Bodyshop April 2012

April 2012 www.bodyshopbiz.com

Bodyshop CANADA’S MAGAZINE FOR COLLISION REPAIR PROFESSIONALS SINCE 1970

Plus: I-CAR Training for Hybrid and Electric Cars Paint Booth Technology Welding New Metals

The Future is

Bright Green Tips for going green on the shop floor

CANADA POST CANADIAN PUBLICATIONS MAIL AGREEMENT #40069240

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Visit www.bodyshopbiz.com

04/04/12 8:58 AM

Meet Navigator™, the industry’s newest color matching tool. It’s the culmination of putting ourselves in your shoes and asking, “How can my job be made easier and more accurate?” What we came up with is a new generation of tool that is setting the standard for confidently selecting and matching color in any situation.

Features more than 5100 popular domestic and import colors.

Sprayed in actual Pro-Spray paint and arranged in chromatic order.

Matched in Pro-Spray H2O Waterborne and Solventborne colors.

Combine the Navigator™ with over 282,000 formulas in the included Pro-Spray PaintXpert™ software and you’ve got a powerful set of tools to work with.

Navigator™ by

For more information: NavigatorColor.com

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AUTOMOTIVE

FINISHES

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Bodyshop CANADA’S MAGAZINE FOR COLLISION REPAIR PROFESSIONALS SINCE 1970

contents

April 2012 l Volume 42, Issue 2

Features 15

Electric Avenue

30

Higher Tech, Lower Costs

32

New Metal

Are you ready for hybrid and electric vehicle repairs?

New developments in paint booth technologies

Welding techniques for new alloys and aluminum

15

27

Cover Story

18

Eco Shop Talk

32

Going green on the shop floor with structural changes, solvent recycling and more.

In Every Issue 4

Viewpoint

37

Advertisers Index

6

News

37

Internet Directory

34

Products

38

From the Publisher

visit us at bodyshopbiz.com In the next issue: We salute our annual Bodyshop of the Year, plus innovations in paint technology and techniques, health and safety, prep stations and supplies, and specialty hand tools. www.bodyshopbiz.com l April 2012 l Bodyshop 3

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Bodyshop CANADA’S MAGAZINE FOR COLLISION REPAIR PROFESSIONALS SINCE 1970

viewpoint

PUBLISHER Andrew Ross 416-510-6763 aross@bodyshopbiz.com

Eco Opportunities

MANAGING EDITOR Noelle Stapinsky 416-510-6839 nstapinsky@bodyshopbiz.com

C

limate change is a hot issue (pun intended). Today’s consumers are well educated on environmental issues, and the eco-friendly alternatives that are available. And with government and regional regulations putting the squeeze on businesses big and small, many are taking a proactive approach and discovering that being eco-friendly attracts business, but there’s a cost savings as well.

This winter season, the bodyshop industry certainly felt the affects of unseasonable temperatures.

Indeed, the lack of nasty cold weather does make the roads safer. And although it’s great for driver safety, it can mean fewer crumpled cars rolling into repair shops.

This winter in Ontario, for example, the Toronto Star reported that vehicle collisions were down 23 per cent in the Greater Toronto Area.

But when talking to shops across the country, I’ve discovered that it’s not solely the lack of winter weather that slows business down.

In Newfoundland, where winter reared its ugly head as usual, one shop manager said business has been up and down. And regardless of the season, some months are just plain slower than others.

In our current economy, many people are pinching their pennies. They may have been in an accident, but opt for driving around with a damaged bumper rather than having it fixed.

The good news is that apart from pulling in a constant stream of business, there are strategies that shops can implement to save money and increase their presence in the community, while capitalizing on the demand for “greener” alternatives.

Since the waterborne paint conversion, many shops have been looking at more environmentally friendly options. And in this industry, some of the smallest changes can save a lot of money.

Replacing old compressors, recycling solvents and waterborne waste inhouse, or even installing more energy-efficient light bulbs throughout the facility, can make a huge improvement in annual operation costs, just to name a few.

Some shops have turned to lean practices—streamlining shop floor activity for increased productivity. And some have even gone as far as to install solar panels on the roof of the shop.

Even something as simple as switching to a paperless system saves money.

For many shops, these conversions make sense, but what they might not realize is that using these “green” initiatives in their marketing can actually attract more customers.

This issue covers everything from repairing hybrids and electric vehicles to sustainable facility structural enhancements and new paint booth technology that will increase your bottom line.

With new advancements in technology, becoming a sustainable, more energyefficient company has never been easier.

B Noelle Stapinsky nstapinsky@bodyshopbiz.com

CONTRIBUTORS Martha Uniacke Breen Nate Hendley SALES MANAGER Jay Armstrong 416-510-6745 jarmstrong@bodyshopbiz.com PRODUCTION MANAGER Steven Hofmann 416-510-6757 shofmann@bizinfogroup.ca ART DIRECTOR Choo Hwee Kuan PRINT MANAGER Phyllis Wright CIRCULATION MANAGER Selina Rahaman 416-442-5600 ext.3528 CUSTOMER SERVICE Roshni Thava 416-442-5600 ext 3555 VICE-PRESIDENT Alex Papanou PRESIDENT Bruce Creighton

BODYSHOP is published by BIG Magazines LP, a div. of Glacier BIG Holdings Company Ltd. 80 Valleybrook Drive, Toronto, ON M3B 2S9 Phone 416-442-5600 Fax 416-510-5140 Subscription rates: Canada – $39.95 (add applicable taxes) per year, $62.95 (add applicable taxes) for 2 years, single copy $7.00. USA and all other foreign – US$61.95 per year. U.S. single copy US$10.00.

All rights reserved. Printed in Canada. The contents of this publication may not be reproduced or transmitted in any form, either in part or full, including photocopying and recording, without the written consent of the copyright owner. Nor may any part of this publication be stored in a retrieval system of any nature without prior written consent.

US Office of Publication: 2424 Niagara Falls Blvd, Niagara Falls, NY 14304-1118. Periodicals postage paid at Niagara Falls, NY. US Postmaster: send address changes to Bodyshop PO Box 1118, Niagara Falls, NY 14304-1118.

From time to time we make our subscription list available to select companies and organizations whose product or service may interest you. If you do not wish your contact information to be made available, please contact us via one of the following methods: Tel: 1-800-268-7742 Fax: 416-442-2191 E-Mail: privacyofficer@bizinfogroup.ca Mail to: Privacy Officer, Business Information Group, 80 Valleybrook Drive, Toronto, ON M3B 2S9 ISSN 0045-2319 Online 1923-354X Canada Post Canadian Publications Mail Sales Product Agreement No. 40069240 Return postage guaranteed. Send change of address notices, undeliverable copies and subscription orders to: Circulation Dept. — Bodyshop Magazine, 80 Valleybrook Drive, Toronto, ON M3B 2S9 We acknowledge the financial support of the Government of Canada through the Canada Periodical Fund (CPF) for our publishing activities.

Member of Member of Inc. Inc.

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Association of Association of Business Publishers Business 205 East 42ndPublishers Street East 42nd Street New205 York, NY 10017 New York, NY 10017

04/04/12 9:04 AM

Stay ahead of the curve in a changing world.

Changes have driven the automotive finishing business in new directions.

With DuPont™ Cromax® Pro waterborne basecoat, you can speed up your operations and increase productivity, without compromising the quality of work you demand. It’s part of an integrated DuPont Refinish system designed to keep you ahead.

Make sure your business stays ahead of the curve.

Talk to your local DuPont Representative or call 1.800.668.6945.

Products change. High standards don’t.

The DuPont Refinish Logo, DuPont™ and all products denoted with ™ or ® are trademarks or registered trademarks of E. I. du Pont de Nemours and Company or its affiliates.

DuPont Canada is a licensee. © Copyright 2012 DuPont Canada. All rights reserved.

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news

A.B. Warehouse Hosts AkzoNobel’s 2012 “Evening with Wanda”

T

he red carpet was rolled out for AkzoNobel’s Wanda car refinish brand, when A.B. Warehouse of Montreal hosted the 2012 “Evening with Wanda” event earlier this year.

The event also marked the first anniversary of A.B. Warehouse’s becoming the first Canadian warehouse distributor to carry Wanda Waterbase, the brand’s VOCcompliant refinish system.

“The timing of our partnership with A.B. Warehouse in 2011 was pivotal, following Canada’s recent market shift to low-VOC compliance. A.B. Warehouse’s strong reputation and impressive distribution network will continue to help propel the growth of the new system throughout the provinces,” said Mark Rapson, AkzoNobel’s business manager

of trade brands, North America, at the event.

More than 30 area distributors and jobbers attended the event and were treated to refreshments and a special anniversary cake featuring the “Wanda” illustrated character.

In addition, the brand’s Wanda spokeswoman emceed the evening’s festivities, which included a lively, interactive game to help educate guests about the many benefits of using Wanda Waterbase, and how it helps eliminate the complexities associated with other compliant systems.

Guests were then invited back the next day to attend a complimentary application demonstration of the Wanda Waterbase system at the A.B. Warehouse training facility.

Mitchell Releases Latest Edition of Industry Trends Report M itchell, a leading provider of technology, connectivity, and information solutions to the property and casualty claims and collision repair industries, recently announced the launch of its new all-digital Industry Trends Report (ITR).

The ITR is Mitchell’s well-respected quarterly publication that, for over a decade, has highlighted ongoing and emerging industry trends and key performance indicators for the automotive physical damage collision and casualty industries. The first-quarter 2012 ITR delivers invaluable insights and perspective to the industry via several editions focused on data-driven, technologyenabled innovations impacting the insurance claims handling marketplace.

The Auto Physical Damage edition of the ITR features the article “A Look at What Is Influencing Alternate Parts Usage,” written by Mitchell’s vice-president of industry relations, Greg Horn. In this article, Horn analyzes an issue key to the

collision repair industry because of its impact on automotive claim severity: What does the future hold for alternate (aftermarket and recycled) and original equipment manufacturer (OEM) vehicle parts sales?

“To determine the possible future direction of parts sales, we analyzed a number of factors influencing parts use, such as new vehicle sales and sales performance for each of the part types by vehicle model year. Parts use has increased in the aggregate due in large part to the aging U.S. car fleet. Looking to the future, the decrease in new vehicle sales since 2008 will definitely impact both parts demand and supply, but which will be greater, and which parts supply channel mechanism will benefit most, the aftermarket or the OEM?” said Horn.

The inaugural 2012 ITR Casualty Edition feature article is “Claims Fraud— Addressing Six Key Challenges to Empower Accelerated Claims Success,”

by Mike Mahoney, a senior director of product marketing with Mitchell. In this article, Mahoney offers a compelling analysis of the fraud challenges facing claims organizations, and outlines a best-practices approach to combating fraud effectively via the appropriate combination of people, process, and technological change.

“To address claims fraud, organizations must examine their traditional methods of fraud detection and claims handling and embrace sophisticated data analytic capabilities,” said Mahoney.

“Integrating advanced technologies into standard claims handling processes in real time across the life of the claim will empower insurers to proactively detect fraud while accelerating prompt, effective, and accurate claims handling.”

Complete content is available in the latest Industry Trends Report, which may be downloaded by visiting www.mitchell. com.

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Vehicle owner, Ron Bovis, was a 2012 winner.

DuPont Calendar Competition V

ehicles painted with DuPont Refinish or DuPont Cromax Pro products can be entered in the 2013 DuPont Refinish calendar competition for a chance to win cash prizes and have the vehicle appear in the calendar.

Any passenger cars (import or domestic), trucks, or motorcycles that are finished exclusively with DuPont Refinish or DuPont Cromax Pro products qualify for entry.

The entrants must own or have finished the vehicle, and be 18 years of age and a legal resident of Canada or the U.S. to enter.

The judging will be based on “best use

of colour,” including finish quality, technical difficulty, and design originality.

Twelve winners will be selected, each receiving a cash prize of $500. There will be one Grand Prize Winner, selected from the 12 winners, who will receive an additional $2,000 cash prize and be featured on the cover of the 2013 DuPont Refinish calendar. All winners will have a professional photo shoot of their vehicle and receive 35 copies of the 2013 calendar.

Winners will be notified by May 7, 2012.

There is no entry fee and entries can be submitted by visiting: www.customfinishescalendar.dupont.com.

PRI Sold to SEMA

erformance Racing Industry (PRI), the producers of the motorsports business magazine and trade show, recently finalized plans to be purchased by the Specialty Equipment Market Association (SEMA).

With more than 20 years of publishing and management experience at PRI, John Kilroy will now serve as vicepresident and general manager of the publication and show, and assume dayto-day operations for the group.

All the operations, employees, and offices will remain intact at PRI’s current location in Laguna Beach, California.

Fix Auto Canada Signs Supply Agreement with UAP

U

AP has entered into a long-term agreement with Fix Auto Canada to be the exclusive supplier of Dupont paint products—the largest global manufacturer of automotive OEM coatings— to more than 200 Fix Auto bodyshops across Canada.

Fix Auto Canada president Manon Duplantie said that this agreement represents a significant step forward for the network, as it will increase and leverage both companies’ strengths and relationships, enabling Fix Auto to offer significant value-added opportunities for further growth.

More Collision Repair Testers Needed for Vehicle Security Professional Program T

he Vehicle Security Professional (VSP) program is a data exchange system conceived and designed cooperatively by automakers and the independent auto repair community in cooperation with the insurance and law-enforcement communities. It allows the aftermarket to access securitysensitive information related to automobiles (i.e., key codes, immobilizer reset information, and similar types of information). The VSP program allows access to security-related information while protecting the safety and security of consumers and the integrity of automobile security systems.

At this time, the VSP program in Canada is being tested and collision repair facilities are invited to apply to be-

come a test shop during this phase. Test shops will not need to pay an application fee at this time, and the costs for criminal record background checks are also covered.

Applications from testers will need to meet the same qualifications as a regular applicant.

Last year in the United States, the program received some 230,000 inquiries (an average of 630 inquiries a day).

Canada did not have the program available at that time, so no Canadian inquiries could be received or acted on.

Collision repair facilities that are interested in becoming test shops can contact the Vehicle Security Professional administrator at johnnorris@ciia.com.

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The Road To Gold I

-CAR, the Inter-Industry Conference on Auto Collision Repair, has announced it is collaborating with the Assured Performance Network in the development of the Road to Gold program, a new dedicated planned approach to achieving the I-CAR Gold Class Professionals designation for its network of 3000+ collision repair shops.

Organizations that enroll in the Road to Gold program commit to earning the I-CAR Gold Class Professionals business designation, which is a requirement for earning the Assured Performance Certification. The Gold Class designation is the highest training recognition available to businesses in the collision repair industry.

Other businesses that have been recognized as Gold Class have reported less rework, retained customer satisfaction, and improved overall operational efficiencies.

“For our Assured Performance Certification, the I-CAR Gold Class Professionals designation is essential to ensuring the shop has training that is in accordance with industry repair standards,” said Scott Biggs, CEO of Assured Performance.

“With this new Road to Gold program, our members can enroll with a clear objective—Gold Class status—and get a plan to achieve and maintain it.”

Jeff Peevy, I-CAR senior director of field operations and segment development, said, “I-CAR commends Assured Performance Network for its commitment to training. The inherit value delivered through the I-CAR Professional Development Program and the Gold Class designation will provide Assured Performance Network member shops with the training needed to perform safe repairs and retain vehicle integrity post-repair.”

From the Grill to the Bumper

A

University of Toronto student recently won a national automotive competition by developing a new biodegradable material made from shrimp and crab shells that can be used to replace petroleum-based plastics used in auto parts.

Aaron Guan, a master of sciences student, won the AUTO21 TestDRIVE competition, receiving a $10,000 scholarship for his work on recyclable, lightweight polymeric nanocomposites.

Basically what this means is that by using fibres from shrimp and crab shells, Guan created a new material that can be used in automotive components, while still meeting strict environmental standards and without compromising vehicle safety.

This new material has a much higher strength-to-weight ratio compared to conventional plastics used in most automotive components today, and provides a higher mechanical strength without aesthetic flaws or deformation at lower densities.

The AUTO21 TestDRIVE competition showcases leading-edge technologies and automotive knowledge development by Canadian university graduate students.

Since its inception in 2001, AUTO21 has supported more than 1,600 graduate student researchers with federal and private-sector funding.

Supreme Appointment

S

upreme Collision Centres (SCC) recently announced the appointment of Pat Ryan as vice-president of procurement and process. Before joining the Supreme team, Ryan owned and operated Canadian Collision Data Services, a business that supplied data management services to the collision repair industry in Ontario.

Ryan also brings with him extensive collision repair industry experience. In the ’90s he worked at Allard’s Collision Centres in Ottawa, followed by a position as an Eastern Ontario sales and training representative for MPX Data Systems.

Ryan also held the role of corporate store support for CARSTAR Canada, co-owned and was an operations manager for Fix Auto Ontario, and spent more than three years as a claims procurement manager at Aviva Canada.

“Pat shares Supreme’s principles of integrity and vision, realizing our goal to be the leading process-centric network in Ontario,” said Marty Reddick, president of SCC. In his new role at Supreme, Ryan will be responsible for all supply chain and procurement functions, and will lead the process implementation team.

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WFP/Michelle Marrion

georgeS_glacier_full_Layout 1 29/03/2012 10:29 Page 1

Join me in the fight against hunger!

"Access to food isn't a privilege. It's not about politics or partisanship.

It's about people in need and our responsibility as humans to be there for one another."

Canadian Ambassador Against Hunger, George Stroumboulopoulos is working with WFP to engage all Canadians in the fight against hunger.

The World Food Programme is the world's largest humanitarian agency fighting hunger worldwide. Each year, on average, WFP feeds more than 90 million people in more than 70 countries.

Text WFP CANADA to 45678 to donate $5

Fighting Hunger Worldwide

AD p10.indd 10

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Lordco’s 22nd Annual Tradeshow

SAVE TIME, SAVE MONEY!

Thousands of jobbers, collision repair professionals, and mechanical technicians took over Vancouver’s Pacific Coliseum this month in search of the newest technology, great show deals, and, of course, the free libations and food.

Here are a few snap shots from the show floor.

THE MOST ADVANCED AUTOBODY PART ORDERING SYSTEM

FBS Distribution Co. displayed this custom motorcycle

by Tony’s Garage. This ride will also be showcased at SEMA this fall.

SATA’s Rick Boychuk shows off the company’s designer paint gun series.

• Order parts FRESE from your PS! L HO L A R preferred FO NOW! TRY IT suppliers • Add new suppliers easily • Data owned and controlled by you • Secure transactions

EVERCOAT’S new Quantum 1 body filler features fast and ultra fast mixtures that dispense the right mix of hardener in an all in one application.

Order parts with a few clicks of your mouse from any computer 24/7

Jay Farquharson, national sales manager for Uni-ram discusses solvent recycler technology.

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New Student Bursary for the Automotive Trades

of Motive Power Educators) college or a have a healthy and vibrant auto repair CARS-approved institute. The Ontario industry, and we couldn’t think of better Automotive Recyclers Association (OARA) partners than the AARO group. They he Automotive Aftermarket Retailers funds the bursaries and OARA members continue to do great things for their members,” says Steve Fletcher, OARA of Ontario (AARO) recently an- will help with the selection process.

“It is important to auto recyclers to executive director. nounced a new program aimed at getting more students working in the automotive trades. Five $2,000 bursaries will be available for students to enter the trades or further their studies that will lead to a career in the automotive aftermarket industry.

LLDATA LLC has released an updated version of its ALLDATA Manage “AARO is investing in our youth to shop management system. ensure we have people in the trades,” The updated system provides repair shop owners and managers with tools said Diane Freeman, executive director to help efficiently operate their businesses. Key features include a more inof AARO. “Helping to fund youth to tuitive user interface, electronic parts ordering with multiple credential support, enter this great industry is something spell check, average car count reporting, and improved performance. near and dear to my heart.”

“This update will successfully compete with any shop management system Applicants must either be graduating on the market,” said David Butler, ALLDATA technical product owner. “It is high school seniors or have graduated a very stable, feature-rich product.” from high school within the past two The Manage program has been on the market since 2008. Stephanie years. They must be enrolling in a collegeBuyagawan, a Washington-based service manager that evaluated the updated level program, university, or accredited system, says that the new version is faster, more responsive and stable, and automotive technical program through easier to use. either a CAMPE (Canadian Association

T

ALLDATA Updates

A

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FBS_BodyShop_Ad_April2012.pdf

3/9/2012

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Plastic components also degrade when exposed to products like mineral spirits, paint thinners, toluene and acetone to name a few.

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Continued from page 12

Sherwin-Williams’ Spring Courses Did you know that when you are spraying a catalyzed paint product in a spray booth or prep deck, the proper personal protection equipment is an air-supplied respirator?

Air supplied respirators must be supplied with Grade “D” Breathable Air. Quality Air Breathing Systems are designed to provide Grade “D” Breathable Air from your existing compressed air system, for compliance with current CSA Standards when using an air supplied respirator.

Systems sized from one person to twelve persons at the same time. We offer complete systems, with proper filtration and carbon monoxide monitors, panel mounted, and ready to use. Available in belt mounted, wall mount, and portable versions.

T

he 2012 Sherwin-Williams Automotive Finishes training sessions are designed for Canadian collision repair industry professionals seeking advancement and increased knowledge in their respective fields.

The second quarter courses—offered from April to June—will include: • Painter certification • Colour adjustment and blending • AWX waterborne systems • ATX refinish systems According to Bob Leibel, SherwinWilliams director of sales and operations

in Canada, the new classes are directly related to the company’s fast-drying, easy-to-mix and apply AWX waterborne system. “It provides excellent colour match, quick flash times between coats, and doesn’t require a baking cycle.”

The ATX Refinish System is a new 3.5 VOC basecoat-clearcoat system developed for mid-range shops with medium production needs that are looking for a solvent-borne system.

For more details on the training schedule, visit www.sherwin-automotive. com.

LORD Offers New Abrasive Clinics

L

ORD Corporation, the maker of Fusor automotive repair adhesives, recently announced that it will be offering new Fusor repair clinics.

The LORD Fusor Training Alliance courses provide the latest adhesive and seam sealer applications procedures to the bodyshop professional.

Developed for automotive OEMs, insurance companies, and collision repair industry experts, these courses are designed to teach proper product repair procedures using lean processes

that result in repairs that match original OEM performance and appearance.

Available in Canada, the new available courses include: • Bumper Repair • Composite Repair and Bonding • Metal Bonding • Weld Bonding • Sealing and Sound Control For more information, visit www.lord. com/repairclinics.

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i-car training

Electric Avenue

Are you ready for hybrid and electric vehicle repairs?

By Andrew Shepherd, I-CAR director of collision training

H

ybrid technologies are an inevitable reality the collision repair world will soon be faced with. There are over 4.5 million hybrids now on the road worldwide, led by Toyota,

Honda, and Ford, and more than 20,000 hybrid vehicles registered in Canada. With a slew of provincial tax incentives, declining production costs, and new battery and drive technologies, hybrids are becoming more affordable, and “green� driving options are more and more attractive for consumers.

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i-car training

Continued from page 15

Of course “hybrid” is a generic term, covering hybrid electric (combined internal combustion and electric motor), ethanol and other biofuels, compressed natural gas, pure electric, and hydrogen fuel cell systems. This can lead to a bewildering array of options and challenges facing the collision repair facility, and in particular the technician with handson responsibility.

As with all repairs, safety is the first priority when dealing with hybrids. Vehicle makers use low, intermediate, and high ratings to categorize different voltage levels in the vehicle, while using differentcoloured sheathing to differentiate them— low-voltage wires are typically coloured black, intermediate-voltage wires are blue on GM vehicles and yellow on Toyota and Lexus vehicles, and high voltage is a standard bright orange. But technicians should always check labelling to be sure.

The technician should also ensure that he or she is wearing “Class 0” electrically insulating rubber gloves and appropriate eye protection when working on and around the vehicle.

A second priority is to ensure the HV system is disabled by following manufacturer

specifications. Understand the HV service disconnect system, which is located on the HV battery. This might be a slide-and-pull type (GM and Chrysler full-frame HEVs), a round handle that moves from a “lock” to an “unlock” position (2008 Ford Escape), a toggle switch (Honda HEV), etc. Some HV service disconnects may contain a fuse, which may or may not be replaceable—again, always follow manufacturer specs.

It’s also important to note that higher temperatures, such as those in the spray booth, may affect battery performance.

Since hybrid vehicle development and sales are in a relatively young stage, it is inevitable that OEs are working on a wide variety of different vehicle systems, looking for efficiency, cost reduction, and competitive advantage. Newer HV batteries have made electric A/C more common. These systems may have a combination electric/belt drive compressor, which uses specific compressor oils—the exact type of oil can have a dramatic impact on vehicle functioning and safety.

And belt-alternator starter systems, fuel and voltage cut-off systems, HV battery cooling mechanisms, and coolant storage systems can all vary substantially between Ford,

Toyota, Lexus, Nissan, Honda, etc.

If this complexity doesn’t convince you of the critical need for training, also consider vehicles using alternative fuels such as biodiesel, ethanol, propane, LNG—some are even using a urea additive to reduce NOX emissions.

Chrysler, Ford, GM, Isuzu, Mazda, and Nissan all produce vehicles with flex-fuel systems, which incorporate fuel type sensors and special fuel tanks. There is no doubt that plug-in hybrid electric vehicles (PHEV), such as the Chevy Volt, which often features lithium ion batteries, will become increasingly common as well.

You can face these emerging technologies by sending the client to another shop, or you can meet the future head on. Start by enrolling in I-CAR Canada’s course called ALT02 – Hybrid Electric and Alternative Fuel Vehicles.

For information on ALT02 and other I-CAR Canada courses, visit www.i-car.ca.

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going green

Eco Shop

Talk

With headline news constantly calling attention to climate change and environmental issues, going “green� is no longer just a buzzword. The consumer demand has never been bigger, and with regulations on recycling, emissions, and processes, many businesses are getting onboard to increase energy efficiency and decrease their environmental footprints. Making such changes certainly shines an admirable eco-friendly light on the business as a whole, but it can also attract more business, while saving the company money. And for bodyshops, which have already taken the first step by converting to waterborne paint, investing in energy saving and advanced technology, and cleaning and recycling solutions not only makes sense for the bottom line, but it can also create a happier, healthier work environment.

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going green

Form and

Function

By Noelle Stapinsky

O

ver the past decade, energy efficiency and alternative energy have become hot topics around the world.

Today, everywhere you look there are solar panels, wind turbines, and a plethora of other energy-efficient technologies being employed to harness as much natural energy that can be captured and feed it into the grid.

And in the current economy, where cost-cutting is top of mind, more and more businesses are looking for ways to benefit from more environmentally efficient technologies and strategies.

With some structural enhancements, collision repair facilities can greatly benefit from “going green,” and there are some shops in Canada that are already reaping those benefits.

Fanshawe College’s green roof and solar tracking skylights.

Eco Education At Fanshawe College’s new $25-million Motive Power Facility in London, Ont., the technology and engineering that went into the building’s structure make it a poster child for sustainability.

Starting at the top, the building has a green vegetated roof that provides a thermal mass that aids in cooling the building during warm weather, and keeping it warm in the winter.

“The plant material and soil on the roof allow for the moisture to be held there and limit heat transfer through the roof,” says Doug Calder, facility project manager for Fanshawe College. “It’s entirely engineered. The roof structure and the weight of materials are calculated in the structural

steel design, to make sure there is enough support to hold all the soil and plants.”

Incorporated in the design of the roof are skylights outfitted with solar tracking technology. Not only do the skylights allow natural light into the facility (always a big selling point), but the tracking technology follows the sun, using a GPS system, to maintain optimal light streaming into the building.

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going green

Continued from page 19

Fanshawe College’s new Motive Power Facility in London, Ont. Cambrian Ford in Sudbury, Ont. installed 24 solar panels on its roof.

The facility has normal fluorescent lighting, but motion detectors and light harvesting sensors control the lighting system. This means that if an abundance of light is coming through a skylight, the sensors will decrease the fluorescent lights around that area.

The motion detector system will turn off the lights after 15 minutes of non-movement and turn on as soon as there’s movement. When walking into the bodyshop, for example, as soon as you enter the room the entire space gracefully illuminates.

The facility has only been open for a year, but with the lighting alone the college is looking at 25 to 30 per cent in energy savings.

“The biggest issue, in regards to designing the new bodyshop facility, was the technology,” says Calder. “We wanted to make sure that we had the most current technology for all the systems—for basic processes, painting, and prep work.

The old facility housed basic service spaces, a paint booth, a storage area, and a small office.”

The new 6,250-sq.-ft. bodyshop features a clean, crisp design with several service areas, and Nova Verta downdraft prep stations and a paint booth from Mississauga, Ont.-based Paint Booth Solutions.

“The paint booth is controlled by an Allen-Bradley variable frequency drive that allows the booth to maintain a constant air flow and volume, depending on what mode the paint booth is in,” says Calder.

The shop also features a large floor trench with a grated opening that collects any wastewater or products used in the shop. Material captured in the trench system goes through extra filtering, to ensure hazardous materials are not introduced to the environment. And the entire shop is ventilated, capturing any form of fumes, vapours, or sanding particles in an exhaust system.

Independent Initiatives There are many bodyshops across Canada that are outfitting their buildings with more efficient structural elements.

Some Fix Auto locations in Ontario are blazing the envirotrail.

Fix Auto Mississauga East replaced its roof two years ago for better insulation, and added skylights to brighten up the shop and lower energy costs.

“The team has greatly appreciated getting more natural light in the building, so this has increased worker satisfaction,” says Michael Longarini, assistant manager at the Mississauga East location.

The shop has also replaced its lighting with “eco-friendly” bulbs, significantly brightening up the work space and turning formerly dark corners of the shop into usable areas. “Honestly, the office is so bright it creates a sensation similar to standing on top of a ski hill on a bright day,” says Longarini.

At the Sudbury, Ont., Cambrian Ford dealership, which houses a Fix Auto bodyshop, it had 24 solar panels installed on the roof to feed energy into the local grid.

Continued on page 22

Mobile Control The Toronto-based smart tech company, Ecobee, offers a revolutionary new mobile application that allows business owners to monitor and control the HVAC unit from virtually anywhere.

Ecobee’s Energy Management System maximizes a building’s efficiency and reduces energy consumption, delivering a significant cost savings.

From a personal computer or smart phone—yes, they have an app for that—business owners can adjust the office and shop floor temperature in real time. This comes in handy, for example, when the weather is unseasonably warm in the winter months or not so hot in the summer. The system will also allow users to program the temperature settings, in order to save energy when the business is closed and adjust it to a comfortable level before the business opens in the morning.

For more information, visit www.ecobee.com.

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g n i h t y r Eve , d e e n u yo d n u o r a t jus r. e n r o c e th

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going green

Continued from page 20

This shop has taken other eco-friendly steps as well, according to bodyshop manager Terry Hall.

Apart from switching over to waterborne paint three years ago, they’ve also invested in HVLP spray guns and have their solvent waste picked up and recycled Fix Auto Mississauga East added Skylights to brighten up the shop.

by Safety-Kleen. an app that will help them through the appropriate steps if “We changed the whole lighting system to high-efficiency they’re in an accident. bulbs and bought a new rotary screw compressor to replace the Proactive shops like this can be hard to locate in Canada, old piston compressor we had,” says Hall. “We also have valvebecause they aren’t necessarily advertising such improvements. less hoods for our painters to get fresh air.”

“All of these improvements have made the shop a happier, safer environment,” he adds.

Brand Power Collision Clinic in St. John’s, Nfld., has achieved increased South of the border, Keenan Autobody, a Pennsylvania-based efficiency by engaging in a lean work culture. The shop was multi-shop operator, includes the phrase “A Green Company” the first in the province to switch over to waterborne paint, and with its branding. since the conversion, according to general manager Sharon With about 12 shops throughout Delaware and Pennsylvania, Wells, they just kept looking for more efficient ways to improve each location features different environmentally friendly and the way they do business. efficient attributes.

“We engage all our employees in lean and green processes Keenan president and COO, Mike LeVasseur explains that on the shop floor, and we’ve switched all of our lighting to enall of the locations are mostly paperless. “There’s a location ergy-efficient bulbs,” says Wells. “And we promote a paperless in Delaware that’s solar powered, we recycle everything, we process. Customers are sent text or emails for appointments. use smart thermostats that reduce or turn off AC units during Instead of an invoice, we give out digital copies on flash drives peak hours, and we use reclaimed tire mulch for the plant with our branding on it.” areas around the outside of the shop.”

Collision Clinic customers can also check on their vehicle usWhat’s more, Keenan shops have already switched to watering a “status on demand” online option, and they can download borne paint, even though it’s not yet required by the states its locations are in.

“It will become mandatory, but I wanted to be completely done with the switch before that time comes,” says LeVasseur.

At the Delaware shop, solar panels ARSTAR has launched its nationwide Give, Green and Growth program, were installed in 2009, providing 65 per which is intended to help network locations to be social, environmental, and cent of the shop’s power when it’s open economic leaders in the Canadian collision industry. and 100 per cent when it’s closed, while With this sustaianability plan, stores can achieve key performance indicators selling power back to the grid.

(KPI) through CARSTAR’s tiered performance program in order to offer the “When we decided to install the Give, Green and Growth Guarantee within their markets. solar panels, the state paid half of the The three sections of the program include: project cost and the federal governGive (Social) – Network locations and Corporate strive to be active leaders ment currently pays 30 per cent of what in their communities, with a focus on supporting programs for children and youth and Cystic Fibrosis Canada—stores invest about $500,000 annually. This we put out,” says LeVasseur. “We sell category also covers employee performance and training, customer service, about $25,000 worth of energy a year.” and franchise and insurance partners.

He adds, “We talk to energy companies Green (Environmental) – By gathering all environmental regulation data all the time about more options, and from municipal, provincial, and federal jurisdictions, the category focuses on we’re always looking for different options environmental compliance, waste reduction, reducing each location’s carbon for our other locations.” footprint by reducing cycle time, reducing energy and water usage, embracing For Keenan, being a green shop is a technology—such as creating a paperless system—and greening the CARSTAR philosophy. “There are some things we supply chain. don’t make money on, but we attract Growth (Economic) – This category includes revenue growth, customer recustomers,” says LeVasseur. tention, and continued improvements in capital and exploration expenditures.

The benefits of implementing enCorporate and each franchise location will aim to achieve a minimum revenue vironmentally sustainable solutions growth of five per cent, while also committing to putting a minimum of five are two-fold. Although it’s easy to be per cent back into the business through investment in capital and exploration humble about internal efforts, using expenditures. And new this year, the entire network is following the NET such elements in marketing your shop Promoter Score system to track customer retention efforts. will help attract more business, while decreasing overall costs.

CARSTAR Rolls Out Sustainability Plan

C

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going green

Ontario Pros Battle for

Easier Eco Reporting

By Nate Hendley

T

he province of Ontario, an auto repair trade association, and a handful of private companies are doing their best to make it easier for bodyshops to “go green.”

One of the biggest changes for the industry came last fall, when the Ontario Ministry of the Environment (MOE) replaced its cumbersome Certificate of Approval (CofA) program for auto refinish shops with a much simpler registry system.

Shops that lack a current CofA for refinishing activities (including waterborne paint) are eligible to sign up with the new environmental registry. The other main registry requirements are that shops use no more than two litres of paint per hour, and for one-booth operations, offer at least 40 metres of distance between their exhaust stack and the nearest residential property line.

Qualifying for a CofA, by contrast, was “a much more complex process,” says John Norris, executive director of Hamilton, Ont.-based Collision Industry Information Assistance (CIIA), which represents the interests of auto repair shops in the province.

To get a CofA, shops had to fill out an 84-page form filled with detailed questions and pay a $600 fee to the MOE. “Shops had to provide huge amounts of data. And we were telling the province, ‘Listen, you set up a program that’s so complex it’s encouraging people to be non-compliant,’” says Norris.

The CIIA lobbied to get the CofA form reduced to 12 pages, but filling it out was still a daunting task.

“You still had to report the size of your building, the size of your booth, your fan speed, etc. And [shops had to also provide] a zoning map and an elevation map,” continues Norris.

So, after more CIIA lobbying, the provincial government ditched the CofA process and replaced it with a more userfriendly environmental registry on October 31, 2011. The CofA program still exists, but only for shops that don’t qualify for the registry. The CIIA, which once guided shops through

the difficult CofA process, now helps companies get listed on the new registry.

“In the past, it took us about nine to 14 months to get an approval. Now we can get an approval in 48 hours,” says Norris.

Shops can provide their information to the CIIA over the phone.

Since October, the association has done about 65 registrations, with a backlog of 40 to 50 additional shops eager to sign on. The CIIA charges member firms $300 and nonmembers $500 to register.

Some private companies in the bodyshop sector have also hoisted the green banner.

Birchmount Collision in Scarborough, Ont., for example, decided to switch over to waterborne paint in August 2007, ahead of federal regulations.

“We knew the government was going to be mandating [low-VOC paint for] all of the bodyshops. We felt, ‘Why leave it to the last minute? Why not get involved and do it out ahead of time?’ That way we’re not going to be left in the dust when the deadline rolls around and every bodyshop in Continued on page 26

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going green

Continued from page 24

“Shops had to provide huge amounts of data. And we were telling the province, ‘Listen, you set up a program that’s so complex it’s encouraging people to be noncompliant,’” says John Norris, executive director of CIIA. the country’s trying to convert to waterborne,” says Wayne Hosaki, president of Birchmount.

As part of the changeover, Birchmount had to modify its paint booths to accommodate air dryer systems, and buy new high-volume low-pressure (HVLP) paint guns to replace guns that sprayed solvent.

“You have to consider them contaminated,” explains Hosaki, of the latter.

For the firm’s efforts, Birchmount won a Canadian Automobile Association (CAA) award for environmental commitment.

Asked if the switch to waterborne was motivated by environmental concerns more than convenience, Hosaki says, “Absolutely. Anything that is going to be discarded by our shop—whether it be solid waste, fluid waste, car parts—we look for where can we recycle them? Where can we put the metal? The plastic? Where can we send it instead of putting it in a dumpster and sending it to landfill?”

Bodyshops around Hamilton and Toronto at least can avail themselves of a free pickup service, provided by Hamilton-based plastic recycling firm Ace Plastix.

“We go to bodyshops and we pick up their plastic waste— their scrap bumpers that they would otherwise throw out. We basically rescue [plastic waste], take it back to our shop, and recycle it. So, we’re keeping that material out of landfill,” explains company administrator Raffaella Pontrelli. hemTRAC, an initiative from Toronto Public Health that requires city With only one truck on the road, Ace picks up businesses to record and report the use and release of toxic chemicals, about 35,000 pounds of plastic waste a week from has inspired widespread criticism in auto repair circles. bodyshops and other auto-related companies.

“It’s very confusing. [I’m a bodyshop owner,] not an engineer or a chemist.

One of the most vocal environmental pundits in Trying to fill out the reports they want is proving baffling,” says Wayne Hosaki, Ontario’s bodyshop sector is P.J. Hnatiuk, vicepresident of Birchmount Collision in Scarborough, Ont. president and general manager of Canadian Auto “How do you figure out what your furnace particulate emissions are?

Collision/Canadian Auto Glass in Brantford, Ont. How do you figure out what your sanding emissions are?” says John Norris, “I have taken the word ‘environment’ and used executive director of Collision Industry Information Assistance (CIIA), based it as a continuous management stimulant, to reduce in Hamilton, Ontario. waste, material costs, and more important, secure Reporting requirements for ChemTRAC (the name stands for “Chemicals health and safety for the future of our children,” in Toronto, Reduction and Awareness in Our Community”) are spelled out in says Hnatiuk.

Toronto’s environmental reporting and disclosure bylaw. Under the bylaw, The shop has won several kudos, including polluwhich came into force in 2010, businesses have to record the use, manution prevention awards from Bodyshop magazine and facture, and/or release of some 25 “priority substances” including lead, the province of Ontario, and the Waste Minimization mercury, nickel compounds, benzene, formaldehyde, etc., beyond certain Award from the Recycling Council of Ontario. threshold levels. Results are tabulated on an annual basis and submitted Hnatiuk wrote an essay for the Autobodyhelp. online to the city. ca website (which is run by the CIIA) on the topic The level of detail required concerns auto repair pundits. of minimizing waste and saving money. Among oth“Not many shops can even monitor their VOCs [volatile organic compounds] er tips, he urges shops to collect scrap metal on a unless they have smart scales,” says P.J. Hnatiuk, vice-president and general daily basis, paint with HVLP guns, recycle solvent, manager of Brantford, Ont.-based Canadian Auto Collision/Canadian Auto Glass. use Smart Scales (computerized mixing scales), and The ChemTRAC program sets reporting deadlines for different businesses. find out if the municipality they are based in accepts Auto repair shops have until June 30, 2012 to report toxic chemical tallies from drop-offs of used motor oil. last year.

Not surprisingly, Hnatiuk is very supportive of Just as they lobbied the Ontario government to simplify provincial environOntario’s decision to drop the CofA process in mental reporting regulations, the CIIA hopes to convince the City of Toronto to favour of an environmental registry. reduce ChemTRAC’s scope.

Across the country, provincial and municipal With Hosaki’s blessing, Norris and two ChemTRAC technicians visited regulations can vary, but understanding the breadth Birchmount Collision in March to measure paint usage and time spent paintof what’s expected in terms of reporting and docuing, sanding, welding, and performing other tasks. The hope is that Toronto menting will keep repair shops ahead of the game.

Public Health realizes the extent of their reporting demands and scales them It’s also important to note—from the example CIIA back. There has been no word on the success of this mission, but Chemhas set—such standards can be challenged and TRAC critics aren’t giving up. altered to make the process easier.

“Every shop is going to pull their hair out with this—it’s so complex. We’re

C

ChemTRAC Chaos

trying to make it as simple as we can,” says Norris.

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going green

Fluid Business For bodyshops that want more control of solvent and wastewater, investing in fluid recyclers just makes sense.

D

ealing with used solvents has always been an issue for collision repair facilities. And as the waterborne paint system is relatively new to the industry, many shops might not consider the wastewater from the new gun cleaning process as a material that needs proper disposal as well.

With two types of paint technologies, there are two very specific cleaning processes.

To decrease waste creation and disposal costs, recyclers and filtration systems are key to maintaining control.

Many bodyshops have traditionally employed third-party waste haulers and recyclers to deal with hazardous materials. But according to Larry Bergmann of Specialty Product Sales (SPS) International Inc., many shops have experienced issues with the quality of recycled solvent they were getting back from third-party companies. “It’s not always consistent. It could be strong, weak, acidic, or neutral. You didn’t really know what you were getting.”

More shops are turning to solvent recyclers and waterborne gun cleaning units with filtration systems to recycle and reuse, saving

them money and the headache of hazardous material disposal.

Solvent Solutions While the technology is not necessarily new, solvent recyclers are now more affordable and easier to use.

“People realized that the cost of having a third party come in to haul waste was excessive, and many want to have control over the quality of the recycled solvent they use,” says Bergmann.

SPS, which represents Uni-ram, a Canadian manufacturer of solvent recyclers and spray gun cleaners, experienced an upswing in solvent recycler sales before shops started to convert to waterborne paint systems.

“When the waterborne conversion happened, we thought we’d see a big decline in the number of solvent recyclers being used, but we haven’t,” says Bergmann. “Even with waterborne clearcoats [coming onto the Continued on page 28 www.bodyshopbiz.com l April 2012 l Bodyshop 27

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Continued from page 27

“There’s a shop in Vancouver that has probably been reusing its solvent for eight to 10 years,” adds Larry Bergmann, Specialty Product Sales. market], there are still primers, commercial applications, and rust paints.”

And using a recycler is simple—training takes less than a half an hour. Painters can simply dump the used solvent from the spray gun cleaner into a recycling unit and press a button. The recycler does the rest.

According to Gord McKay, general manager of Uni-ram, its solvent recyclers use a distillation process. “When you have a solution of solvent and paint and you want to separate them, you heat the solvent.”

The fluid boils at a low temperature to turn the solvent into a vapour that runs through a condenser to cool it and turn it back into a liquid. The waste paint ends up in a bag, and the recycled solvent can be reused in the gun cleaning process.

Kennesaw, Ga.-based Becca Inc. also offers distillation-based recyclers, a technology that Becca president Barry Thomas humorously compares to moonshine stills.

“The process of a still and distillation system are one in the same; the difference is the purpose,” Thomas laughs.

“The idea is to recapture the solvent used for cleanup, so it can be used again for that purpose.”

Thomas stresses that the recycled solvent is to be used for cleaning purposes only, because shops often ask him if the recycled solvent can be reused for thinning down the paint mix.

“We tell people ‘no,’ because when you put the solution through distillation, there might still be co-solvents left behind in the solution,” says Thomas. Those co-solvents won’t affect the gun cleaning process, but should not be reintroduced back into the painting process.

“The intent of the distillation or filtration processes is to get multiple uses out of that material and save the waste that’s generated and normally hauled off,” says Thomas.

The key to maximizing on recycled solvent is in the hands of the operators.

Bergmann says, “Depending on what kind of solvent you’re using, and if it’s done

Uni-ram Solvent Recycler

properly—we recommend adding 10 per cent of new solvent to each batch of recycled solvent—you’ll keep the strength of it consistent, you’ll know what you’re working with, and it will last indefinitely.”

“There’s a shop in Vancouver that has probably been reusing its solvent for eight to 10 years,” adds Bergmann. “But the results can vary. It depends on how committed the shop is to doing it. To be successful, it requires a basic understanding of what’s happening, what results you’re trying to achieve, and basic house cleaning such as making sure the seals are functioning properly.”

Waterborne Waste Although waterborne paints are marketed as more environmentally friendly, it doesn’t mean you can just swish some warm water

around in the spray gun and dump it down the drain.

Whether it’s solvent or waterborne, properly cleaning a spray gun is essential to maintaining the atomization of the gun.

Residues can be left behind, causing buildup and contamination as time goes on.

That buildup can disrupt the airflow, creating turbulence in the paint delivery and loss of trigger control.

Both Uni-ram and Becca offer waterborne spray gun cleaning units that use special cleaning additives to properly cleanse the guns of built-up residue. But from such systems also comes wastewater.

“To clean waterborne spray guns, we use a concentrate that mixes with the water to enhance the cleaning properties.

That solution is used to clean the spray gun, and then the water can be reclaimed using a different process called flocculation,” says McKay. “With this process, you add two scoops of the flocculant material, [then] agitate the solution by adding air, which causes the paint to clump and move to the surface, leaving clean water underneath. Shops are reusing the water up to 11 times.”

Becca took its solvent concept and extended it into waterborne, which Thomas claims still has solvent in it.

“You can’t just dump waterborne down the drain,” says Thomas, whose filtration system also uses a flocculation process.

Once waterborne paint dries completely, it cannot be re-liquified. Therefore, once the paint waste that’s removed by the waterborne filtration system dries, it can, in some regions, be simply thrown out.

Depending on how much the distillation and filtration systems are used, the return on investment can be anywhere from three to 14 months. And with the units available on the market today, shops can invest in single units or opt for combination cleaning and recycling units.

It’s clear that having such systems in place is an environmentally friendly approach to dealing with hazardous material handling.

But it will also extend the longevity of spray guns and give shops more control, while saving them money.

Comments? Email nstapinsky@bodyshopbiz.com

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paint booth technology

Higher Tech, Lo For any bodyshop operation, the paint booth consumes the most energy. But with the latest innovations in spray booth technology, shops can have high quality output, while saving some dough. But before any capital investment, it’s essential to do your research. Here are some of the latest technologies.

Grand Prix Tech Highlights: The SAIMA direct-fired unit with 20,000 CFM air volume range comes equipped with a variable frequency drive (VFD) and is fully programmable for accelerated cure cycles and the option to minimize airflow when the operator is not spraying.

These booths are constructed with two-inch insulated panels and are available in a variety of configurations—downdraft, semi-downdraft, and cross-draft.

Unique Features: The unit has shadowless lighting accessible inside of the booth and a reverse blade exhaust with a backward blade double inlet centrifugal fan. “These fans generate more pressure than radial or squirrel cage fans,” says Ralph Iovannone, president of Grand Prix. “They provide an advantage over the long run with minimal spray buildup on the fan fins and longer-lasting exhaust filters.”

Custom Controls: The VFD controls the airflow in the booth and can be programmed for both waterborne and solvent paint setups.

And operators can configure specific temperatures and timing for various cycles. The logic controller also monitors filter life, which can help with diagnosis and reduce downtime.

Energy Savings: Energy efficiency is achieved by reducing air flow during preparation, when the gun is not in use, and during drying cycles by recirculating up to 80 per cent of the inside air of the booth.

Shops can save up to 30 per cent in energy costs and air filters.

Nova Verta (Spray Booth Solutions Ltd.)

Tech Highlights: Nova Verta paint booths use an in-direct fire burner, which allows for air recirculation during preparation and painting, and are controlled by Allen Bradley variable frequency drive (VFD) units and software. For waterborne paint users, Nova Verta’s Velocity Cure design eliminates the need for auxiliary blowers, automatically raising air speeds in the booth during flash-off, and will return to paint application speeds without the use of additional horsepower.

Unique Features: The control system balances positive pressure in the booth during all operations—prep, paint, flash, and cure cycles—to .015 inches of water column. “This means that your fan motors are operating at the lowest possible energy and maintaining pressure automatically without the need for adjustments,” says Domenic Muzzi, president of Spray Booth Solutions Ltd. Custom Controls: The NEMA 4X rated Allen Bradley VFD controls are designed for paint technicians and are easy to operate. These wash-down drives eliminate harsh dust particles from entering the units. The software features pop-up reminders for maintenance, and a logging screen that automatically tracks the maintenance when performed. If a problem occurs, the system monitors the issue and time-stamps it, and a pop-up photo will show the operator how to reset the problem.

Energy Savings: With the in-direct fire burner technology, shop owners save 30 per cent or more on fuel, electricity, and filtration— based on a four-job cycle per day, that’s a savings of about $4,000 annually.

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paint booth technology

h, Lower Costs Spray-Tech

Tech Highlights: Spray-Tech’s Junair 4 Series spray booths feature its patented multi-tiered flash and baking system, enhanced by its QADs waterborne drying system. Using a multi-speed variable frequency drive (VFD) control system, painters can easily program the booth for flash and cure cycles based on the different types of products being applied. The Junair also features T-5 high output lighting, and fit and finish cabins.

Unique Features: Spray-Tech uses smart sensors to monitor spray gun air usage, which allows painters to switch the booth mode just by pulling the spray gun trigger. “The painter doesn’t even need to leave the booth to switch modes on the control panel,” says Tyler Rand, owner of Spray-Tech. “And all booth functions are channelled through a system called Energy Monitor, which uses a group of automatic sensors built into the control system to monitor booth operations. If the spray gun is idle for ten minutes, the booth will automatically switch to economy mode.”

Custom Controls: The multi-speed twin programmable VFD allows the intake and exhaust motor drives to operate at their optimum frequency in all stages of the refinishing process. Included with the control panel is an Auto Balance system that monitors the pressure within the booth and measures the resistance of the airflow across the filters. This information is transmitted to the VFDs, which will adjust the pressure accordingly.

Energy Savings: The advanced sensors and integrated VFDs reduce energy usage by up to 80 per cent.

Flat Line Spray Booth Specialists Inc. Tech Highlights: Blowtherm BlowPower spray booths feature heat recuperation and waterborne drying systems, and job costing analysis, controlled by a variable frequency drive (VFD). The heat recuperation system decreases the amount of gas consumption that is used by the burner. And with the VDF control panel, painters have full control of the environment with programmable options to maximize booth production output.

Unique Features: The booth runs on a fully integrated system, allowing users to evaluate job costing, even while the vehicle is still in the booth. And for waterborne applications, this system features an integrated water-base curing system for short cure times, and Blowtherm’s “True Bake” system for shorter bake times.

Custom Controls: The VFD control panel is completely programmable to meet the criteria desired by the user. “The control panel is easy to use and communicates the status of the filters used in the system and will help with troubleshooting issues, if required,” says Matt Gibson, Flat Line Spraybooth Specialists.

Energy Savings: With the heat recuperation system and VFDs, operators can save 25 to 40 per cent in gas and electrical costs.

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welding

New Metal

By Noelle Stapinsky

A

little more than a decade ago, welders used one basic wire for all welding operations on both heavy- and light-gauge steels.

Today, however, with vehicles rolling off the assembly line with a varied mixture of alloys, aluminum, and steel, manufacturers have very specific recommendations about the machine, wire, shielding gas, and even the position that the welder is using in every step.

And this is not just manufacturer-specific, but model-specific.

To meet such parameters, welders need to adapt to new techniques and approaches. The good news is that such welding techniques can be achieved on both new and older technology; the learning curve is not steep. But being able to identify the metal materials and mastering the techniques is vital to restoring vehicles to their designed performance.

Brent Williams, Miller TIG project manager, says, “Aluminum is the easiest because its properties are relatively consistent from alloy to alloy. High strength low alloy (HSLA) steels [on the other hand] are more difficult to discuss because there are so many different alloy properties.”

Identifying the different metals and what procedure is required is a huge part of what students are learning in colleges today. At Okanagan College in Kelowna, B.C., the collision repair classes use Lincoln Electric and Miller, MIG and TIG welding technology.

What sets these classes apart from the College’s welding department is that students need to learn about the differences between mild steel, the new high-strength steels such as

transformation induced plasticity (TRIP), boron, dual phase (DP), and carbon manganese (CMn), which all require very specific procedures for welding and reworking.

“Whether it’s a GM, Ford, or Chrysler, the manufacturers dictate how welding procedures are done,” says Jeff Francis, chair of the collision repair department at Okanagan College. “For example, Chrysler requests AWS ER70S-3 welding wire, but GM wants an ER 70S-7, and Ford an ER70S-5.”

Elongation could be another factor in the choice of wire. AWS ER70S-3, for example, is a milder wire with different elongation properties. The manufacturer demands these standards to match the shaping, forming, and strength properties of the steels they use.

If you use a wire with the wrong mechanical properties, problems could arise such as stress cracking in the weld joint.

“With GM vehicles, which have increased amounts of boron steel that’s extremely heatsensitive, we may be requested to perform MIG brazing as a means of replacing, for example, an outer panel welded to a structural boron panel,” Francis says. “That’s a very specific procedure GM requires rather than conventional MIG welding with a steel electrode.”

Francis explains that for MIG brazing, they convert one of the 220V machines to a silicon bronze wire. “We change the welding gas as well, from a C-25 gas (75 per cent of argon and 25 per cent CO2) to 100 per cent argon or a blend of helium and argon. This produces a much cooler weld with which in turn has less heat effect on the boron steel. It burns

less of the corrosion protection as well.”

Ten years ago high-strength steels were only found in frame rails, but now door skins and exterior panels may be constructed of some form of high-strength steel. This makes it a lot more challenging for the repairers to work on these vehicles.

“When we’re talking about high-strength steels, it’s important to keep in mind that they get their strength from higher carbon content or a higher carbon equivalent,” says Williams.

“Low-alloy steel is mainly iron and carbon with a few trace elements.”

Williams explains that with a low carbon content of below .20, it’s almost impossible to harden or embrittle the material with conventional welding processes. And now that the carbon content is increased or has other alloys added, such as chromium or molybdenum, the material becomes more sensitive to heating and cooling.

In fact, normal welding processes and uncontrolled heating or cooling can cause changes in the microstructure that will change the mechanical properties of the material.

“Take 4130 chromoly. It’s low carbon, but the addition of chrome increases the carbon equivalent and allows the carbon to be forced into a brittle microstructure if it’s heated and quenched or cooled too quickly,” says Williams. “The same is true with cast iron. As a result, the best welding practices use low heat input and slow cooling rates.

Pulse welding, for example, provides the heat to weld the material with a lower average amperage, lowering the heat input.”

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welding When it comes to welding aluminum, you need high heat ability. Aluminum is a great conductor of electricity and heat; therefore, it doesn’t like to form a puddle without enough amperage to overcome those factors.

“The next issue is that aluminum forms an invisible oxide before the surface oxide, making a big mess,” says Williams.

With the new technology available today, Williams suggests using a DCEP, which helps to provide oxide cleaning during welding.

“It’s also recommended to use a stainless steel wire brush to remove oxides within one to two hours of welding because the oxidation is almost immediate and reforms in a very short time.”

Heat, moisture, and the environment accelerate oxidation; therefore, it’s wise to use a wire brush between passes or on new material before welding. William explains that this will provide the heat input of spray welding with a lower average amperage. “This heating and cooling affect allows for improved weldability of aluminum and it allows for welding out of position.”

Francis says, “Technicians and shops that are capable of MIG welding aluminum can easily make the transition to MIG brazing.”

Of course there are many different kinds of aluminum to be concerned with, and they all can’t be painted with the same brush, according to Francis. There are 1,000 through 7,000 series and techs need to be able to identify those materials or the welding process will compromise the integrity of the repair.

“Most cars today have 5,000, 6,000, and 7,000 series aluminum panels on them,” says Francis. “With those three different materials, there are two basic choices for welding wire— 4043 and 5356 for example.”

And then the welder needs to make a choice about whether he will use MIG or TIG. Francis says that the problem with TIG welding is that so far, none of the manufacturers recommend it for structural repairs. “TIG is far more particular and requires a greater skill set to master. Plus it requires a higher standard of cleanliness to perform, and bodyshops aren’t always the cleanest places for that type of procedure.”

“TIG is slightly more complicated to set up and not as easy to control the heat effect zone around the weld,” says Francis. “We teach TIG steel and aluminum welding as a value-added bonus for our students, but it’s not currently part of our curriculum.”

If a welder is confident with using TIG on aluminum, Williams suggests using an AC unit, which provides both cleaning and penetration.

An inverter power source allows for cleaning control to improve quality and appearance, and for arc width control.

“A focused arc makes it easier to weld aluminum, especially in corners or tight locations,” says Williams. “A wide, lazy arc takes the path of least resistance and can jump around, often ruining adjacent features or the arc marking sensitive areas.”

Indeed, new technology is designed for these specific procedures, but shops with older technology could invest in a spool gun for MIG applications. Both Lincoln Electric and Miller offer accessories or spool gun assemblies that attach to 110V and 220V machines to enable these capabilities.

Although the collision repair industry is seeing more of a shift to replacement over structural repair, it’s essential for technicians to keep up on such techniques and procedures as new metals get introduced into the overall makeup of today’s vehicles.

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products

Clean Air Miller Electric Manufacturing Co.’s FILTAIR 400 Industrial HighVacuum System is its latest line of weld fume extraction solutions.

The FILTAIR 400 provides consistent 400 cfm operation and ease of maintenance. Its surface-loading technology captures submicron particles at the surface, providing high-quality weld fume filtration and cleaning quality, extending the life of the filter, with automated filter cleaning for long periods of maintenance-free operation.

The four-port access means the unit can be centrally located while maintaining flexibility, especially when paired with FILTAIR accessories such as fume extraction guns.

Miller Electric Mfg. Co. www.millerwelds.com

Double Impact IMPACT, a traditional atomizing gun by Anest Iwata, features a larger spray pattern combined with all stainless steel wetted parts and high chrome finish for both waterborne and solvent. It’s available in a nozzle range of 1.3 mm to 2 mm.

Anest Iwata www.anestiwata.com

Strong Bond

Act Fast Ingersoll Rand’s one-inch 2155QiMAX Impactool is designed to deliver power, durability, and productivity when technicians and maintenance managers need it most. The one-inch drive is engineered for assembly and disassembly of vehicles, machinery and heavy equipment, and equipment maintenance applications. This tool delivers 1,350 ft-lb of maximum reverse torque with 1,150 blows per minute and has a forward torque range of 200-900 ftlb. Weighing only 7.4 lbs. with an overall length of 8.8 inches, the 2155QiMAX is light enough for extended use and compact enough to access tight spaces, yet is designed to withstand even the toughest use in rugged environments.

Ingersoll Rand www.ingersollrandproducts.com

Permatex’s PermaPoxy General Purpose Epoxy comes in an innovative self-mixing syringe, eliminating the need for separate mixing of components for an easier and more accurate application. The PermaPoxy syringe comes with a special mixing head that blends the proper amount of resin and hardener as it’s being dispensed, allowing you to apply it directly where it’s needed. The product bonds ceramics, glass, metal, chrome, hard plastic, and rubber, great for sealing cracks in castings, filling holes, automotive trim parts, ornaments, knobs, cracked tail lights, damaged grilles, mount components, body mouldings, and more.

Permatex www.permatex.com

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products

The Graveyard Shift Lincoln Electric’s Graveyard Shift design is the latest addition to its VIKING 2450 Series of auto-darkening welding helmets. The new design features a matte black surface with a gothicinspired skull and barbed wire theme. The viewing area is 2.4 inches high with a standard 5.25 by 4.5inch lens cartridge with four arc sensors. The grind mode allows the helmet to be used as a grinding shield for weld prep or post-weld clean up activities and its able to perform at a low three-amp DC and five-amp AC polarity for the GTAW (TIG) process. Weighing in at 602 grams, this helmet also features solar power with battery assistance and variable delay to adjust required time for switching from a darkened view to light state.

Lincoln Electric Canada www.lincolnelectric.ca

Dark Transitions The Tweco WeldSkill auto-darkening welding helmet, manufactured

by Thermadyne in St. Louis, Mo., features four sensors for enhanced performance, can be used in both weld mode and grind mode, and will darken when TIG welding even at five amps. The helmet has a large viewing area of 3.86-inches by 1.69-inches, weighs 453 grams, and uses solar power to eliminate the need to change batteries. The helmet darkens in 33 microseconds and users can select from three speeds—short (0.25s to 0.35s), medium (0.35s to 0.50s) and long (0.50s to 0.80)—when switching from light to dark. The sensitivity and delay knobs are placed on the outside of the helmet shell so that operators can make adjustments while welding. The WeldSkill is offered in Carbon Fiber, Patriot Eagle, Chopper Rider and Skull and Fire designs.

Thermadyne www.thermadyne.com/tweco

Water-Cooled Control

Smooth Arc Weldcraft has expanded its premium tungsten electrode offering to include two per cent lanthanated and zirconiated tungsten electrodes. These electrodes provide similar characteristics as the 1.5 per cent lanthanated tungsten electrode, but with improved arc starting and stability, and less tip erosion. They are also a good substitute for two percent thoriated tungsten electrodes. The zirconiated tungsten electrodes resist spitting in higher current applications, minimizing the opportunity for contamination. The electrodes also ball up easily in AC applications creating a smoother arc.

Weldcraft www.weldcraft.com

Weldcraft’s WP-280 water-cooled TIG torch is designed with the company’s exclusive Super Cool Technology, providing consistent and dependable cooling performance. The design improves the torch’s efficiency, resulting in less downtime due to overheating and a longer-lasting torch. The torch body also includes an anti-rotation feature to prevent handle movement during welding, and a TriFlex hose and cable assembly, which is designed to remain flexible in cold weather, improve operator control, and prevent cracking. The ColorSmart hose and cable sets differentiate input water, water/ power cable, and gas hoses to simplify torch installation.

Weldcraft www.weldcraft.com

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products

Air Supply

Martech Services Co.’s Model P-20 Personal Air Breathing Unit works with existing filtered compressed air supplies, providing grade “D” breathable air for NIOSH-approved respirators. It comes with a 54-inch tool air hose assembly to allow for a bypass of air for a paint spray gun. The unit is a 20 scfm system, allowing it to be used with full hoods that are equipped with vortex cooling tubes.

The belt-mounted unit comes complete with a built-in filter with a filter monitor and a carbon monoxide monitor, featuring audible and visual alarms. The monitor runs on a single battery.

Martech Services Company www.breathingsystems.com

Fresh Start Pro-Spray recently launched its new 3.5 VOC Solvent Basecoat system, which features an improved formula to optimize coverage, spray ability, and colour quality with an easy-touse 1:1 mix ratio. This system uses Pro-Spray solvent toners, low-VOC binders, and the new BCA-200 Activator/Reducer.

The basecoats—available in more than 63,000 3.5 VOC formulas—can be used over Pro-Spray 2.1 VOC sealers and primers, and topped with any Pro-Spray 2.1 VOC clearcoat.

Pro-Spray Automotive Refinishes www.prosprayfinishes.com

Glass Act Get a streak-free glass finish with Meguiar’s new Perfect Clarity Glass Cleaner. Formulated with a dustrepellent solution, the product comes with a guarantee to help glass surfaces stay cleaner for longer.

Using a unique lubricant, the product is easy to apply. Spray directly on the glass surface and spread evenly. Flip the towel to buff the glass dry. It can even be applied in direct sunlight.

Meguiar’s www.meguiars.com

Gold Upgrade Mirka has upgraded its all-round Gold abrasive product by adding extra strong aluminum oxide grains in the P80-P800, giving an excellent cut. The optimized grain distribution and a combination of calcium and zinc-base stearate allows the product to perform faster with less clogging. The upgraded product also has improved backing paper for more even coating of grains and resin.

Mirka Canada www.netstanding.com

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Automotive Internet Directory Visit these companies directly at their web addresses or check out the growing list of Hot Links at www.autoserviceworld.com.

To find out how your organization can be included in this directory and on the web, contact aross@jobbernews.com

BUSINESS MANAGEMENT SERVICES

AUTOMOTIVE PARTS & ACCESSORIES

NGK Spark Plugs Canada Limited www.ngksparkplugs.ca The World Leader in Spark Plugs, Oxygen Sensors and Ignition Wire Sets.

Used by 87% of the World’s OE Manufacturers S.B International Inc. www.sbintl.com “We keep engines humming”

AUTOMOTIVE RECYCLERS Carcone’s Auto Recycling and Wheel Refinishing www.carcone.com With over 32 years of experience Carcone’s Auto Recycling & Wheel Refinishing is your one stop for quality recycled products and wheel refinishing needs. Call today at 1-800-263-2022 or visit us on line at www.carcone.com Standard Auto Wreckers View Our Online Inventory @ www. standardautowreckers. com or call 416-286-8686.

Experienced Shipping Department to Ensure Parts Arrive Safely.

The Automotive Aftermarket E-Learning Centre Ltd www.aaec.ca AAEC - BEST Business Evaluation Support & Training - Instructing and Coaching with the Proven Business Management Tools that drives a shop’s Bottom Line, Team Culture and Marketplace Credibility.

HAND CLEANERS GOJO Industries, Inc. www.automotive.gojo.com GOJO is a leading manufacturer of skin care products and services for many marketing including automotive and manufacturing. GOJO continues to pursue a commitment of creating well-being through hand hygiene and healthy skin.

REFRIGERANT

Bestbuy Distributors Limited www.bestbuyautoparts.ca Independent buying group and warehouse distributor that allocates its profits to member shareholders and provides unbeatable value for independent jobbers.

The E.R.I. Group www.theerigroup.com Canada’s Premier Machine Shop Buying Group Kerr Machine Shop Group Inc.

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Marketplace

ADVERTISERS INDEX Page #

Agna Brakes (www.agnabrakes.com) . . . . . . . . . . . . . . . . . . . 29 . . . . . . . . . . . . . . . . . . . . . . .www.aiacanada.com . . . . . . . . . . . . . . . . . . .IFC AIA Canada

Akzo ( Wanda ) Division

7

BMW

40

DuPont Performance Coatings

5

FBS

13

www.fbs-online.com

First Choice Auto Repair Systems Inc 11

www.Ezpartorder.com & www.EZShopManager.com

www.wandarefinish.com www.bmw.ca www.cromax.dupont.com

Kennedy Paint

25

www.southernpolyurethanes.com

Martech Services

14

www.breathingsystems.com

Mirka

33

www.mirka.com

NACE

23

www.asrwevents.com

Nova Verta

12

www.novavertausa

Pro-Spray Automotive Refinishes

2

Sherwin Williams Automotive Refinishes

21

www.sherwin-automotive.com

Spray-Tech

39

www.spraytech.com

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WAREHOUSE DISTRIBUTORS & BUYING GROUPS

www.kerrmachineshopgroup.com Buying group for machine shops and performance shops.

Duracool Refrigerants

advertiser index Company

JOBBER NEWS / MARCH 2012

AIR LIQUIDE CANADA INC. www.airliquide.ca Your one-stop shop for all your industrial gases and welding supplies.

www.ProSprayFinishes.com

MONEY IS SHORT

Goodyear Engineered Products www.goodyearep.com/aftermarket www.goodyearbeltsandhose.com The officially licensed belt of NASCAR. Gatorback, the quiet belt. You can never replace Goodyear quality.

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www.bodyshopbiz.com l April 2012 l Bodyshop 37 37

02/03/12 02/04/1211:43 2:00AM PM

from the publisher

FRAUD’S NOT FUNNY A press release from the Insurance Bureau of Canada arrived in my inbox with a clunk.

“Insurance Fraud Follies,” it promised. It was a collection of those “world’s stupidest criminals” type of anecdotes. Now, I don’t know if it was my mood or the content, but I didn’t really find anything funny in it at all.

Here is one example included in the release: “It was apparently a long and winding road filled with all kinds of hazards and a few lies. The man told the insurance company he had hit a deer and claimed that his car was badly damaged. Then his story changed. Maybe it wasn’t a deer, he said; it could have been a rabbit or even a groundhog. The investigator thought they must have some pretty big rabbits and groundhogs in these parts. Well, said the man, maybe it was a fence or a post. How a fence or a post jumped out onto the road was never made clear.

Claim denied.”

While credit should go to the Insurance Bureau of Canada for at least indicating the outcome, I guess the thing is that I don’t find fraud funny. It costs us all money— whether it’s in our premiums or elsewhere in the business world, and when it comes to cases touching this industry, it really stings.

“But sometimes you can’t help but laugh at some of the outrageous scams and schemes of would-be fraud artists,” said the release.

Well, I’m not laughing, and you shouldn’t be, either.

Business owners will all have a story or two from their past where they have been approached to “help a friend out of a jam,” and I am confident that no legitimate player in this industry would turn a blind eye to the type of activities that recently hit the news.

One, which the police dubbed “Project Enterprise,” targeted the rebuilding of salvage vehicles, replacing the VINs, and selling them as simply used vehicles. In one case highlighted by investigators, the front of one totalled BMW was mated to the rear half of another that had been stolen. The car was then sold to an unsuspecting customer for some $40,000.

While some 500 charges against six individuals from three businesses are still unproven in court as I write this, it is disgusting that anyone would do this. Not only was the customer lied to about the history of the vehicles, but if this BMW is anything to judge by, the vehicles themselves were incredibly unsafe.

In a completely unrelated case from late last year, a shop was charged after police alleged a customer was flagged down outside a collision reporting centre, directed to a shop, and then damage inflated to defraud the insurance company.

My point is that nowhere in the articles surrounding these cases, or through media releases following them, was the collision industry represented.

While I don’t consider this activity (or anybody who was involved) to be a part of this industry, the media doesn’t distinguish.

The way the cases are reported puts the insurers and the police on one side, and this industry on the other.

This puts it in a very bad light. I think it is high time that this industry stood up and let the public know that it does not consider those who would perpetrate fraud to be part of its industry.

Industry organizations need to get out in front of the issue, and work to ensure that the legitimate industry is represented well in the public eye before, during, and after these cases come up.

Ignoring it will not make it go away. It’s time to break the silence.

B Andrew Ross aross@bodyshopbiz.com

38 Bodyshop l April 2012 l www.bodyshopbiz.com

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03/04/12 1:56 PM

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