Def Stan 03-32 Part 4 Paint-Systems For Ferrous Metals
Def Stan 03-32 Part 4 Paint-Systems For Ferrous Metals
Contents
Tables
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DEF STAN 03-32 Part 4 Issue 4
Foreword
AMENDMENT RECORD
REVISION NOTE
This Part of the Defence Standard has been reviewed and revised to align with the latest (Land HQ)
policy on the painting of Vehicles, Engineer Equipment and Components and the use of VOC and CAR
paint systems. Some paint systems listed in earlier issues have been withdrawn or declared obsolescent
– these are listed in Part 1, Table 2.
HISTORICAL RECORD
DREE10A
DGFVE 2012
MVEE 666 dated April 1983
Def Stan 03-32 (Part 3) / Issue 1 dated July 1993
Def Stan 03-32 (Part 3) / Issue 2 dated 14 May 1999
Def Stan 03-32 (Part 3) / Issue 3 dated 24 May 2002
a) This standard provides requirements for Systems for Ferrous Metal, Excluding Armour for the
Pretreatment and Painting of Vehicles, Engineer Equipment and Components.
b) This standard has been produced on behalf of the Defence Material Standardization Committee
(DMSC) by Corrosion Prevention and Metallic Materials Standards Production Group (E3).
c) This standard has been agreed by the authorities concerned with its use and is intended to be used
whenever relevant in all future designs, contracts, orders etc. and whenever practicable by
amendment to those already in existence. If any difficulty arises which prevents application of the
Defence Standard, the Directorate of Standardization (DStan) shall be informed so that a remedy
may be sought.
d) Any enquiries regarding this standard in relation to an invitation to tender or a contract in which it is
incorporated are to be addressed to the responsible technical or supervising authority named in the
invitation to tender or contract.
e) Compliance with this Defence Standard shall not in itself relieve any person from any legal
obligations imposed upon them.
f) This standard has been devised solely for the use of the Ministry of Defence (MOD) and its
contractors in the execution of contracts for the MOD. To the extent permitted by law, the MOD
hereby excludes all liability whatsoever and howsoever arising (including, but without limitation,
liability resulting from negligence) for any loss or damage however caused when the standard is
used for any other purpose.
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DEF STAN 03-32 Part 4 Issue 4
Introduction
This Defence Standard comprises self contained parts which are based on the substrate to be treated.
They include pretreatment process, for example, methods of cleaning, metal coating, passivation and
preservation. The form of presentation was adopted to assist the user by detailing each major paint system,
for each major paint substrate, as a complete section. However, the range of requirements covered is wide,
and some cross references are necessary. This form of presentation also enables the major painting
requirements to be specified in terms of the sections in the document.
Equipment treated in accordance with the appropriate requirements of this Standard will be expected to
meet the Service Department requirements for operational use. The paint system required for any particular
equipment or component shall be stated in either the relevant order or drawings/equipment specification
issued by the Design Authority.
This Standard has been compiled in accordance with the general requirements of Def Stan 03-30
“Treatments for the Protection of Metal Parts of Service Stores and Equipment against Corrosion”.
Def Stan 03-32 Part 1, dealing with general requirements, shall be read together with any subsequent part
specified.
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DEF STAN 03-32 Part 4 Issue 4
1 Scope
This Part of the Defence Standard details painting systems for application to ferrous metal, excluding
armour surfaces. The conditions and requirements of Part 1 of this Defence Standard shall be read with
and applied to this Part of the Defence Standard. The paint systems detailed at 4.6, 4.8 and 4.9 are given
twice with variations according to the substrate concerned (non-ferrous surfaces and phosphated
surfaces). To assist with identification they have been identified as A (non-ferrous) and B (phosphated).
2 Warning
The Ministry of Defence (MOD), like its contractors, is subject to both United Kingdom and European
laws regarding Health and Safety at Work, without exemption. All Defence Standards either directly or
indirectly invoke the use of processes and procedures that could be injurious to health if adequate
precautions are not taken. Defence Standards or their use in no way absolves users from complying with
statutory and legal requirements relating to Health and Safety at Work.
3 Normative References
The publications shown below are referred to in the text of this standard. Publications are grouped and
listed in alpha-numeric order.
Designation Title
NOTE 1 Great importance is placed upon satisfactory treatment of the metal surface prior to application of the correct paint system.
High tensile strength, greater than 1100 MPa, and surface hardened steels which are subjected to pickling, phosphating, electroless
/electrolytic plating, passivation etc, will require heat treatment in accordance with Part 6 prior to painting.
NOTE 2 The cleaning processes shall be selected from Def Stan 03-2 Methods D through Z, and unless specified otherwise, shall be
followed by one of the protective processes detailed in clause 5. (See also Part 1.)
NOTE 3 In certain cases, e.g. large castings, rubber bonded items (tank wheels, see Part 6) and partially closed fabrications, the
treatments listed below may not be suitable. In such cases advice shall be sought and the method selected shall be part of the process
schedule.
NOTE 4 Surfaces inaccessible after fabrication or assembly and thereby unable to be finished with the complete paint system, shall be
cleaned by a suitable method from Def Stan 03-2 and then coated with Zinc Dust Priming Paint in accordance with BS 4652 Type 3, unless
the surface has been treated with a protective coating as listed in clause 5 when further protection is unnecessary.
5 Protective Processes
5.1 Phosphating
5.1.1 This shall be in accordance with Def Stan 03-11. Where oil is specified, Class I only shall be
used. Where sealing by paint is specified, Class II or I is acceptable except for light gauge materials (up
to 1.25 mm) when Class III or II shall be used.
5.1.2 Where phosphated and painted sheet is to be deformed during fabrication, Class IV is
acceptable.
NOTE Paint pretreatment (Etching Primer) is not recommended for application to phosphate surfaces.
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DEF STAN 03-32 Part 4 Issue 4
5.2.1 Surfaces shall be grit blasted and metal sprayed in accordance with BS EN 22063, except that
for vehicles the minimum thickness of coating shall be 76 µm and for structures the minimum shall be
200 µm. The maximum thickness shall be not greater than 300 µm.
5.2.2 The chemical compositions of the sprayed metals shall be: Aluminium 99.5 per cent (BS EN
1301: EN AW-1050A), Zinc 99.95 per cent (BS EN 1179: Z3). When the sprayed metal surface is to be
painted it shall be treated in accordance with 5.7
5.3.1 This shall be in accordance with one of the following specifications: BS 417, BS EN 10244-2, BS
EN 1461, BS 3083, BS EN 10143. The minimum thickness of Zinc coating shall be 43 µm (0.305 kgm -
2).
5.3.2 When the coating is damaged, e.g. during welding, the damaged areas shall be thoroughly
cleaned and touched up with Zinc Dust Primer to BS 4652, Type 3.
5.3.3 When the galvanised surface is to be painted, it shall be cleaned and treated in accordance with
5.7. When the galvanised surface is to be kept unpainted, it shall be passivated.
5.4 Sheradizing
Sheradizing will be in accordance with BS 4921. The minimum coating thickness shall be 30µm. When
the sharadized surface is to be painted, it shall be treated in accordance with 5.7.
When the coating is damaged, e.g. during welding, the damaged areas shall be thoroughly cleaned and
touched up with Zinc Dust Primer to BS 4652, Type 3 prior to further painting if required. Unless
otherwise specified the surface shall be treated in accordance with 5.7.
5.6.1 Cadmium plating shall be in accordance with Def Stan 03-19 and passivation in accordance with
BS 6338 unless paint is to be applied.
NOTE Environmental considerations do not support use of cadmium unless there are strong justifications for
doing so. Design Authorities should, therefore, avoid use of cadmium (particularly electroplated cadmium). See Def
Stan 03-36.
NOTE 2 Vapour deposition of aluminium or cadmium (see 5.6.6) or the electrodeposition of zinc-nickel alloy, zinc-
cobalt alloy, aluminium, tin-zinc alloy etc. may be employed to replace electrodeposition of cadmium.
5.6.2 Zinc plating shall be in accordance with Def Stan 03-20 and passivation in accordance with BS
6338 unless paint is to be applied.
5.6.5 Electroless nickel plating shall be in accordance with BS EN ISO 4527. The nickel coated
surfaces shall be treated by Def Stan 03-2 Method D2 (non-metallic abrasives) immediately prior to
painting.
5.6.6 Vapour deposition of aluminium, cadmium or other metals shall be in accordance with Def Stan
03-28.
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DEF STAN 03-32 Part 4 Issue 4
5.6.7 Except for the substrates in 5.6.3 to 5.6.6, when subsequent painting is to be applied, the
surface shall be treated in accordance with 5.7.
5.7 Paint pretreatment (Etching Primer) complying with BS 2X32 shall be applied to the clean surface
or freshly deposited metal surface with the minimum of delay and in any case within 16 hours (see Part
1, clause 9).
5.8 When metallic coatings are required of a thickness greater than that specified in individual
Defence Standards. The required thickness must be specified in the drawing contract or order.
6 Paint Systems
The paint systems suitable for use on Ferrous Metal, excluding Armour are detailed in Tables 2 – 7.
NOTE Some paint systems have been withdrawn since Issue 1 of this Defence Standard. They are listed in
Part 1, Table 2 with their system numbers because of the large number of drawings and specifications in service use
that refer to the old system number. However, the details of these withdrawn and obsolescent paint systems are no
longer referred to in Parts 2 - 6 inclusive.
Table 2 — Paint System 4.6A - Internal Epoxide (Two-Pack) (Non-Ferrous Surfaces e.g. Zinc
Plate), VOC Compliant
Coating Air Drying Colour Air Drying Air Drying Dry Film
Specifications BS 381C System System Thickness
(Note 1) Colour No. Minimum Maximum (µm)
Recoat Time Recoat Time (Note 2)
(hours) (hours)
NOTE 2 The minimum total dry film thickness of the paint system shall be not less than 90 µm.
NOTE 4 If in exceptional circumstances the paint film has been allowed to dry for more than the specified maximum
recoat time, the surface shall be lightly rubbed down with abrasive paper grade A320 complying with BS ISO 6344-1 before the
next coat is applied. Prior to further application the abraded surface shall be degreased (Def Stan 03-2 Method A2).
Alternatively the primer coating may be refreshed before overcoating (see Part 1, 10.1 NOTE 2)
NOTE 5 Other colours and gloss levels may be specified by drawing, contract or order.
NOTE 6 This may consist of two coats or one high build coat at 55 ± 5 µm.
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DEF STAN 03-32 Part 4 Issue 4
Table 3 — Paint System 4.6B - Internal Epoxide (Two-Pack) (Phosphated Surfaces), VOC
Compliant
Coating Air Drying Colour Air Drying Air Drying Dry Film
Specifications BS 381C System System Thickness
(Note 1) Colour No. Minimum Maximum (µm)
Recoat Time Recoat Time (Note 2)
(hours) (hours)
NOTE 2 The minimum total dry film thickness of the paint system shall be not less than 90 µm.
NOTE 3 If in exceptional circumstances the paint film has been allowed to dry for more than the specified maximum
recoat time, the surface shall be lightly rubbed down with abrasive paper grade A320 complying with BS ISO 6344-1 before the
next coat is applied. Prior to further application the abraded surface shall be degreased (Def Stan 03-2 Method A2).
Alternatively he primer coating may be refreshed before overcoating (see Part 1, 10.2 NOTE 2)
NOTE 4 Other colours and gloss levels may be specified by drawing, contract or order.
NOTE 5 This may consist of two coats or one high build coat at 55 ± 5 µm.
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DEF STAN 03-32 Part 4 Issue 4
Table 4 — Paint System 4.8A - External IRR Matt (Multi-Pack) Polyurethane, VOC Compliant,
Chemical Agent Resistant (Non-Ferrous Surfaces e.g. Zinc Plate)
Coating Air Drying Colour Air Drying Air Drying Dry Film
Specifications BS 381C System System Thickness (µm)
(Note 1) Colour No. Minimum Maximum (Note 3)
Recoat Time Recoat Time
(hours) (hours)
(Note 2)
NOTE 2 To allow for additional coats of the same or different colours i.e. disruptive patterns
NOTE 3 The minimum total dry film thickness of the paint system shall be not less than 75 µm
NOTE 5 If in exceptional circumstances the paint film has been allowed to dry for more than 72 hours, the surface shall be
lightly rubbed down with abrasive paper grade A320 complying with BS ISO 6344-1 before the next coat is applied. Prior to
further application the abraded surface shall be degreased (Def Stan 03-2 Method A2). Alternatively the primer coating may be
refreshed before overcoating (see Part 1, 10.1 NOTE 2)
NOTE 6 Other colours and Infra Red Reflectance requirements may be specified by drawing, contract or order
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DEF STAN 03-32 Part 4 Issue 4
Table 5 — Paint System 4.8B - External IRR Matt (Multi-Pack) Polyurethane, VOC Compliant,
Chemical Agent Resistant (Phosphated Surfaces)
Coating Air Drying Colour Air Drying Air Drying Dry Film
Specifications BS 381C System System Thickness (µm)
(Note 1) Colour No. Minimum Maximum (Note 3)
Recoat Time Recoat Time
(hours) (hours)
(Note 2)
NOTE 2 To allow for additional coats of the same or different colours i.e. disruptive patterns
NOTE 3 The minimum total dry film thickness of the paint system shall be not less than 75 µm.
NOTE 4 If in exceptional circumstances the paint film has been allowed to dry for more than 72 hours, the surface shall be
lightly rubbed down with abrasive paper grade A320 complying with BS ISO 6344-1 before the next coat is applied. Prior to
further application the abraded surface shall be degreased (Def Stan 03-2 Method A2). Alternatively the primer coating may be
refreshed before overcoating (see Part 1, 10.1 NOTE 2)
NOTE 5 Other colours and Infra Red Reflectance requirements may be specified by drawing, contract or order.
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DEF STAN 03-32 Part 4 Issue 4
Table 6 — Paint System 4.9A - External High Gloss (Multi-Pack) Polyurethane, VOC Compliant,
Chemical Agent Resistant (Non-Ferrous Surfaces e.g. Zinc Plate)
Coating Air Drying Colour Air Drying Air Drying Dry Film
Specifications BS 381C System System Thickness
(Note 1) Colour No. Minimum Maximum (µm)
Recoat Time Recoat Time (Note 3)
(hours) (hours)
(Note 2)
NOTE 2 To allow for additional coats of the same or different colours i.e. disruptive patterns
NOTE 3 The minimum total dry film thickness of the paint system shall be not less than 75 µm.
NOTE 4 If in exceptional circumstances the paint film has been allowed to dry for more than 72 hours, the surface shall be
lightly rubbed down with abrasive paper grade A320 complying with BS ISO 6344-1 before the next coat is applied. Prior to
further application the abraded surface shall be degreased (Def Stan 03-2 Method A2). Alternatively the primer coating may be
refreshed before overcoating (see Part 1, 10.1 NOTE 2)
NOTE 5 Other colours and Infra Red Reflectance requirements may be specified by drawing, contract or order.
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DEF STAN 03-32 Part 4 Issue 4
Table 7 — Paint System 4.9B - External High Gloss (Multi-Pack) Polyurethane, VOC Compliant,
Chemical Agent Resistant (Phosphated Surfaces)
Coating Air Drying Colour Air Drying Air Drying Dry Film
Specifications BS 381C System System Thickness
(Note 1) Colour No. Minimum Maximum (µm)
Recoat Time Recoat Time (Note 3)
(hours) (hours)
(Note 2)
NOTE 2 To allow for additional coats of the same or different colours i.e. disruptive patterns
NOTE 3 The minimum total dry film thickness of the paint system shall be not less than 75 µm.
NOTE 4 If in exceptional circumstances the paint film has been allowed to dry for more than 72 hours, the surface shall be
lightly rubbed down with abrasive paper grade A320 complying with BS ISO 6344-1 before the next coat is applied. Prior to
further application the abraded surface shall be degreased (Def Stan 03-2 Method A2). Alternatively the primer coating may be
refreshed before overcoating (see Part 1, 10.1 NOTE 2)
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