requirements (all systems)
Cross-cut Adhesion Degree of blistering
Test load Test requirement
(scratch test)
DIN EN ISO 2409 MAN 277 DIN EN ISO 4628-2
Thermal ageing
3 h at 105 °C max. Gt 1 max. K 2 ---
to DIN EN ISO 3248
Condensed water - Constant
climate 1 1 1
240 h max. Gt 1 ) max. K 2 ) m0/g0 )
to DIN EN ISO 6270-2 - CH
1
) Evaluation after regeneration time of 24 h at RT
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9 Adhesion
Test samples: Systems 1 and 3 on substrates in accordance with Table 8
1
Table 8 Adhesion ), substrates
Overpainting
Substrates / test plates after drying with
Pre-treatment
coated with (time at systems 1
temperature) and 3
1. Stainless steel, uncoated (test plate 200x100x1)
2. Filler to M 3079-2 (test plate 1)
3. Primer 1K – M 3086 Systems 1 and 3 (test plate 1)
4. Primer 2K – M 3162 Systems 1 and 3
5. Plastic GRP – uncoated M6.400.50
(sample approx. 200x100)
6. Plastic GRP – coated M 3022 Type 2 unground and min. 7 days
(sample approx. 200x100) x
ground at RT
7. Commercially available air-drying or stove-enamelled
2
coating to M 3018 ) 1K
8. Commercially available air-drying or stove-enamelled
2
coating to M 3018 ) 2K
9. Poorly degreased steel sheet
10. Top coat M 3031-3
1
) In special cases, proof of adhesion on substrates exposed to natural weathering may also be required.
2
) Reference coating will be provided by Dept. EMTA, Nuremberg works.
Table 9 Adhesion, tests and requirements
Properties and requirements (all systems)
Cross-cut Adhesion Degree of blistering
Test load Test requirement
(scratch test)
DIN EN ISO 2409 MAN 277 DIN EN ISO 4628-2
Thermal ageing
3 h at 105 °C max. Gt 1 max. K 2 ---
to DIN EN ISO 3248
Condensed water - Constant
climate 1 1 1
240 h max. Gt 1 ) max. K 2 ) m0/g0 )
to DIN EN ISO 6270-2 - CH
1
) Evaluation after regeneration time of 24 h at RT
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10 Corrosion resistance
The requirements of edge- and intersection characteristics according to M 3549 have to be considered and
followed.
10.1 Corrosion resistance in primed systems according to Table 4
Test samples: Systems 1 and 3 on test plates to Table 10 prepared as follows:
Preparation: The coating is damaged in a defined manner down to the plate substrate
using a 0,5 mm wide diamond cutter (see diagram).
Please note: A separate milling cutter shall be used for each test plate (steel, galvanised,
Al) due to the electro-chemical contact corrosion.
S ys t em Systems
S y s t e m3e 32 u n d 3
System 1 1
250 65
1 Test plateNr.
Prüfblech No.4 4
(aluminium sheet)
(Alublech)
2
Test plateNr.
Prüfblech No.33
200 190
(steel sheet)
(Stahlblech)
3
Prüfblech
Test plateNr.
No.55
1 2 3 4 (galv.Stahlblech)
(verz. steel sheet)
4 1
TestPrüfblech
plate Nos.Nr. 1, 52, 5
1, 2, Prüfblech
Test Nr.44
plate No. Test plateNr.
Prüfblech No.55
(Stahlblech (aluminium
(Alublech)sheet) (galv.Stahlblech)
steel sheet)
(steel sheet and und
galv.verz. (verz.
steelStahlblech)
sheet)
Prüfblech
Test plate No.Nr.3 3
(Stahlblech)
(steel sheet)
Table 10 Corrosion resistance, test load
Test requirement Test plate to Table 3
Code Test load 3 3
System 1 System 3 System 1 ) System 3 )
Salt spray fog
a 240 h
to DIN EN ISO 9227 – NSS
Condensed water - Constant
b climate 120 h 240 h
to DIN EN ISO 6270-2 – CH 2
1 and 2 6 )
MAN weathering simulation test
c 3 cycles 4 cycles
to MAN 365-1
Natural weathering 1
d 2 years )
to ISO 2810 – 1974
1
) Natural weathering status from EMTA
2
) Start-grind aluminium plate
3
) Overpainted with top coat M 3094-3
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Table 11 Corrosion resistance, requirements
Requirements
Properties Test load Evaluation
System 1 System 3
and test to
plates 1 Test plate
Test to ) Test plate 4 Test plate 3 Test plate 5
1 and 2
Degree of blistering Surfaces,
according to DIN EN ISO a; b; c; d cut, m0 / g0
4628-2 edges
Degree of rusting
a; b; c; d Surfaces, Ri 0
according to edges
DIN EN ISO 4628-3
Infiltration a; b; d max. 1 0 max. 2
(corrosion including Cuts,
delamination) as per c edges max. 2 max. 1 max. 3
DIN EN ISO 4628-8 (mm)
Cross-cut
according to a; b; c; d Surfaces --- max. Gt 1 max. Gt 2
DIN EN ISO 2409
Adhesion (scratch test)
a; b; c; d Surfaces max. 1 ---
to MAN 277
1
) For test loads a and b, evaluation is performed after a regeneration time of 24 h at RT.
10.2 Corrosion resistance in top-coated systems to M 3031/M 3094
Table 12 Corrosion resistance in top-coated systems
Coating systems according to Test conditions and test Properties Requirements
works standard requirements
Systems 3, 4 to M 3031 Degree of blistering to M 3031
to M 3031 Table 4 Table 10 Degree of rusting Table 10
Systems 8 to M 3094 Infiltration to M 3094
to M 3094 Table 4 Table 10 Cross-cut Table 10
11 Resistance to other media
11.1 Temperature resistance to DIN EN ISO 3248
Test samples: Systems 1 and 3 according to Table 4 on test plate No. 1 according to Table 3
Test load: Thermal exposure 48 h at 80 °C
Requirements:
Table 13 Temperature resistance
Requirements
Properties
System 1 System 3
Cross-cut to DIN EN ISO 2409 max. Gt 1
Adhesion (scratch test) to MAN 277 max. K 1
1
Cupping (mm) to DIN EN ISO 1520 2 )
1
) Evaluation with 10x magnifying glass
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12 Compatibility with elastomers/plastics (by agreement only)
Elastomer materials: SRE-NBR 28 to DIN 53538-3
SRE-EPDM to DIN 53538-5
Plastics: POM, PES, PA 12, PP, PVC, PUR
Number of test pieces: 3 standard test bars S 2 in each case (DIN 53504)
Test load: The standard bars are sprayed on both sides with the layer thicknesses stated in
Table 4 and stored for 24 h at RT.
Requirements:
Table 14 Compatibility with elastomers/plastics
1
Properties Requirements )
Test to Systems 1 and 3
Change in hardness (Shore A) to DIN 53505 ±5
Change in tensile strength (%) to DIN 53504 + 10 to - 15
2
Change in elongation at break (% of %) to DIN 53504 + 10 to - 15 )
1
) Change referred to uncoated test piece
2
) Not carried out with PP
13 Identity test
Table 15
Requirements
Properties
System 1 System 3
3
Density – coating (g/cm ) MAN 278
Percentage volume of non-volatile matter (Vol %) to be specified
DIN 53219
Binder base (IR spectral analysis) N 669
Pigment base (spectral analysis of pigments)
produced by EMTA
Gel permeation chromatogram (determination of
mean binder molecular weight)
14 General conditions
The 2K base coating material (primer) must be supplied in suitable containers (metal or plastic).
The containers must be clearly marked as follows in accordance with MAN 312-1:
- MAN trademark
- MAN item number
- MAN approval number
- Manufacturer's name or trademark
- Manufacturer's quality designation (material identification or formula No.)
- Batch number
- Quarter and year of manufacture
The 2K base coating material must continue to exhibit all characteristics in these technical terms of delivery
after being stored for 12 months from the delivery date at approx. 15 °C.
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Standards quoted
DIN 1623 Flat products from steel, cold-rolled strip and plate, technical terms of delivery
DIN 53219 Testing of paints and varnishes; determination of percentage volume of non-volatile
matter
DIN 53220 Paints, varnishes and similar coating materials,
paint consumption required for coating an area,concepts and parameters
DIN 53221 Paints and varnishes,
testing of recoatability of a coating
DIN 53504 Testing of rubber and elastomers;
determination of tensile strength at break, tensile stress at yield, elongation at break
and stress values in a tensile test
DIN 53505 Testing of rubber, elastomers and plastics, hardness test to Shore A and D
DIN 53538-3 Standard reference elastomers; acrylonitrile-butadiene rubber (NBR), low sulphur
cured, for characterising service fluids with respect to their action on NBR
DIN 53538-5 Standard reference elastomers; ethylene propylene diene rubber (EPDM), peroxide
cured,
for characterising service fluids with respect to their action on EPDM
DIN EN 10130 Cold-rolled flat products from soft steels for cold forming, technical terms of delivery
DIN EN ISO 1514 Coating materials, Standard panels for testing
DIN EN ISO 1519 Coating materials, Standard panels for testing
DIN EN ISO 1520 Coating materials, cupping test
DIN EN ISO 1523 Coating materials, cupping test
DIN EN ISO 2409 Paints and varnishes, cross-cut test
DIN EN ISO 2431 Paints and coating materials, determination of flow time by use of flow cups
DIN EN ISO 2811-1 Paints and varnishes, determination of density, pyknometer method
DIN EN ISO 3248 Paints and varnishes - Determination of the effect of heat
DIN EN ISO 4628-2 Coating materials, evaluation of degradation of coatings, designation of quantity and
size of defects and of intensity of uniform changes in appearance, assessment of
degree of blistering
DIN EN ISO 4628-3 Paints and varnishes; evaluation of degradation of coatings, assessment of quantity
and size of defects, and of intensity of uniform changes in appearance, assessment
of degree of rusting
DIN EN ISO 4628-8 Paints and varnishes - Evaluation of degradation of coatings - Designation of
quantity and size of defects, and of intensity of uniform changes in appearance - Part
8: Assessment of degree of delamination and corrosion around a scribe
DIN EN ISO 6270-2 Paints and varnishes - Determination of resistance to humidity - Part 2: Procedure
for exposing test specimens in condensation-water atmospheres
DIN EN ISO 6721 ff. Plastics, determination of dynamic mechanical properties
DIN EN ISO 9117-5 Paints and varnishes - Drying tests - Part 5: Modified Bandow-Wolff test
DIN EN ISO 9227 Corrosion tests in artificial atmospheres - Salt spray tests
ISO 2810-1974 Paints and coating materials, guidelines for performing natural weathering tests
M 3018 Corrosion protection and coating systems for purchased parts; technical terms of
delivery
M 3022 Coating materials for components made of plastics; technical terms of delivery
M 3031 One-component top coating materials, 1K top coat; technical terms of delivery
M 3079 One-component fillers; 1K fillers, technical terms of delivery
M 3086 1K base coating materials; technical terms of delivery
M 3094 Two-component top coating materials, 2K top coat; technical terms of delivery
M 3106 Detergents and thinners; technical terms of delivery
M 3161 Cleaning metallic surfaces
M 3549 Edge- and intersection quality for parts of metallic materials, requirements of edge-
and intersection characteristics relating to corrosion protection
M01.010 Flat product from steel; hot galvanised strip and plate from general construction
steels; quality standard
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M6.400.50 Glass fibre reinforced unsaturated polyester resins (UP-GF); material supply
conditions
M7.242.19 Blind rivets (POP cup rivets)
MAN 239-1 ff. General terms of delivery for purchased parts, all parts
MAN 262-1 Adhesives
MAN 277 Adhesion test (scratch test)
MAN 278 Coating; determining density of dry coating
MAN 312 Identification labelling; requirements and implementation
MAN 365 MAN natural weathering simulation test, test loads, test conditions
N 669 Pyrolysis of non-metallic materials for IR spectral analysis
SS 055900 Preparation of steel substrates before application of paints and related products -
Visual assessment of surface cleanliness - Part 1: Rust grades and preparation
grades of uncoated steel substrates and of steel substrates after overall removal of
previous coatings
VbF (Regulation on Regulation on installations used for the storage, filling and transportation of
flammable liquids) flammable liquids in Germany (regulation on flammable liquids - VbF)
Previous issues: M 3162 / 05.80, 03.82, 04.82, 01.84, 05.84, 08.84, 10.85, 12.86, 04.90, 06.90, 03.93,
1997-04, 2003-11, 2003-12, 2004-08, 2005-07, 2006-01, 2007-04, 2010-01, 2010-12
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Changes: Compared to issue 2003-11 the following changes have been made:
- Table 12: System 8 added
Compared to issue 2003-12 the following changes have been made:
- Table 1: Drying according to manufacturer's specifications and Index 1 added
Compared to issue 2004-08 the following changes have been made:
- Table 4: Layer thicknesses Type A adapted
Compared to issue 2005-07 the following changes have been made:
- Table 10: Index 3 new assignment
- Table 6: Drying according to manufacturer's instructions and Type 3A and 3B to
M 3094 added
- Table 5: Index 3 modified
- DIN 53209 replaced by DIN EN ISO 4628-2
- DIN 53210 replaced by DIN EN ISO 4628-3
Compared to issue 2006-01 the following changes have been made:
- Type B omitted
- Table 1: Column "Application" adapted
- Table 3: DC01A to DIN EN 10130 added
Compared to issue 2007-04 the following changes have been made:
- Dept. EMTA was MTWV
- DIN 50017 replaced by DIN EN ISO 6270-2
- DIN 50021 replaced by DIN EN ISO 9227
Compared to issue 2010-01 the following changes have been made:
- DIN EN ISO 7253 replaced by DIN EN ISO 4628-8
Compared to issue 2010-12 the following changes have been made:
- Section 7.1 revised
- Tables 7, 9 and 11: Regeneration time generally increased to 24 h
Compared to issue 2012-07 the following changes have been made:
- Section 10: note on M 3549 added
- Section 12: reference to system 4 according to M 3094 was omitted
- DIN 53150 replaced by DIN EN ISO 9117-5
