Monday 25 May 2015

Polishing auto Glass



Glass Technology

[:Modern windshield or windscreens are generally made of laminated safety glass, a type of treated glass, which consists of two (typically) curved sheets of glass with a plastic layer laminated between them for safety, and are glued into the window frame.]

The term windshield is used generally throughout North America. The term windscreen is the usual term in the UK and Australia/New Zealand

Glass windshields first appeared around 1905.  The first automobile windshields were a luxury, sold as optional equipment to motorists who needed something a little more dashing than goggles. With the invention of safety glass, tempered glass (tempering is a heat treatment) to make it especially hard and resistant to shattering. This type of windshield was popular well into the middle of the century, but it was eventually replaced by windshields made of laminated glass

Automakers began using laminated safety glass, also known as auto glass, for automobile windshields in 1927. To make laminated safety glass, the manufacturer sandwiches a thin layer of flexible clear plastic film called polyvinyl butyl (PVB) between two or more pieces of glass. The plastic film holds the glass in place when the glass breaks, helping to lessen injuries from flying glass.

PPG Industries has developed Optech clear coating, it’s made up of a single component designed to provide improved resistance to marring and environmental etch.

According to PPG, the high solids formulation, developed over a six year period, allows it to bond with an adhesive to join the windshield, backlight and sidelight windows to vehicle bodies thereby eliminating the need for a urethane primer commonly used to ensure adhesion.

Optech also meets the Federal Motor Vehicle Safety Standard for windshield retention during roll-over accidents and crashes. The technology can improve scratch and etch resistance characteristics by approximately 25 to 100 percent when compared to conventional one-component clear coats that are currently used, says PPG. Optech is currently being used in two plants in North America.

Laminated glass is a multilayer unit consisting of a plastic layer surrounded by two sheets of glass. In many countries, including the U.S., auto windshields are required by law to be made of laminated glass. Laminated glass can bend slightly under impact and is less likely to shatter than normal safety glass. This quality reduces the risk of injury to the automobile's passengers.

After the glass is tempered and cleaned, it goes through a laminating process. In this process, two sheets of glass are bonded together with a layer of plastic (the plastic layer goes inside the two glass sheets). The lamination takes place in an autoclave, a special oven that uses both heat and pressure to form a single, strong unit that is resistant to tearing. The plastic interlayer is often tinted to act as an ultraviolet filter.

When laminated glass is broken, the broken pieces of glass remain bound to the internal tear-resistant plastic layer, and the broken sheet remains transparent. Thus, visibility remains good. Unlike traditional safety glass, laminated glass can be further processed—cut, drilled, and edge-worked, as necessary. A typical laminated windshield is very thin: each glass layer is approximately 0.03 inch (0.75 millimetres) thick, while the plastic interlayer is approximately 0.098 inch (2.5 millimetres) thick.

There are two main types of auto glass; tempered glass and laminated safety glass.

a)      Tempered glass, which typically is used on the rear and side windows, goes through a special process where it is heated and then quickly cooled.

b)      Laminated safety glass, which is typically used on windshields, is composed of two pieces of glass with a thin layer of vinyl. It's then heated and pressed together in an oven called an autoclave.

Both types of glass are stronger and more impact resistant than regular glass. When tempered glass receives a strong hit, it will shatter, but it will shatter and fall to the ground into small pieces that do not have sharp edges like regular glass. When laminated safety glass receives a strong impact it will also shatter but, generally, the pieces will adhere to the vinyl and not fall to the ground.

 Types of Glass Surface Corrosion

 a) Stage I Corrosion [: defined as a surface with light to moderate corrosion damage to the paint surface]

 b) Stage II Corrosion [: definition when the dirt/corrosion deposits are no longer on the surface but have started to break down the molecular structure, leaving an etched or white haze on the surface after the stain has been removed, with moderate to serious stains /  damage] (See also Glass Cleaning Process article)

Should I repair or replace my windshield?

Be aware the some imperfections cannot be removed (by doing so you will compromise the glass surface optics) and you may have to replace it. If you can catch your fingernail in the scratch 0.4 Mil (0 .004 –inch deep) you should consult a professional glass repair / replacement company.

A replacement windscreen can sometimes be claimed on an insurance policy without loss of no-claim bonus, dependent upon coverage (check first with insurance company).Some windscreen ‘glass’ is actually a plastic resin and will scratch easily, consult your dealer to find out what material was used for the OEM windshield.

There are various types of windshield glass; some newer cars have acoustic glass or rain sensors built in, so be sure you get the correct type of glass. Aftermarket glass is not required to meet the same Federal Motor Vehicle Safety Standards (FMVSS) regulations as OEM glass

OEM glass is usually stronger and this may be important when you realize that the windshield becomes the backing plate for your air bags in a crash. The glass windshield provides up to 60% of the cage strength in the event of a rollover accident. OEM glass is more expensive as it is more costly to make. Yet the windshield may save your life or your family's lives in a crash.  

See also -http://www.bestglass.com/faq.html#faq1

Rock Chips

These micro-chips are caused by road grit impacting the glass surface and leaving small holes that show up as white spots when waxing or applying a sealant. In a recent windshield damage study conducted by the Motor Industry Research Association (MIRA), it was found that; extreme temperatures and structural fatigue will cause existing windshield chips to spread quickly, requiring glass replacement.

Thermal shock occurs when a thermal gradient causes different parts of an object to expand by different amounts, this differential expansion can be understood in terms of stress or of strain, equivalently, at some point, this stress overcomes the strength of the material, causing a crack to form. 

If nothing stops this crack from propagating through the material, it will cause the object's structure to fail. This occurs if you wash a cold surface with warm / hot water or conversely a warm / hot surface with cold water Thermal shock can be prevented by reducing the thermal gradient seen by the object ( i.e. by changing its temperature more slowly)

In cold weather conditions, windshields will develop a more concave shape. As a result, windshield chips and dings are more likely to spread in a horizontal fashion. Chips were likely to spread more than 80 percent of the time at temperatures of 14.OF degrees (-10.OC). Those tested at 32.OF (0.OC) were nearly 60 percent likely to crack.
Warm weather conditions cause windshields chips to spread more vertically. The same study conducted suggested that the heat itself distorts the shape of the windshield glass, which can lead to cracking by itself. However, it was also found that the cooling effect of the air conditioning unit is likely to set off a crack.

Driving over a speed bump, pothole or other uneven terrain can cause a chip to become a fracture. The force radiates through the car and puts additional pressure on the edges of the chip, which can quickly lead to a glass fracture.

Although it is not possible to suggest how long it will take for a chip to spread, the study suggests that stressors like weather changes and simple driving will eventually cause or lengthen a windshield crack.

 What kind of damages can be repaired?

A windshield repair is a process that uses skill to repair stone damage on a windshield instead of replacing it altogether. Stone damage or stone "chips" up to the size of a quarter can usually be polished out, however, if you can catch your fingernail in the scratch 0.4 Mil (10µ) deep, you should consult a professional auto glass company

Best results are obtained when the damage is repaired right away, before contamination occurs from car washing, road grime, or inclement weather. 

 Once the glass surface has been washed and cleaned (detailers clay) any minor imperfections can be removed with an abrasive glass polish (CarPro CeriGlass, Autoglym Car Class Polish or Zaino Z-12 Clear-View Glass Polish) These products remove "light" scratches, acid water spots, bird and bug stains, including alkaline mineral deposits, and then smoothes out etched glass (See article “Polishing Glass”) 

Should I repair or replace my windshield?

Be aware the some imperfections cannot be removed (by doing so you will compromise the glass surface optics) and you may have to replace it. If you can catch your fingernail in the scratch you should consult a professional glass repair / replacement company.

A replacement windscreen can sometimes be claimed on an insurance policy without loss of no-claim bonus, dependent upon coverage (check first with insurance company).Some windscreen ‘glass’ is actually a plastic resin and will scratch easily, consult your dealer to find out what material was used for the OEM windshield.

There are various types of windshield glass; some newer cars have acoustic glass or rain sensors built in, so be sure you get the correct type of glass. Aftermarket glass is not required to meet the same Federal Motor Vehicle Safety Standards (FMVSS) regulations as OEM glass

OEM glass is usually stronger and this may be important when you realize that the windshield becomes the backing plate for your air bags in a crash. The glass windshield provides up to 60% of the cage strength in the event of a rollover accident. OEM glass is more expensive as it is more costly to make. Yet the windshield may save your life or your family's lives in a crash.  

See also -http://www.bestglass.com/faq.html#faq1

Glass Polishing Pad

Groit’s Garage synthetic 6-inch glass polishing pads for use with a random orbital polisher Use these pads along with a glass polish to remove etched water marks and other tenacious surface residue. Once thoroughly cleaned they can be re- used

Alternative - Lake County - GPS PRO Glass Polishing System

Glass Polishing

Cerium Oxide (CeO2) Polishing Powder [: includes a variety grades and of purities from 96% to 99.99% and particle sizes from nanoscale to submicron (- 325 mesh). It is generally considered to be the most efficient glass polishing agent for precision optical polishing]

Common sense dictates that if you want to remove a scratch, then you must remove some of the material (paint, glass, etc.) to get down to the bottom of the scratch.

Glass is very hard and the polishing process for the correction of scratches requires pressure, which combined with kinetic energy produces heat, if the glass surface becomes too hot the surface can warp leading to distortion. When polishing glass use capacious amounts of water and periodically check the surface temperature

Use caution when polishing glass, especially with polishes that contain abrasives like cerium oxide (belonging to the group of elements known as rare earth) use optical grade only on auto glass and observe all necessary safety precautions (see also personal protection equipment (PPE) with regard to the dust produced.

They also have the potential to damage glass by removing layers; compromising its optical clarity, strength and rigidity, necessitating replacement An airbag relies on the glass windshield as it ‘backing plate’ (i.e. it supports the inflated bag and gives it the necessary rigidity, as it is unable to arrest forward motion without some kind of strong support) so don’t do anything that would compromise it.

Once the glass surface has been washed and cleaned (detailers clay) any minor imperfections can be removed with an abrasive glass polish (CarPro CeriGlass, Autoglym Car Class Polish or Zaino Z-12 Clear-View Glass Polish) Removes "light" scratches, acid water spots, bird and bug stains, including alkaline mineral deposits, and then smoothes out etched glass

Methodology
         Clean glass to remove dirt, dust or road grime from surfaces  
         Use masking tape to protect windscreen rubber sealing
         Apply clay (Magic Clay®) and lubricant solution (Woolite™ / Water 5:1) onto the glass surface (
         CarPro CeriGlass is a special glass polishing technique developed by the innovative special ceramic, Cerium Oxide, together with some other nano components that can be used by hand or machine and is so effective, it even removes fine to medium scratches and it leaves glass crystal clean and crystal clear.
         Apply a quarter (coin) size amounts of the glass polish using an LC Glass polishing pad, is made of dense polyurethane foam with very small cells.

The pad’s density enables it to keep the glass polish on the surface, rather than soaking into the foam. You’ll use less polish to get the job done, despite its density; the pad still has plenty of flexibility to conform to the curvature of the glass, speed #4 on a PC random orbital polisher

         Heat caused by abrasive polishing can soften and damage glass; foam pad and product used must minimize heat build-up. Since glass is a poor heat conductor any friction heat built up from polishing must be kept to a minimum by using sufficient product and regular misting of both the polishing pad and glass surface with distilled water.

         Apply to half of the windshield, polishing first in an up and down motion then in a left-to-right motion and then repeat on the other side, proceed to other glass surfaces.

         Go over the glass several times in each direction, glass will polish virtually residue free.
         Wipe off any residue, and polish with a clean dry 100% cotton Micro fibre cloth.
         Inspect glass for clarity and smoothness. Repeat if necessary.
       
  If the glass has PPG Industries Optech clear coating a more aggressive polish may be required

For heavy surface imperfections - apply a quarter (coin) size amounts of CarPro CeriGlass to a CarPro 5-inch Glass Rayon Polishing Pad. The pad’s density enables it to keep the glass polish on the surface, rather than being absorbed by the pad. You’ll use less polish to get the job done, despite its density; the pad still has plenty of flexibility to conform to the curvature of the glass. 

Using a rotary polisher (you could also use an orbital polisher, but a rotary is preferable). Use a spray bottle of distilled water and keep the glass very wet, this will also help to cool the surface.

• Heat caused by abrasive polishing can soften and damage glass; foam pad and product used must minimize heat build-up. Since glass is a poor heat conductor any friction heat built up from polishing must be kept to a minimum by using sufficient product and regular misting of both the polishing pad and glass surface with distilled water to keep the glass very wet.
• Apply to half of the windshield, polishing first in an up and down motion then in a left-to-right motion and then repeat on the other side, proceed to other glass surfaces.
• Go over the glass several times in each direction, glass will polish virtually residue free.
• Wipe off any residue, and polish with a clean dry 100% cotton Micro fibre cloth.

• Inspect glass for clarity and smoothness. Repeat if necessary. 

If you can catch your fingernail in the scratch 0.4 Mil (10µ) deep, you should consult a professional glass repair / replacement company.
Alternative products / methods:
a)     Apply Zaino Z-12 with a damp cotton cloth to cool glass, apply to small sections at a time and allow to completely dry, buffing with a clean dry cotton towel. If there is any smearing or residue left just use Stoner’s Invisible Glass or any good quality glass cleaner to remove excess residue.

b)    Glass Technology Inc - http://www.gtglass.com/scratchremoval.htm 

Alternative pads- these 4-inch ‘Metal Polishing Pads’ are made from 600 grit nylon (Scotchbrite®) and are designed for hard / rough surfaces like aluminium diamond plate, pitted aluminium, chrome, and glass. TOL

Cerium Oxide (CeO2)
Is considered one of the most efficient agents for precision polishing of optical components is primarily used as a glass polishing powder and it has been used for the past six decades, and has been proven to be an effective polishing agent. 

During the process of polishing glasses, cerium Oxide reacts with the glass surface to produce a cerium-oxygen-silicon compound which is softer than glass, and is therefore easier to work with to produce the final polished surface. If your nail doesn’t catch, this abrasive should remove the pitting etc. Mix the powder 1:1 with distilled water to produce polishing slurry and periodically check surface heat

MSDS - http://www.keelingwalker.co.uk/downloads/saftey%20data%20sheets/MSDS-009%20Cerium%20Oxide.pdf

Glass Scratch / Rock Chip Removers

This glass polishing kit comprises one 2-inch diameter felt bob mounted on a ¼-inch shaft, with a tub of abrasive optical grade Cerium powder. This will remove glass scratches that you can’t feel with your fingernail (approximately 0.004") To remove scratches that you cannot feel with your fingernail, mark them on the inside of the glass with a crayon or a piece of tape. (Deeper scratches may not be possible to completely remove.)

Tape off glass surrounds with 3M Green Tape masking tape, as it’s water-resistant whereas the 3M Blue is not. Mix up a small quantity of the abrasive powder with some water to make wet slurry, and dip the flat end of the felt bob in it and use the fastest electric drill speed available, work the slurry up and down across the scratch until it is removed, keep the surface wet - do not allow the slurry to dry out, otherwise the glass will get hot - http://www.caswellplating.com/buffs/glass.htm 

Note -  Do not use an abrasive polish on Targa ‘glass’ tops as they are actually a plastic (Lexan) and an abrasive will remove the tint Suggested product- Plexus (BTI Chemicals Plexus® 

Glass Polish & Cleaner)

Glass Polishing Kit for Deep Scratches most glass polishers contain Cerium Oxide an optical polishing compound (belonging to the group of elements known as rare earth) all necessary precautions should be used with regard to the dust produced. Removes deep scratches from automotive glass and save the replacement costs, this abrasive system literally grinds away imperfections until scratches disappear, works best with a Rotary set at 1500-2000 RPM.

The Lake Country Glass Restoration Kit #2 is for heavy duty glass polishing. This kit will polish and restore automotive glass and other glass surfaces. This machine powered system restores clarity by removing wiper tracks, light scratches, water spots and other minor defects. Designed for use on automotive windshields and Automotive Glass; most other glass surfaces. For use with rotary buffers or dual-action polishers, the kit contains enough materials to polish and seal approximately 7,200 square inches.

Warning- these systems remove glass, maintain a wet surface and keep pad moving to avoid heat build-up and optical distortion

Cerium oxide

[: Cerium oxide, ceric oxide, ceria, or sometimes simply cerium oxide CeO2 or cerium dioxide, is a pale yellow-white powder. It is used in ceramics, to polish glass, and to sensitize photosensitive glass. It is also used in lapidary as jeweller’s rouge; it is also known as optician's rouge]

Modern automotive windshields hardness is 6/10 on the Mohr’s harness scale and contains a thin plastic sheet between two layers of glass (interior and exterior). Glass is very hard and the polishing process for the correction of scratches requires pressure, which combined with kinetic energy produces heat, if the glass surface becomes too hot the plastic sheeting can warp leading to distortion. 

When polishing glass use capacious amounts of water and periodically check the surface temperature
Use caution with polishes that contain abrasives like cerium oxide (belonging to the group of elements known as rare earth) use optical grade only on auto glass and observe all necessary safety precautions (see also personal protection equipment (PPE) with regard to the dust produced. They also have the potential to damage glass by removing layers; compromising its strength and rigidity, necessitating replacement An airbag relies on the glass windshield as it ‘backing plate’ (i.e. it supports the inflated bag and gives it the necessary rigidity, as it is unable to arrest forward motion without some kind of strong support) so don’t do anything that would compromise it. Caswell Inc. Glass Polishing Kit (with optical grade cerium oxide)

Glass Polishing System (Lake County GPS Kit)

Polish and restore automotive glass and other glass surfaces, machine powered system restores clarity by removing wiper tracks, light scratches and other minor defects
         3 7/8 – inch Backing Plate (5/8” x 11 Thread)
         DA Adapter
         4 oz. Glass Polish
         3.5 oz. Glass Sealant
         Sealant Applicator
         2 - Abraded Levelling Discs

Lake County Mfg. - http://www.lakecountrymfg.com

Warning- these systems remove glass, maintain a wet surface and keep pad moving to avoid heat build-up and optical distortion

Notes - 
1.      Do not use on Lexan™, Plexiglas or clear plastics (See Polishing Plastic)
2.      Don't use abrasive glass polish on aftermarket-tinted glass or you will probably scratch the surface
3.      For deeply etched water spots' or pits (caused by sand or road stones) in the glass surface, do not attempt to polish them out, consult an automotive glass vendor as glass used on later model cars is soft and thin (this may vary by manufacturer) due to weight / cost savings by vehicle manufactures and polishing could cause glass to crack.
4.      Do not use on glass with either internal antenna or defroster elements.
5.      Some windshields and mirrors have a tinted plastic coating or a blue tint that will scratch or be damaged, only polish or use synthetic wool on uncoated glass.

Material data sheets (MSDS)
Be aware of dangerous ingredients and request Materials Safety and Data Sheets (MSDS) from the manufacturer if there is any question. An (MSDS) is required under the OSHA Hazard Communication Standard. The MSDS is a detailed informational document prepared by the manufacturer or importer of a hazardous chemical.  It describes the physical and chemical properties of the product. MSDS’s contain useful information such as flash point, toxicity, procedures for spills and leaks, and storage guidelines.

Information included in a Material Safety Data Sheet aids in the selection of safe products, helps you understand the potential health and physical hazards of a chemical and describes how to respond effectively to exposure situations. Although there is an effort currently underway to standardize MSDS’s the quality of individual MSDS’s vary. A MSDS may be useful but it cannot substitute for prudent practices and comprehensive risk management.

An MSDS should be available for every chemical you use. Read these and follow the recommendations for safe use and disposal of the material. The target audience for information in a MSDS is the occupation worker who may be exposed to chemicals at work. However, much of the information is also relevant to consumers.

Read the manufacturers application instructions and then obtain and read the MSDS sheet to ascertain the chemicals used. Although it should be said that an MSDS is a document that contains details of the hazards associated with a particular chemical and provides information regarding its safe use. The MSDS is required to state the chemical's risks, safety and impact on the environment.

An MSDS is a fact sheet developed by manufacturers describing the chemical properties of a product. Material Safety Data Sheets include brand-specific information such as physical data (solid, liquid, colour, melting point, flash point, etc.), health effects, first aid, reactivity, storage, handling, disposal, personal protection and spill/leak procedures.

Personal Protective Equipment (PPE)

PPE is specialized clothing or equipment worn by an employee for protection against a hazard. General work clothes (e.g., uniforms, pants, shirts or blouses) not intended to function as protection against a hazard is not considered to be personal protective equipment.

 For your safety and the legally required protection of employees, you will need to have personal protective equipment available that will include a respirator fitting for you and your employees. At no time should you endanger yourself or others, take any unnecessary risks or infringe any laws. OSHA standards require that employers maintain or improve workplace conditions to protect employees.

Protection from Potential Health Hazards

1.      Warning: Always use a ground circuit fault indicator) (GFPI) when using any electrical device around water
2.      Eye Protection: I would strongly advise the wearing of safety glasses or visor when operating any machine polisher.
3.      Hearing Protection; the constant pitch of a polishing machine could affect your hearing so wearing ear plugs would be wise to protect you from hearing loss.
4.      Hand Protection; Gloves- with the verity of chemicals a detailer uses on a daily basis wearing chemical-resistant gloves resist penetration and permeation, and will provide protection against dermatitis and chemical burns. Gloves can provide protection, but they must be chosen with care, the proper selection matched to the hazard is critical. Chemical-resistant gloves resist penetration and permeation, and cam protect against dermatitis, chemical burns and corrosion.
5.      Respiratory Protection (N95): Materials such as aluminium oxide (Aluminium oxide is on EPA's TRI list if it is a fibrous form) or silicon carbide (Nuisance particulate-Accumulation in lungs) used in polishes and compounds, and powdered fillers
6.      Crystalline silica (polishes and compounds) poses a serious inhalation hazard because it can cause silicosis and Isocyanate clear coat residue represent a hazard to your lungs and may cause respiratory distress. Use  a NIOSH-approved half face respirator equipped with a combination filter cartridge should be worn while using them
7.      Consult the current 3M Respiratory Selection Guide for additional information or call 1-800-243-4630 for 3M technical assistance.
8.      Material Safety Data Sheets:  Use a ring binder or other filing system to ensure the appropriate MSDS is always available to identify hazardous substances
9.      Work Hygienic Practices: Rinse cloves under running water before removing them
10.    Protect yourself, work safe. As in all things, allow common sense to prevail and proceed with due caution

Health and Safety Executive (HSE) Control of substances hazardous to health (COSHH) is the UK law that requires employers to control substances that are hazardous to health - http://www.hse.gov.uk/coshh/basics.htm

GFCI and Extension Cord

Ground circuit fault indicator (GFCI) and Extension cord selection is based on two main principles. First, the cable should be able to carry the current load imposed on it without overheating. It should be able to do this in the most extreme conditions of temperature it will encounter during its working life.
Second, it should offer sufficiently sound earthing to (a) limit the voltage to which people are exposed to a safe level and (b) allow the fault current to trip the fuse or MCB in a short time. To meet these requirements requires consideration of the circuit load current (AMPS) a reasonable voltage drop, cable thickness (G) and length (feet) and the over-current protection device

Prime Wire & Cable Duplex GFCI -residual current device is also known as a ground fault circuit interrupter (GFCI) junction Box with 6-Ft. cord, Model# GF200806 Portable GFCI duplex receptacle detects power leaks and shuts off electricity in less than a second to prevent shock. Test and reset buttons Tough jobsite box with 6-ft. 12/3 SJTW power cord UL listed, meets OSHA standards.

Prime Wire & Cable 50-Ft extension 12/3 Neon Power Cord — Blue, Model# NS514830 Bright NEON extension cord stands out for easy identification. 12 Gauge, SJTW, 3 prong cord features super-flexible vinyl jacket with a cold temperature rating of -31°F. LIGHTED connector indicates when power is on. Cord is water and flame resistant and rated at 15 amps, 125V, 1875 watts, UL listed and meets OSHA standards – Northern Tool

I would like to think that these articles become an asset to anyone who is new to detailing and to professionals alike, as well as industry experts who seek to advance their knowledge.

I hope the above article was informative. By having some understanding of the ‘What’ and ‘Why’ as well as the ‘How’ along with a little science to help you understand how the chemicals we use react, you can achieve the results you desire.

I would appreciate it if you would share this article as it helps other detailers further their knowledge.
Questions and/ or constructive comments are always appreciated.


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