The following passenger car series are produced at the Mercedes-Benz Bremen plant
Model 129 (SL class)
Model 170 (SLK class)
Model 202 (C class)
Model 208 (CLK class)
The following two charts show the corrosion protection processes in the Bremen plant, starting with the pre-treatment of the body-in-white through to assembly of the painted and protected body. The temperatures specified relate to the target temperature of the bodies.
Models R 129 and R 170 are painted on a different production line, but the sequence of production operations is basically identical.
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The first chart shows the process sequence for the use of water-based paint, the second chart shows the sequence for paints containing solvents.
The following chapters or documents show how reliable corrosion protection is achieved for passenger cars produced in Bremen through desiged processes, sequences of operations during production, painting processes and the use of special materials.
The transport film is offered as special equipment to protect the painted surface from damage:
Material: PEPP
Processing method: Affixed manually before assembly
Film thickness: approx. 50 - 70 μm
Function: Assembly and transport protection
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P98.00-2257-09
Water-Based paint
A Manual
1 Pre-treatment (cleaning)
2 Cataphoretic immersion priming (KTL)
3 KTL Drier, 175°C, 15 min.
4 Sanding KTL (flaws only)
5 Body seam sealing (NAD)
12 Intermediate drier
13 Application of clear coat 2K (ESTA)
14 Top coat drier, 130°C, 22 min.
15 Cooling zone
16 Cavity protection (IGS)
17 Wax drier, 50°C, 6 min.
6 Underbody protection (UBS)
7 UBS/NAD drier, 155°C, 15 min.
8 Filler application (ESTA)
9 Filler drier, 155°C, 20 min.
10 Sanding fillre (flaws only)
11 Water-based paint base coat application (ESTA)
P98.00-2258-09
Base paint containing solvents
A Manual
1 Pre-treatment (cleaning)
2 Cataphoretic immersion priming (KTL)
3 KTL Drier, 175°C, 15 min.
4 Sanding KTL (flaws only)
11 Base coat application (pneumatic)
12 Application of clear coat 1K (ESTA)
13 Top coat drier, 130°C, 22 min.
14 Cooling zone
15 Cavity protection (IGS)
16 Wax drier, 50°C, 6 min.
5 Body seam sealing (NAD)
6 Underbody protection (UBS)
7 UBS/NAD drier, 155°C, 15 min.
8 Filler application (ESTA)
9 Filler drier, 155°C, 20 min.
10 Sanding fillre (flaws only)
P98.00-0706-06
Paint structure, layer thicknesses:
1 Steel sheet
2 Zinc-phosphatizing approx. 2.5 g/m2
3 Electro-dipcoat emersion 18 - 20 μm
4 Primer/Filler
on vertical surfaces 30 35 μm
on horizontal surfaces 30 35 μm
Solid color water-based paint
5 Base coat 20 5 μm
Metallic base coat
5 Base paint containing
solvents 13 2 μm
5 Water-based base coat 13 2 μm
Clear coat
6 1K clear coat (base paint
containing solvents)
on vertical surfaces 33 2 μm
on horizontal surfaces 43 2 μm
6 2K clear coat (water-based paint)
on vertical surfaces 33 2 μm
on horizontal surfaces 43 2 μm
Paintwork structure