Chartek 7 8+1709 Application Manual Rev0 010507

ID Rev. Date APP MAN UK 0 01/05/07 Chartek® Application Manual

©International Paint Limited, 2007 This document and its contents are the copyright of International Paint Limited and may not be reproduced in whole or in part without the express permission of International Paint Limited. All products supplied and technical advice or recommendations given are subject to our standard Conditions of Sale.

Application Manual Chartek Fire Protection

Prepared by: International Paint Ltd.

ID Rev. Date APP MAN UK 0 01/05/07 Chartek® Application Manual Page 1 of 29


Table of Contents SECTION A – GENERAL (ALL PRODUCTS) .......................................................................... 10

Contact Information ............................................................................................................. 11

Chartek Application Manual Revisions .............................................................................. 12

A1.0 INTRODUCTION............................................................................................................... 13

A1.1 Purpose ........................................................................................................................ 13

A1.2 System Description ..................................................................................................... 13

A1.3 Quality Control Requirements .................................................................................... 13

A2.0 SURFACE PREPARATION.............................................................................................. 14

A2.1 Introduction.................................................................................................................. 14

A2.2 Degreasing ................................................................................................................... 14

Table A1: Chartek Surface Preparation Requirements .................................................... 17

A3.0 PRIMERS.......................................................................................................................... 18

Table A2: Primer System Maximum Dry Film Thicknesses............................................. 18

A4.0 QUALIFIED CHARTEK APPLICATION CONTRACTORS............................................... 20

A4.1 Chartek Products Not Applied Within Two Years..................................................... 20

A5.0 CHARTEK THICKNESS MEASUREMENT ...................................................................... 21

A5.1 Thickness Measurement ............................................................................................. 21

A6.0 TOPCOATS ...................................................................................................................... 23

A6.1 Special Applications.................................................................................................... 24

A7.0 REMOVAL AND REPAIR, ADDITIONAL WORK, WELD CUTBACK AND REPAIR OF DAMAGED AREAS................................................................................................................... 25

A7.1 Removal........................................................................................................................ 25

A7.2 Weld Cutback............................................................................................................... 25

A8.0 SAFETY AND ENVIRONMENT ........................................................................................ 27

A9.0 SPECIAL APPLICATIONS ............................................................................................... 28

A9.1 Repair Procedure for Damaged or Delaminated Chartek......................................... 28

A9.2 Coatbacks .................................................................................................................... 28



SECTION B – CHARTEK 7......................................................................................................... 1 B1.0 CHARTEK PACKAGING AND STORAGE......................................................................... 2

B1.1 50kg (110lb) Kit .............................................................................................................. 2

B1.2 20kg (44.1lb) Kit ............................................................................................................. 2

B1.3 Cast Grade ..................................................................................................................... 2

B1.4 Storage Conditions for Chartek.................................................................................... 2

B2.0 CARBON FIBRE MESH REINFORCEMENT ..................................................................... 3

B2.1 Meshing Designs ........................................................................................................... 3

Table B1: Mesh Requirements ............................................................................................. 3

B2.2 HK-1TM and HK-1 (M)TM Carbon Fibre Mesh Reinforcement ....................................... 3

B2.3 Packaging of HK-1 and HK-1 (M) Carbon Fibre Mesh Reinforcement....................... 3

B2.4 General Rules for Meshing ........................................................................................... 3

B3.0 METAL MESH REINFORCEMENT..................................................................................... 4

B3.1 Metal Mesh Reinforcement Uses.................................................................................. 4

B3.2 Metal Mesh Reinforcement Types ................................................................................ 4

B3.3 Installation of Pins......................................................................................................... 4

B3.4 General Rules for Metal Meshing ................................................................................. 5

Table B2: Meshing Designs for Structural Members and Tanks....................................... 5

B4.0 CHARTEK APPLICATION WITH SINGLE LEG AIRLESS SPRAY EQUIPMENT............. 6

B4.1 Ambient Conditions....................................................................................................... 6

B4.2 Surface Cleanliness....................................................................................................... 6

B4.3 Primer and Surface Preparation................................................................................... 6

B4.4 Kit Size............................................................................................................................ 7

B4.5 Material Preparation for Single Leg Airless Spray Application ................................. 7

B4.6 Heated Storage Units .................................................................................................... 8

B4.7 Mixing Equipment.......................................................................................................... 9

B4.8 Use of Solvent.............................................................................................................. 10

B4.9 Mixing Procedure......................................................................................................... 11

B4.10 Single Leg Airless Spray Equipment ....................................................................... 11

B4.11 Single Leg Spray Application Method ..................................................................... 13



B4.12 Water Contamination................................................................................................. 14

B4.13 Surface Finish............................................................................................................ 14

B4.14 Terminations .............................................................................................................. 15

B5.0 CHARTEK APPLICATION WITH PLURAL SPRAY EQUIPMENT................................... 16

B5.1 Ambient Conditions..................................................................................................... 16

B5.2 Surface Cleanliness..................................................................................................... 16

B5.3 Primer and Surface Preparation................................................................................. 16

B5.4 Material Preparation for Plural Component Spray Application ............................... 17

B5.5 Plural Component Spray Equipment ......................................................................... 17

Table B3: Operating Parameters for Plural Component Spray Machines ....................... 18

B5.6 Ratio Checks................................................................................................................ 19

B5.7 Plural Spray Application Method................................................................................ 19

B5.8 Water Contamination................................................................................................... 21

B5.9 Surface Finish.............................................................................................................. 21

B5.10 Terminations .............................................................................................................. 21

B6.0 HAND TROWEL APPLICATION ...................................................................................... 22

B6.1 Ambient Conditions..................................................................................................... 22

B6.2 Surface Cleanliness..................................................................................................... 22

B6.3 Primer and Surface Preparation................................................................................. 22

B6.4 Material Preparation for Hand Trowel Application ................................................... 23

B6.5 Mixing ........................................................................................................................... 23

B6.6 Hand Trowel Application Method............................................................................... 24

B6.7 Mixing of Partial Kits ................................................................................................... 24

B6.8 Water Contamination................................................................................................... 25

B6.9 Surface Finish.............................................................................................................. 25

B6.10 Terminations .............................................................................................................. 25



APPENDICES ........................................................................................................................... 26 APPENDIX A – HK-1TM Meshing Arrangements....................................................................................27 APPENDIX B – Metal Meshing Arrangements ......................................................................................31

APPENDIX C – Certified Thicknesses - Bulkheads and Decks...........................................................35

APPENDIX D – Typical Standards of Finish and Mesh Overlap Photographic Reference...............40

APPENDIX E – Chartek Checklist ..........................................................................................................44

APPENDIX F – Procedure for Inspection, Test and Replacement of Failed Fire Protection............46

APPENDIX G – Technical Note TN/F/083 “Overcoating of aged and zinc primers” .........................51

APPENDIX H – Technical Note TN/F/101 “Disposal of Chartek” ........................................................55 APPENDIX I – Definitions and Abbreviations.......................................................................................57



SECTION C – CHARTEK 8......................................................................................................... 1 C1.0 CHARTEK PACKAGING AND STORAGE......................................................................... 2

C1.1 50kg (110lb) Kit .............................................................................................................. 2

C1.2 20kg (44.1lb) Kit ............................................................................................................. 2

C1.3 Cast Grade ..................................................................................................................... 2

C1.4 Storage Conditions for Chartek.................................................................................... 2

C2.0 CARBON FIBRE MESH REINFORCEMENT ..................................................................... 3

C2.1 Meshing Designs ........................................................................................................... 3

Table C1: Mesh Requirements .............................................................................................. 3

C2.2 HK-1TM and HK-1 (M)TM Carbon Fibre Mesh Reinforcement ....................................... 3

C2.3 Packaging of HK-1 and HK-1 (M) Carbon Fibre Mesh Reinforcement....................... 3

C2.4 General Rules for Meshing ........................................................................................... 3

C3.0 APPLICATION WITH SINGLE LEG AIRLESS SPRAY EQUIPMENT ............................... 5

C3.1 Ambient Conditions....................................................................................................... 5

C3.2 Surface Cleanliness....................................................................................................... 5

C3.3 Primer and Surface Preparation................................................................................... 5

C3.4 Kit Size............................................................................................................................ 6

C3.5 Material Preparation for Single Leg Airless Spray Application ................................. 6

C3.6 Heated Storage Units .................................................................................................... 7

C3.7 Mixing Equipment.......................................................................................................... 8

C3.8 Use of Solvent................................................................................................................ 9

C3.9 Mixing Procedure......................................................................................................... 10

C3.10 Single Leg Airless Spray Equipment ....................................................................... 10

C3.11 Single Leg Spray Application Method ..................................................................... 12

C3.12 Water Contamination................................................................................................. 13

C3.13 Surface Finish............................................................................................................ 13

C3.14 Terminations .............................................................................................................. 14

C4.0 CHARTEK APPLICATION WITH PLURAL SPRAY EQUIPMENT................................... 15

C4.1 Ambient Conditions..................................................................................................... 15

C4.2 Surface Cleanliness..................................................................................................... 15



C4.3 Primer and Surface Preparation................................................................................. 15

C4.4 Material Preparation for Plural Component Spray Application ............................... 16

C4.5 Plural Component Spray Equipment ......................................................................... 16

Table C2: Operating Parameters for Plural Component Spray Machines ....................... 17

C4.6 Ratio Checks................................................................................................................ 18

C4.7 Plural Spray Application Method................................................................................ 18

C4.8 Water Contamination................................................................................................... 20

C4.9 Surface Finish.............................................................................................................. 20

C4.10 Terminations .............................................................................................................. 20

C5.0 HAND TROWEL APPLICATION ...................................................................................... 21

C5.1 Ambient Conditions..................................................................................................... 21

C5.2 Surface Cleanliness..................................................................................................... 21

C5.3 Primer and Surface Preparation................................................................................. 21

C5.4 Material Preparation for Hand Trowel Application ................................................... 22

C5.5 Mixing ........................................................................................................................... 22

C5.6 Hand Trowel Application Method............................................................................... 23

C5.7 Mixing of Partial Kits ................................................................................................... 23

C5.8 Water Contamination................................................................................................... 24

C5.9 Surface Finish.............................................................................................................. 24

C5.10 Terminations .............................................................................................................. 24

APPENDICES ........................................................................................................................... 25 APPENDIX A – HK-1TM Meshing Detail ..................................................................................................26

APPENDIX B – Not Applicable...............................................................................................................30

APPENDIX C – Certified Thicknesses - Bulkheads and Decks...........................................................31





APPENDIX H – Technical Note TN/F/101 “Disposal of Chartek” ........................................................51

APPENDIX I – Definitions and Abbreviations........................................................................ 53



SECTION D – CHARTEK 1709................................................................................................... 1 D1.0 CHARTEK PACKAGING AND STORAGE......................................................................... 2

D1.1 50kg (110 lb) Kit ............................................................................................................. 2

D1.2 20kg (44.1 lb) Kit ............................................................................................................ 2

D1.3 Cast Grade ..................................................................................................................... 2

D1.4 General Storage Conditions for Chartek ..................................................................... 2 D1.4.1 Storage Conditions ................................................................................................. 2 D1.4.2 Storage Temperature .............................................................................................. 2

D2.0 HK-1TM CARBON FIBRE MESH REINFORCEMENT......................................................... 4

D2.1 Meshing Designs ........................................................................................................... 4

Table D1: HK-1 Mesh Requirements.................................................................................... 4

D2.2 HK-1 and HK-1 (M) Carbon Fibre Mesh Reinforcement.............................................. 4

D2.3 Packaging of HK-1TM and HK-1 (M)TM Carbon Fibre Mesh Reinforcement................ 4

D2.4 General Rules for HK-1 Meshing (where required*).................................................... 4

D3.0 METAL MESH REINFORCEMENT..................................................................................... 5

D3.1 Metal Mesh Reinforcement Requirements .................................................................. 5

D4.0 APPLICATION WITH SINGLE LEG AIRLESS SPRAY EQUIPMENT ............................... 6

D4.1 Ambient Conditions....................................................................................................... 6

D4.2 Surface Cleanliness....................................................................................................... 6

D4.3 Primer and Surface Preparation................................................................................... 6

D4.4 Kit Size............................................................................................................................ 7

D4.5 Material Preparation for Single Leg Airless Spray Application ................................. 7

D4.6 Heated Storage Units .................................................................................................... 8

D4.7 Mixing Equipment.......................................................................................................... 9

D4.8 Use of Solvent.............................................................................................................. 10

D4.9 Mixing Procedure......................................................................................................... 11

D4.10 Single Leg Airless Spray Equipment ....................................................................... 11

D4.11 Single Leg Spray Application Method ..................................................................... 13

D4.12 Water Contamination................................................................................................. 14

D4.13 Surface Finish............................................................................................................ 14

D4.14 Terminations .............................................................................................................. 15



D5.0 CHARTEK APPLICATION WITH PLURAL SPRAY EQUIPMENT................................... 16

D5.1 Ambient Conditions..................................................................................................... 16

D5.2 Surface Cleanliness..................................................................................................... 16

D5.3 Primer and Surface Preparation................................................................................. 16

D5.4 Material Preparation for Plural Component Spray Application ............................... 17

D5.5 Plural Component Spray Equipment ......................................................................... 17

Table D2: Operating Parameters for Plural Component Spray Machines ....................... 18

D5.6 Ratio Checks................................................................................................................ 19

D5.7 Plural Spray Application Method................................................................................ 19

D5.8 Water Contamination................................................................................................... 21

D5.9 Surface Finish.............................................................................................................. 21

D5.10 Terminations .............................................................................................................. 21

D6.0 HAND TROWEL APPLICATION ...................................................................................... 22




D6.4 Material Preparation for Hand Trowel Application ................................................... 23

D6.5 Mixing ........................................................................................................................... 23

D6.6 Hand Trowel Application Method............................................................................... 24

D6.7 Mixing of Partial Kits ................................................................................................... 24


D6.9 Surface Finish.............................................................................................................. 25

D6.10 Terminations .............................................................................................................. 25



D5.0 CHARTEK APPLICATION WITH PLURAL SPRAY EQUIPMENT................................... 16




D5.4 Material Preparation for Plural Component Spray Application ............................... 17

D5.5 Plural Component Spray Equipment ......................................................................... 17

Table D2: Operating Parameters for Plural Component Spray Machines ....................... 18

D5.6 Ratio Checks................................................................................................................ 19

D5.7 Plural Spray Application Method................................................................................ 19


D5.9 Surface Finish.............................................................................................................. 21

D5.10 Terminations .............................................................................................................. 21

D6.0 HAND TROWEL APPLICATION ...................................................................................... 22




D6.4 Material Preparation for Hand Trowel Application ................................................... 23

D6.5 Mixing ........................................................................................................................... 23

D6.6 Hand Trowel Application Method............................................................................... 24

D6.7 Mixing of Partial Kits ................................................................................................... 24


D6.9 Surface Finish.............................................................................................................. 25

D6.10 Terminations .............................................................................................................. 25



APPENDICES ........................................................................................................................... 26 APPENDIX A – HK-1TM Meshing Details ................................................................................................27

APPENDIX B – Not Applicable...............................................................................................................31

APPENDIX C – Not Applicable...............................................................................................................32





APPENDIX H – Technical Note TN/F/101 “Disposal of Chartek” ........................................................48 APPENDIX I – Definitions and Abbreviations........................................................................ 50



SECTION A – GENERAL (ALL PRODUCTS)



Contact Information Region Office Address Telephone/Fax Head Office and

Europe, Middle East & Africa

Essex House 141 Kings Road Brentwood Essex CM14 4DR United Kingdom

Tel: +44 (0)1277 229192

Fax: +44 (0 1277 228745

Scandinavia Karistoe 13 4045 Hafrsfjord Norway

Tel: +47 95 40 21 35

Fax: +47 51 59 36 78

India, South East Asia & China 3 Neythal Road Jurong Town 628570 Singapore

Tel: +65 6663 3050

Fax: +65 6261 8125

The Americas 6001 Antoine Drive 77091 Houston Texas USA

Tel: +1 713 684 1223

Fax: +1 713 684 1514

Korea 17th Floor National Pension Building #1422-8 Yeonsan-dong Yeonje-gu Busan South Korea

Tel: +82 51 5806150 Fax: +82 52 2342377

Australasia 115 Hyde Road Yeronga Brisbane Queensland, 4140 Australia

Tel: +61 738928887

Fax: +61 738923642

Websites: www.chartek.com www.international-pc.com



Chartek Application Manual Revisions RReevv.. DDaattee RReevviissiioonn NNootteess

0 01/05/07 New format NOTES: This Chartek Application Manual is verified by the International Paint Ltd’s Technical Engineering Manager, Oil, Gas, Fire & Insulation. From the date of approval the contents of the manual are to be considered effective. The registration of the verification and approval of every edition of this manual and the original document are held in the archives of the Head Office, which has the responsibility of conserving the document in its approved state and of distributing copies that conform to the last deposited revision. The previous editions are also held in the archives, separately, and conserved for possible consultation. The original language of the manual is English. In the event of discordance with successive translations, the company and addressees of the manual must make reference to the English edition. The document is identified by an ID code, revision number and issue date. This information is printed in the heading of every page. This manual is distributed internally and externally with the aim of providing consistent information to all parties involved in the application of Chartek fireproofing systems. This Chartek Application Manual can be distributed in a controlled or non-controlled form. The Regional Office Technical Manager is responsible for identifying the need to transmit the manual to company departments, clients, companies, bodies, etc., and decides the form of distribution. International Protective Coatings will ensure that successive revisions of the manual are sent to recipients of controlled copies. It is the responsibility of the recipient of the controlled copy to substitute the new revision throughout his organisation. This manual uses metric (SI) and Imperial units of measure (in brackets). The information given in this manual is not intended to be exhaustive: any person applying the product by any method other than that specifically recommended in this manual without first obtaining our written confirmation as to the suitability of the proposed method does so at his own risk. We try very hard to ensure that all advice we give about application of our product (whether in this manual or otherwise) is correct but we have no control over either the quality or condition of the substrate or the many factors affecting application of the product. In the event of any doubts or misunderstandings, International Protective Coatings should be consulted for clarification. The information contained in this manual is liable to modification from time to time in the light of experience and our policy of continuous product development. It is the user’s responsibility to check that this manual is current prior to using the product. Unauthorized changes or reproduction of the manual are forbidden. Unless we agree differently in writing all our goods and related technical advice are supplied on our standard conditions of sale, a copy of which is available on request.



A1.0 INTRODUCTION A1.1 Purpose This Application Manual contains instructions on how to install Chartek fireproofing systems. Passive fireproofing materials prevent potentially catastrophic structural failures from occurring by providing an insulating shield against the intense heat of a fire. The Chartek fireproofing systems are the result of over 30 years of research and development and possess extensive certification for a wide range of fire protection ratings. Since both fire protection performance and pre-fire durability critically depend on the correct application of the system, International Protective Coatings requires that the Chartek fireproofing systems are installed only by qualified applicators in strict accordance with the instructions contained in this Application Manual. Our Regional Office Technical Service Managers provide the support necessary to ensure that Chartek fireproofing projects are carried out in accordance with the instructions of this manual and any additional project specific requirements. A1.2 System Description The Chartek passive fireproofing system consists of an epoxy intumescent coating designed to protect substrates from fire and corrosion. Dependent on the fire type, rating and design, Chartek fireproofing systems may require mesh reinforcement. Chartek provides effective fire protection to a wide range of structures, divisions and equipment in almost any fire scenario. In a fire, Chartek fireproofing will intumesce (expand) to form an insulating layer of char. It is this char and its formation that protects the substrate from the effects of fire. A1.3 Quality Control Requirements The quality control activities required to verify that application is carried out in accordance with this manual are described in the Quality Control Manual for Chartek Fireproofing Systems, which is available to customers and applicators upon request.



A2.0 SURFACE PREPARATION A2.1 Introduction Good surface preparation is critical for the success of any coating system and Chartek is no exception. The primary objectives of surface preparation include:

• to provide the best bond possible between the metallic substrate and chosen (qualified) primer

• to produce a surface roughness that will maximise the bond between substrate, primer and Chartek

• to guarantee effective corrosion resistance of the whole system Acceptable surface preparation standards include, but are not limited to:

• ISO 8501: Preparation of steel substrates before application of paints and related products (visual assessment of surface cleanliness)

• ISO 8503: Preparation of steel substrates before application of paints and related products (surface roughness characteristics of blast cleaned substrates)

• SSPC (The Society for Protective Coatings) - surface preparation standards) • NACE (The National Association of Corrosion Engineers) - surface preparation standards

Applicators should be familiar with surface preparation techniques and have access to the measurement instruments required to verify the specified surface preparation requirements. For a range of definitions and abbreviations refer to Appendix I. The particular method of surface preparation required depends on the type of substrate being coated. Table A1: Chartek Surface Preparation Requirements (at the end of this section) summarises the requirements for most substrates. Where there are special conditions not shown International should be consulted for advice. Table A1 makes reference to a number of surface preparation operations that are defined below. The correct interpretation and execution of these operations is required in order to achieve the objectives mentioned above. A2.2 Degreasing The presence of surface oil or grease prevents a coating from properly adhering to the substrate and can lead to rapid failure of the whole system. For this reason, all visible oil, grease and other soluble contaminants must be removed before the application of both primer and Chartek. Degreasing is also important before blast cleaning activities.



Definition: The removal of all visible oil, grease or other soluble contaminants (SSPC-SP1). Acceptable methods of degreasing include:

steam cleaning using detergents or emulsion/alkaline cleaners followed by steam or fresh water wash to remove detrimental residues

wiping or scrubbing the surface with rags or brushes wetted with solvent (NB: use clean solvent for the final wiping)

vapour degreasing using stabilized chlorinated hydrocarbon solvents The applicator must select the method most appropriate to the situation, giving due consideration to applicable health and environmental regulations. In all cases, International recommends removing any heavy oil or grease first by scraper and completing the degreasing activity with a thorough fresh water rinse. The primer manufacturer’s recommendations regarding degreasing must also be observed at all times. A2.3 Blast Cleaning Blast cleaning is widely accepted as being the best way of preparing a metal substrate before application of a protective coating and it is a very important part of the whole Chartek application process. Chartek is very rarely applied directly to blast cleaned substrates due to the risk of flash rusting. Therefore, when a primer is used, blast cleaning should be carried out in accordance with the primer manufacturer’s instructions. Definition of degrees of cleanliness: Near white blast cleaning The general requirement prior to Chartek application is near-white blast cleaning. A near white blast cleaned surface, when viewed without magnification, shall be free of all visible oil, grease, dust, dirt, mill scale, rust, coating, oxides, corrosion products and other foreign matter except for staining (light shadows, streaks or discolorations caused by stains of rust, mill scale or previously applied coatings) limited to no more than 5% of the surface (Sa 2½, SSPC-SP10, NACE No. 2). Sweep (Brush-off) blast Removal of all loose mill scale, loose rust and loose coating with abrasive blast cleaning (Sa 1, SSPC-SP 7, NACE No. 4). Blast profile For carbon steel substrates the blast profile (Rz) must be 50 to 75 microns (2 to 3 mils). Angular abrasive should be used in order to produce a suitably sharp surface profile. The recommended method for measuring the blast profile is with replica tape.



For stainless steel substrates a suitable non-metallic abrasive should be used and a profile of 35 to 50 microns (1.5 to 2 mils) is required. For aluminium a suitable non-metallic abrasive should be used and a deep profile of 75 to 100 microns (3 to 4.mils) is required. For galvanised substrates a sweep (brush-off) blast to Sa 1 (ISO 8501-1), equivalent to SSPC-SP7 or NACE No. 4, is required, as a minimum, in order to produce a suitably roughened surface. The blast profile (Rz) should be 50 to 75 microns (2 to 3 mils). Wet abrasive blasting Wet abrasive blasting is an acceptable method of surface preparation. Surface profile and cleanliness shall be as detailed above. A qualified wet blast primer must be used with this method of surface preparation. Hydro-blasting (high pressure water jetting) Hydro-blasting may be an acceptable method of surface preparation of previously coated substrates. However, this is conditional on an adequate surface profile being revealed as detailed above. Where a suitable surface profile is not revealed, then sweep blasting or abrasive blasting will be required. A qualified wet blast primer must be used with this method of surface preparation. A2.4 Power Tool Cleaning It is not generally an acceptable method for preparing metal substrates for either primer or Chartek application; however it may used for small areas of repair. Power tool cleaning may also be used to abrade glass or fibre reinforced plastic substrates. Definition: Removal of all loose mill scale, loose rust, loose paint and other loose detrimental foreign matter (SSPC-SP 3). Small areas, for example, welds and local repair areas, may be prepared by power tool cleaning as generally prescribed by ISO 8501-1 to surface finish ST3 (or SSPC-SP3). Power tool cleaning is not acceptable for preparing larger surface areas.



Table A1: Chartek Surface Preparation Requirements

Substrate Operation Required Steel Galvanised Steel Aluminium Stainless

Steel

Glass Or Fibre Reinforced

Plastics

Degreasing

Power Tool Cleaning See Note 2 See Note 2 See Note 2 See Note 2

Near White Blast Cleaning

Sweep (brush-off) Blast Cleaning

Blow down

Primer Epoxy

primer only See Note 1 See Note 1

Blast Profile

50 to 75 microns

(2 to 3 mils)

50 to 75 microns

(2 to 3 mils)

75 to 100 microns

(3 to 4 mils)

35 to 50 microns

(1½ to 2 mils)

Abrade to remove glaze

Note 1: If there is a risk of oxidisation of the surface prior to application of Chartek a suitable primer should be used. Refer to Chartek Qualified Primer List. Note 2: Power tool cleaning is not generally an acceptable method for preparing metal

substrates for either primer or Chartek application, however it may used for small areas of repair (typically not exceeding 1m2 (10ft2), for example welds and local repair areas). It should be carried out as described by ISO 8501-1 to surface finish ST3 (SSPC-SP3)



A3.0 PRIMERS While Chartek may be applied directly to blast cleaned steel, in most cases primers are used to prevent flash rusting of the steel surface. Correct primer type and thickness are required to achieve strong bonding of Chartek to the substrate. In order to ensure optimal bonding between the Chartek and substrate, the primer must bond well to the substrate, the Chartek must bond well to the primer and the primer itself must have a high cohesive strength. Primer Thickness Optimal bonding is achieved when the primer’s dry film thickness (dft) is sufficient to just cover the peaks of the blast profile and maintain a rust free condition prior to application of Chartek. Excessive thickness produces weaker cohesive strength and may lead to premature failure of the system. For this reason, careful monitoring and measurement of primer thickness is required. Measurement of dft should be carried out with a thickness gauge that has just been calibrated on a smooth calibration plate (no compensation for blast profile is to be made). Primer Type Three types of primers may be used for steel surfaces – epoxy, zinc epoxy and ethyl silicate inorganic zinc. Tie coats may be used when required by site conditions with the latter two types. Epoxy based primers have the highest bond strength. Inorganic zincs are not as consistent and generally not recommended. However, if used, must be very carefully applied taking care to obtain the curing conditions specified by the manufacturer. The maximum allowable primer system dft’s are summarised in the following table: Table A2: Primer System Maximum Dry Film Thicknesses

Primer System Dry Film Thickness Normal Areas Overlap Areas

Epoxy primer: Carbon steel substrate

50 to 75 microns

(2 to 3 mils)

100 microns

(4 mils)

Stainless steel substrate 35 to 50 microns (1.4 to 2 mils) 75 microns (3 mils)

Aluminium substrate 75 to 100 microns (3 to 4 mils) 150 microns (6 mils)

Epoxy zinc primer 50 to 75 microns (2 to 3 mils) 100 microns (4 mils)

Epoxy zinc primer plus tie coat 75 to 110 microns (3 to 4.4 mils) 125 microns (5 mils)



NOTES:

• Epoxy tie coat (25 to 35 microns (1 to 1.4 mils) dft) should be used with zinc primers if Chartek is not applied immediately after the primer has cured or if the primer is exposed to humid or outdoor conditions prior to application of Chartek.

• “Overlap areas” refers to internal angles of structural sections and other areas where multiple

spray passes are unavoidable. Dft’s may be exceeded in stripe coat areas.

Reduction of Excessive Primer Thickness Excessive primer thickness should be reduced to the dft’s indicated in the foregoing Table A2. The preferred method to be used is abrasive sweep blasting. Sanding with P80-P100 grade aluminium oxide abrasive paper may be suitable for small areas; however care should be taken to prevent polishing of the surface which would lead to inadequate adhesion of the Chartek. Polishing must be avoided and frequent changes of the abrasive paper should be made.

After primer reduction surfaces should be cleaned of dust and contaminants, potable water washed and thoroughly dried prior to the application of Chartek. Care should be taken to ensure that systems have reached sufficient levels of cure prior to overcoating with Chartek. Generally this will not be less than three days. However, the primer manufacturer and International should be consulted for minimum and maximum cure times. It should be recognized that a thick film epoxy coating (Chartek) is being applied over the primer system. The primer manufacturer’s application instructions should be followed. It is the responsibility of the applicator installing the Chartek to assess the condition of the primer coating before the Chartek is applied. Should the primer’s suitability for the overcoating with Chartek be in doubt in any way, for example, primer type, thickness, condition etc., the primer manufacturer and International should be consulted before the application of Chartek. Qualification of inorganic zinc primer systems requires testing to ASTM D-1002 and the system meeting the minimum cohesive strength values set by International Protective Coatings. International maintains a current list of qualified primers at each of its sales offices. It is the application contractor’s responsibility to ensure that only these products are used. NOTE: International Protective Coatings is able to offer a complete package of primer system, fireproofing, thermal insulation (if required) and topcoat.



A4.0 QUALIFIED CHARTEK APPLICATION CONTRACTORS A4.1 Chartek Products Not Applied Within Two Years Qualified Chartek Application Contractor Companies who have not applied Chartek products within a period of two years must undergo Chartek refresher training prior to starting any Chartek application work. If the Contractor Company can prove they have employed Chartek qualified and experienced Supervisory/QC personnel and hands-on application personnel, the refresher training may not be necessary.



A5.0 CHARTEK THICKNESS MEASUREMENT A5.1 Thickness Measurement As the fire protection rating is determined by the Chartek thickness, it is imperative that applicators constantly measure and record thicknesses during application. Chartek is a 100% volume solids product, so wet and dry film thicknesses are the same. The following procedure for thickness measurement must be followed. A. Method for measuring wet Chartek thickness: The recommended method of measuring wet thickness is to use a pre-cut bridge gauge having a width of approximately 25mm (1”), typically made from a putty knife. Notch or pin gauges are not acceptable because they limit the measurement to one point. The gauge should just touch the rolled Chartek surface. International strongly recommends the continuous use of the bridge gauge by all members of the application team (sprayer, trowellers and rollers). This is the only way of ensuring the design thickness will be applied to the whole surface. B. Method of measuring dry Chartek thickness: Dry film thickness can be measured by either of the following methods:

drill small holes typically 2 to 3mm (1/8”) in diameter and checking the Chartek thickness with a depth gauge (care must be taken not to damage the substrate and to refill the holes with Chartek as soon as possible);

using an electromagnetic or ultrasound thickness gauge (care must be taken to correctly calibrate the gauge immediately before taking any readings on a smooth calibration plate). Electromagnetic gauges cannot be used if the Chartek is reinforced with wire mesh.

Measurement Criteria It is recognized that the applied Chartek layer will never be perfectly even and that areas of lower than specified design thickness (“valleys”) are compensated by areas of higher than design thickness (“peaks”). Consequently, the following measurement criteria must be followed: Location It is recommended that no thickness measurements are taken within 25mm (1”) of the edge of structural sections and divisions, or within 25mm (1”) of the join of flange to web of, for example, an ‘I’ section. Thickness measurements should be taken randomly over the remaining areas of the coated structural sections and divisions with a frequency described below. Frequency The number of thickness readings to be taken shall be agreed by all parties before application commences.



As a guidance, it is recommended that readings are taken as follows: • ‘I’ sections, tee sections and channels:

Webs: 2 readings per metre length on each face Outer flanges: 2 readings per metre length on each face Inner flanges: 1 reading per metre length on each face

• Square or rectangular angles and hollow sections:

2 readings per metre length on each face • Circular hollow sections:

8 readings per metre length spread evenly around the section • Divisions and large flat plates:

2 readings per 1m2

Acceptance Criteria Unless specifically stated otherwise in the project documentation, the minimum acceptable thickness at any point shall not be less than 85% of the design or certified thickness up to a maximum of 1.5mm (1/16”) less than the design or certified thickness. In other words, for thicknesses up to and including 10mm (3/8”) the minimum allowable thickness is 85% of the design or certified thickness. For thicknesses above 10mm (3/8”) the minimum allowable thickness is the design or certified thickness less 1.5mm (1/16”). In all cases, the average thickness must be at least the specified passive fireproofing design or certified thickness. Where any single thickness reading is found to be less than the 85% or 1.5mm criteria of the design or certified thickness, a further 3 readings shall be taken within a 300mm radius of the low reading. Should one or more of the additional readings also be less than the 85% or 1.5mm criteria, further readings shall be taken to establish the extent of the area of under-thickness and the affected area shall be brought up to the required thickness. The above measurement criteria meets or exceeds the requirements specified in ASFP TGN 003: Part 1, SSPC-PA2 and ASTM E605. Thickness readings should be accurately recorded on suitable quality control forms. See the Quality Control Manual for Chartek Fireproofing Systems Application for further details.



A6.0 TOPCOATS Chartek has been extensively tested to industry recognised standards to demonstrate its ability to withstand weather and environmental exposure, both with and without topcoats. Generally Chartek will be topcoated to meet owners’ colour schemes and finish requirements. International Protective Coatings recommends the use of topcoats in all external applications. There are specific situations where the use of a topcoat is considered mandatory and these include:

Use of Chartek on offshore installations or where coastal location conditions are similar to an offshore environment.

Area of high UV exposure: like all epoxy products, Chartek may chalk when exposed to high levels of UV for prolonged periods. This can result in fading of the original colour.

Areas of high moisture exposure: where the Chartek is likely to be in continuous contact with moisture, such as the upper surfaces of horizontal decks and flanges and areas in the splash zone.

Coarse sprayed finishes: a stippled finish may collect airborne contamination and result in shading of the Chartek surfaces.

It is recommended that Chartek is topcoated when it is sufficiently cured and the surfaces are clean and dry, and prior to any possible contamination. Recommended minimum overcoating intervals: Temperature Minimum

°C (°F) (hours) 15 (59) 12 25 (77) 6 40 (104) 4

Maximum overcoating times are dependent upon environmental exposure, type of topcoat system used and other factors. The topcoat manufacturer should be consulted. Excessive rollering with solvent can, in extreme cases, cause amine bloom on the surface of the Chartek. This is not acceptable for application of topcoats. If amine bloom occurs, surfaces must be suitably washed with one of the approved methods in Section A2.0, prior to application of any topcoat. Chartek can be overcoated with a wide range of suitable topcoats to meet specific requirements. For example, International’s Interthane® 990 and Interfine® 878 are recommended topcoats. For heavy duty protection and to prevent shading on stippled finishes, International recommends one of the following topcoat systems:



1. Two coats of Interthane® 990 or Interfine® 878 at 50 microns (2 mils) dft. 2. One coat of epoxy polyamide primer at 75 microns (3 mils) dft plus one coat of

Interthane 990 or Interfine 878 at 50 microns (2 mils) dft. On all occasions, the recommendations of the topcoat manufacturer should be sought regarding application and service conditions.

A6.1 Special Applications A. Non-slip finishes

For upper horizontal surfaces where foot traffic will be experienced, a non-slip coating should be provided as a topcoat. The non-slip coating should incorporate an inert aggregate such as quartz and be of sufficient thickness to properly fix the aggregate to the surface.

Recommended International non-slip deck systems:

Interzone® 954 500 to 1000 microns (20 to 40 mils) Interzone® 505 500 to 1000 microns (20 to 40 mils) Interzone® 1000 500 to 1000 microns (20 to 40 mils)

All the above products should incorporate an appropriate aggregate such as GMA132.

B. Heavy moisture exposure For areas of heavy moisture exposure, such as the undersides of cold operating vessels or

upper horizontal areas, it is recommended that a topcoat of minimum 250 microns (10 mils) dft be provided. For horizontal surfaces, the Chartek should be sloped sufficiently to avoid ponding.

Note: For splash zone areas, there are specific instructions covered in Technical Note TN/F/058 “Use of Chartek in Way of the Splash Zone” available from International Protective Coatings or www.chartek.com



A7.0 REMOVAL AND REPAIR, ADDITIONAL WORK, WELD CUTBACK AND REPAIR OF DAMAGED AREAS A7.1 Removal Chartek can be removed after application for additional work, e.g. welding of attachment, by the use of handheld air driven pistol chisel using a sharp chisel bit of the appropriate width, usually 25 or 50mm. The tool should be used to split the bond between Chartek and the steel, taking care not to gouge or damage the steel substrate. N.B.: Operators should wear suitable dust masks and eye protection. A7.2 Weld Cutback For small weld operations, such as addition of clips and hangers, a cutback of 50mm from weld area should be made. For large welds of heavy angle or other members, a cutback of 75mm should be made. Chartek can be removed with a fair degree of accuracy on an identified cut line without damage to surrounding material. After welding has taken place, the surrounding Chartek should show no sign of discolouration or damage. If discolouration, change of applied colour or ‘browning’ is seen, then discoloured material should be removed back to sound material. In the case of allowance of cutback for welding of structural members and structural members themselves which are to be pre-coated with Chartek prior to assembly, the following recommendation is made: No weld preheat: 300mm either side of weld Weld preheat: See following table

Preheat °C (°F)

Duration Hours

Free Distance mm (in)

100 (212) 4 to 8 750 (30) 100 (212) 9 to 12 1000 (40) 150 (302) 4 to 8 750 to1000 (30 to 40) 150 (302) 9 to 12 1000 to 1250 (40 to 50)

The above figures are expected to be conservative, actual distance is a combination of factors, including mass of steel at weld junction and method of preheat. As previously noted, discolouration of surrounding material will indicate insufficient cutback or overheating of area and will have to be removed. REPAIR OF DAMAGED AREAS – CUTBACK Repair of damaged areas, in the fabrication yard or during service life, and cutback areas should follow the undermentioned procedures:



1. Application conditions must conform with specified conditions for primer topcoat and Chartek application.

2. Repair of damaged primer system should conform with instructions of specification for surface

treatment and coatings. All traces of corrosion of substrate steel will have to be removed and surface prepared to the required level.

3. Should the repair area be large and require mesh, as defined by requirements for mesh

application for Chartek, this should be attached as detailed in the Chartek Application Manual. 4. The ‘border’ area of surrounding Chartek should be checked for soundness and adhesion in the

joint area. 5. The surrounding ‘border’ area of 50-75mm of Chartek should be roughened by abrasives to

remove topcoat and/or ‘glazed’ finish of Chartek to ensure sound adhesion of new material. After roughening, a suitable PMA solvent should be used to ensure that the area is clean.

6. Chartek should be applied to the repair area and interfaced with the existing material bringing

the repair area to the same coating thickness. Application should follow International Paint’s procedures, noting that trowel application of Chartek is acceptable for repair areas.

7. Ensure the Chartek material used for repairs and patching meets the required specification in terms

of fire protection rating, reinforcement and thickness. 8. Topcoat replacement and repair should follow International Protective Coatings’ guidelines and

topcoat manufacturer’s instructions.



A8.0 SAFETY AND ENVIRONMENT Chartek is an epoxy based compound and can be a skin irritant to some people. It is therefore good practice to keep covered up and avoid skin contact. Eye protection should always be worn. It is important to stay as clean as possible. Periodic washing with soap and warm water is recommended to minimise continued contact with the material. Appropriate Material Safety Data Sheets and local Health & Safety personnel protection requirements must be observed.

PMA is a solvent that is benign in nature. However, in common with all solvents, care should be taken during its use of PMA. Work areas should be adequately ventilated. Containers should be kept closed and rollers only lightly sprayed with the solvent. If PMA comes into contact with the eyes flushing with clear, clean water for 15 minutes is recommended followed by suitable medical attention. Consult PMA manufacturer’s material safety data sheets for questions relating to health and safety issues.

As Chartek is delivered primarily through high pressure spray equipment, there is always a possibility that a fitting or line could fail. Therefore, any maintenance operation or changing of spray tips should be done with all pressure off the machines. If it is suspected that spray lines have become clogged, extreme caution should be used when unscrewing fittings, as it may not be possible to vent the pressure. Refer to the manufacturer’s specific instructions with regard to equipment safety.

For instruction on the disposal of Chartek refer to Appendix H.



A9.0 SPECIAL APPLICATIONS A9.1 Repair Procedure for Damaged or Delaminated Chartek

A. Mark out the area to be repaired. B. Using a disc grinder, cut through the Chartek and mesh (take care not to damage substrate). C. Using chosen tools (hammer and chisel or pneumatic chisel), cut into patch to remove damaged

Chartek. Make sure all uncured material is removed. D. Alternatively, ultra high pressure water jetting (UHP) can be used to remove Chartek and is

recommended as the removal method when Chartek is applied to pressure vessels and piping. E. Reinstate primer to specification. Small areas, for example, welds and local repair areas, may be

prepared by power brushing as generally prescribed by ISO 8501-1 to surface finish ST3 (or SSPC-SP3). Power brushing should not be used as a primary surface preparation method for large areas.

F. Abrade adjacent surfaces for a distance of 150mm (6”) from edge of repair area. G. Reinstate mesh to specification. If the repair area is less than 150mm x 150mm (6 x 6”), meshing

is not necessary, except for jet fire areas. H. Reinstate Chartek to specification, in terms of fire protection, reinforcement and thickness, taking

care to smooth over the repair area edges. Reference Section A7.0 of this Manual.

Appendix F, “Procedure for Inspection, Test and Replacement” for Chartek fireproofing systems contains comprehensive instructions on the repair and replacement of passive fire protection systems. The procedure should be used, as necessary, in association with the current Chartek Application Manual. NOTES: A. For repairs, Chartek may be applied directly to blast cleaned steel. B. Masking should be done around the area to be repaired in a square or rectangular shape. This will

give the patch a clean appearance once completed. C. If any existing mesh is left from original installation, whole or edge pieces, be sure that all loose

Chartek is removed from around or behind the mesh. This will prevent the formation of voids or adhesion problems.

D. Refer to hand application for examples. A9.2 Coatbacks The coatback distance for all secondary attachments to primary members is typically 450mm (18in), measured from the extremity of the primary member along the secondary attachment. However, secondary members and minor attachments that either individually or collectively, in a typical length of 1 metre (for structural members) or 1m2 (for divisions), do not exceed 3000mm2 (4.65in2) in cross-sectional area need not be provided with any coatback fire protection material.



Summary of coatback requirements: Cross-sectional area (per linear metre) ≤ 3000mm2: No coatback > 3000mm2: Coatback Whilst there is no specific standard relating to coatbacks, this is often taken as industry norm to deal with a heat transfer situation. Note, however, that the requirements of owners, classification societies, designers and engineers may require that projects have coatback distances different to this figure or indeed no coatback at all. Where doubt exists, consultation with the project specification, design engineer, classification society or owner should be made.



SECTION B – CHARTEK 7

ID Rev. Date APP MAN UK 0 01/05/07

Chartek® Application Manual Page 2 of 60


B1.0 CHARTEK PACKAGING AND STORAGE B1.1 50kg (110lb) Kit For plural component spray equipment, Chartek is supplied in a 50kg (110lb) kit comprising of two drums of grey coloured resin (Part A) and one drum of light coloured hardener (Part B). Part A (2 Drums)

35.48kg (78.2 lb)

Part B (1 Drum)

14.52kg (32.0 lb)

Total 50.00kg 110.2 NOTE: 50kg (110lb) kits are only suitable for use with plural spray equipment. B1.2 20kg (44.1lb) Kit For single component pumps and trowel application, Chartek is supplied in a 20kg (44.1lb) kit comprising of one part filled drum of grey coloured resin (Part A) and one plastic pail of light coloured hardener (Part B). This allows the hardener to be decanted into the Part A resin for mixing. Part A 14.2kg (31.3lb)Part B 5.8kg (12.8lb)Total 20.0kg (44.1lb) NOTE: 20kg (44.1lb) kits can also be used with plural spray equipment. B1.3 Cast Grade For casting work a less viscous version, Chartek cast grade, is available. For further details contact International Protective Coatings. B1.4 Storage Conditions for Chartek Chartek should be stored dry, indoors and out of direct sunlight. The following storage temperature ranges must be maintained:

• Minimum 1°C (34°F), maximum 30°C (86°F)




B2.0 CARBON FIBRE MESH REINFORCEMENT B2.1 Meshing Designs The meshing requirements are given below. Particular attention should be paid to the Chartek type and thickness, and fire type. Refer to Appendix A for HK-1TM mesh design drawings. Table B1: Mesh Requirements Use Hydrocarbon (Pool) Fires Jet Fires

Structural steel I and Open Sections

HK-1 mesh installed at mid film thickness with 50mm (2”) overlaps. Beams and columns with webs less than 250mm (10”) deep do not require mesh on webs.

HK-1 mesh installed at mid film thickness with 150mm (6”) overlaps and with 100% coverage.

Structural steel Hollow Sections HK-1 mesh installed at mid film thickness with 50mm (2”) overlaps and with 100% coverage.


Tanks, Vessels and Pipework HK-1 mesh installed at mid film thickness with 50mm (2”) overlaps and with 100% coverage.


Divisions – Bulkheads And Decks HK-1 mesh installed at mid film thickness with 50mm (2”) overlaps and with 100% coverage.


B2.2 HK-1TM and HK-1 (M)TM Carbon Fibre Mesh Reinforcement HK-1 and HK-1 (M) carbon fibre meshes are knitted cloth of carbon filaments and glass thread. Both meshes are equivalent to each other with respect to their construction and constituent materials, and their performance. The designation of HK-1 and HK-1 (M) relates only to their manufacturing source. B2.3 Packaging of HK-1 and HK-1 (M) Carbon Fibre Mesh Reinforcement HK-1 and HK-1 (M) are available from International Protective Coatings in 165m2 (1776ft2) and 167.3m2 (1800 ft2) rolls respectively. B2.4 General Rules for Meshing 1. Cut mesh to required sizes before starting Chartek application. 2. Apply mesh to wet Chartek at approximately mid thickness. 3. Roll the mesh thoroughly into the wet Chartek with short nap rollers dampened with PMA

solvent. 4. Overlap adjacent pieces of mesh by at least 50mm (2”). For jet fire applications, overlap

by at least 150mm (6”). 5. To minimise waste the straight carbon (black) fibres are parallel to flange edges and the axis of

hollow sections. 6. After installing HK-1, either continue to build up the required thickness or spray a light coat of

Chartek over the mesh to leave a good key for subsequent coats. 7. For jet fire applications the minimum overlap shall be 150mm (6”) and the HK-1 shall cover all

surfaces (i.e. 100% coverage without any gaps) of the member regardless of dimensions.




B3.0 METAL MESH REINFORCEMENT B3.1 Metal Mesh Reinforcement Uses Metal mesh reinforcement may be required for installations where NORSOK requirements are being strictly enforced by the client or approval authority. Additionally, metal mesh reinforcement may be required for specified jet fire applications. The general method of mesh attachment and retention is by welding pins to the substrate. Refer to Appendix B for metal mesh design drawings. B3.2 Metal Mesh Reinforcement Types The metal mesh reinforcement systems used are:

• 12.7 x 12.7mm (½” x ½”) square opening, 1mm diameter (19 gauge) galvanised wire mesh (“hardware cloth”);

• 12.7mm hexagonal opening, 0.75 to 0.9mm diameter (20-22 gauge) galvanised wire mesh

(“poultry netting”). In both cases, the mesh must be galvanised after manufacture. All wire mesh, mesh stand-off devices (when required) and lacing wire must be galvanised. For stainless steel substrates and jet fire applications where required by the project, stainless steel mesh must be used. Stainless steel mesh should be Type 316 (18-10) with 12.7 x 12.7mm (½” x ½”) square openings of 1mm diameter (19 gauge) wire mesh. All pins, mesh stand-offs and lacing wire must also be stainless steel. B3.3 Installation of Pins 1. Weld pins shall be 25mm (1”) to 38mm (1½”) long and 3mm (1/8”) in diameter. (Note: 2mm (5/64”)

diameter pins may be used for Chartek 7 thicknesses up to 7mm (275 mils)). 2. Pins must be tested for weld integrity by achieving a 95% success rate on bend tests of at least

20 pins each day (see the Quality Control Manual for Chartek Fireproofing Systems Application for details).

3. Spacing of pins should generally be no more than 300mm (12”) on centres in any direction, unless the specific fire design allows less frequent spacing.

4. The normal method of pin attachment is by capacitance discharge welding. 5. Weld areas must be suitably ground before welding to remove all mill scale, rust and other

contamination. 6. Where grinding has been done in the paint system to facilitate welding, the area must be

cleaned and touched up with an International Protective Coatings’ qualified epoxy primer. NB: It is more practical to install the pins prior to blasting and priming.

7. For carbon steel substrates, copper coated mild steel pins should be used. For aluminium or stainless steel substrates, pins must be made of compatible materials.

8. The use of adhesive bonded pins or studs is not permitted.




B3.4 General Rules for Metal Meshing 1. Adjacent pieces must not have more than 50mm (2”) gap between them.

For jet fires, adjacent pieces of mesh shall be installed as close as reasonably possible to each other and, in all cases, gaps shall not exceed 25mm (1”). Effectively the mesh shall provide 100% coverage including web depths of less than 250mm (10”).

2. Mesh shall be brought as close as possible to the point where the Chartek 7 terminates. 3. Chartek 7 shall be applied as soon after mesh installation as possible to avoid surface

contamination. 4. Chartek 7 shall always be trowelled to ensure that the mesh is fully encapsulated and no voids

around the strands of mesh are formed. Table B2: Meshing Designs for Structural Members and Tanks

Metal Mesh Reinforcement

Chartek 7 Thickness

Flange Edges Webs Over 250mm (10”) in Depth

Hollow Sections and Tanks

Up to 12mm A A A or C

13mm+ B B B or D A = 12.7 x 12.7mm (½” x ½”) square opening 1mm diameter (19 gauge) galvanised wire mesh

(“hardware cloth”) pinned or tied to the surface B = 12.7 x 12.7mm (½” x ½”) square opening 1mm diameter (19 gauge) galvanised wire mesh

(“hardware cloth”) stood off 3mm from the surface C = 12.7mm (½”) hexagonal opening 0.75mm - 0.9mm (20-22 gauge) galvanised wire mesh

(“poultry netting”) pinned or tied to the surface D = 12.7mm (½”) hexagonal opening 0.75mm to 0.9mm (20 to 22 gauge) galvanised wire mesh

(“poultry netting”) stood off 3mm (1/8”) from the surface

Note on NORSOK M-501 metal mesh requirements: For projects where NORSOK Standard M-501 is specified there may be a requirement for welded pins and metal mesh. The project specification should be closely consulted. Note on jet fire metal mesh requirements: Metal meshing designs for jet fire exposure are detailed in project specifications and in accordance with classification society approvals.




B4.0 CHARTEK APPLICATION WITH SINGLE LEG AIRLESS SPRAY EQUIPMENT B4.1 Ambient Conditions Suitable application conditions are of critical importance for the successful application of Chartek. Consequently, Chartek should only be applied when the ambient conditions are within the following parameters: • Air temperature: minimum 10°C (50°F) • Relative humidity: maximum 85% • Surface temperature: at least 3°C (5°F) above dew point temperature However, Chartek may be applied at an air temperature minimum 5°C (41°F) using plural spray equipment only, recognising that the time to cure will in such applications be extended. Additionally, there may also be a higher propensity for amine bloom formation which would affect overcoating with further layers of Chartek, where required, and may affect overcoating with topcoats. For such low air temperature applications, plural equipment is the only recommended dispensing method. B4.2 Surface Cleanliness To ensure proper adhesion of Chartek to the primed substrate, the surfaces to be coated must be dry and free from oil, grease, dirt or any other contaminants that have been deposited since surface preparations were completed. It is the applicator’s responsibility to inspect all surfaces to be coated and clean them if necessary (see the notes on degreasing in Section A2.2). Ambient conditions are of critical importance for a successful application. If they cannot be kept within the above parameters, Chartek application may only proceed if adequate environmental protection is provided. B4.3 Primer and Surface Preparation It is the applicator’s responsibility to verify that the correct primer type (included in the list of qualified primers), thickness (as specified in Section A3.0) requirements are complied with. It is also the applicator’s responsibility to ensure that the preparation of the surface which is to be overcoated with Chartek is in accordance with the requirements of this Application Manual and other documents that may be applicable. For acceptance of the primed surface, checks shall include, but not be limited to, the following: (a) The surface profile is in accordance with this Application Manual and other documents that

may be applicable. (b) The surface condition at the time of primer application, both in terms of degree of visual

cleanliness and presence of surface contaminants. (c) That the primer is qualified by International for use with Chartek.




(d) That the applicator has access to, and is familiar with, the primer manufacturer’s application data, and that the application process and environmental conditions are in compliance with the primer manufacturer’s requirements.

(e) Primer thickness values shall not exceed the tolerance levels stated in Section A3.0, Table A2: “Primer System Maximum Dry Film Thicknesses”.

(f) Age and condition of primer at point of overcoating with Chartek. See Appendix G, Technical Note TN/F/083 “Overcoating of aged and zinc primers”.

It is the applicator’s responsibility to ensure that the primed surface and the primer itself are in an acceptable condition for overcoating with Chartek. Such factors as ageing of the primer (degradation and surface chalking), contamination, rust bloom, etc. shall be considered when determining a surface’s suitability before overcoating with Chartek. Where there is any doubt as to a primer’s acceptance, the primer manufacturer should be consulted and International Protective Coatings advised. NB: Overcoating a primer system with a 100% solids epoxy material such as Chartek is different to overcoating with further layers of material, especially solvented materials. Consequently, it is important that the primer manufacturer should be fully informed of the overcoating system and purpose of that system when directing any questions to the manufacturer concerning overcoating. International should be consulted where any doubt exists.

B4.4 Kit Size For single leg airless spray pump application, Chartek is supplied in a 20kg (44.1 lb) kit comprising of one part-filled drum of grey coloured resin (Part A) and one plastic pail of light coloured hardener (Part B). Use of this kit size ensures provides sufficient space in the drum to allow the Part B hardener to be decanted into the Part A resin for mixing. Only full kits should be mixed to ensure the material is mixed in the correct ratio. B4.5 Material Preparation for Single Leg Airless Spray Application Material preparation for single leg airless spray application requires the Chartek to be brought up to the ideal temperature for spraying. Temperature is critical to ensure the correct viscosity to allow good spray application to be achieved. This needs to be carefully monitored, too cold and the material will not atomise and spray, too hot and the pot life will be reduced and there will be the risk of blockages and curing of materials in the lines. For guidance on working pot life see the following table:

Figure B1: 20kg (44.1 lb) Kit




25°C (77°F) 30°C (86°F)

30 minutes 20 minutes Note: Pot life is a guide to the time from mixing of the kit to the complete spray-out of the mixed kit and ability to trowel and roll the material once applied to the steel. It is not a measure of time for mixing to start of spraying. Once a kit is mixed, spraying of the kit should commence as soon as possible, ideally within a few minutes, as the exothermic reaction of the mixed material in the drum will cause the temperature to rise and pot life to be dramatically reduced. Prior to spraying Chartek with single leg airless spray equipment, the material should be brought to a temperature of 25 to 30°C (77 to 86°F) for a minimum of 24 hours prior to use. Material temperature should be measured using a thermometer (such as a digital temperature probe type). Best spray results will be achieved when the material temperature is within the following range:

Optimum mixed temperature oC

30 to 35 Accelerated methods of heating the Chartek containers, such as electrical heaters in direct contact with the containers or hot water baths, are not permitted. Such methods can cause overheating of the outer layers of Chartek in the container, which may produce undesirable changes to its properties (including shorter pot life). B4.6 Heated Storage Units To achieve the correct temperatures it may be necessary to use heated storage units, especially in cold and temperate climates. Such storage units are typically built from standard site storage containers. The container will generally be lined with thermal insulation (see photographs below) and should be suitably ventilated.

Figure B2: Digital thermometer and probe.




Figure B3: Typical storage container, showing insulation on inside In addition the container will normally require to be fitted with a thermostatically controlled heater. Heater and electrical installation should be carried out by a qualified electrician to meet prevailing regulatory requirements. Heaters should be protected by guards to prevent accidental damage and also to prevent Chartek drums being placed directly against the heaters. Alternatively heaters may be installed under a grated floor allowing the heat to rise through stacked drums of Chartek. Figure B4: Example fin tube heaters (heater type dependent on local regulations) The number of heaters used and their power rating will depend on the size of container used, local climate conditions and amount of insulation fitted. Heater manufacturer should be consulted for advice. For smaller projects, or where greater portability is required, custom made hot boxes can be used, these should be of adequate size and number to allow sufficient material to be held at the correct temperature for the work to progress smoothly. QA/QC measurement of storage conditions should be maintained. It should also be noted in tropical or desert climates it may be required to fit refrigeration equipment to ensure the material does not become too hot. B4.7 Mixing Equipment There are two critical aspects to mixing Chartek, firstly to ensure that the two components are thoroughly mixed and secondly to undertake the mixing operation as quickly as possible to ensure maximum working pot life is maintained.




Utilising the correct equipment can assist the process greatly. Chartek is a high viscosity material and is difficult to mix; normal paint mixers will not be able to mix Chartek sufficiently thoroughly or quickly and should not be used. The mixer should be a high torque, variable speed, paddle mixer of minimum 5 HP air motor or 1000W/110V electric motor. It should be equipped with 250mm (10”) diameter paddle. For best results, the mixer should be mounted on a power ram base to ease the effort required and to allow vertical movement of the paddle blade. The mixer should incorporate a drum stand or clamp to ensure the drum is held firmly during the mixing operation.

Proprietary Chartek mixing equipment is available from a number of manufacturers. B4.8 Use of Solvent If a single leg airless spray pump application is utilised, the Chartek must be premixed and generally will require the use of solvent to reduce viscosity for mixing and spraying and to extend the working pot life of the material. Propylene Methoxyacetate (PMA) solvent is the approved solvent type for use with Chartek. It is essential that the solvent is of high quality, clean and not contaminated with water or other contaminants. It must be of “Virgin”, “Technical”, “Laboratory” or “A1” grade and with certified water content less than 100ppm. It should be stored in drums/containers that are airtight and re-sealable. Under no circumstances should recycled or reclaimed solvents be used or old, used containers refilled. International Protective Coatings’ product GTA123 is recommended.

Figure B5: Suitable Chartek mixing equipment




The solvent is added to Part A (resin) of the Chartek kit. The amount of PMA solvent required varies with initial material temperature but typically will be 0.5 litres (1 pint) per full 20kg (44.1 lb) kit of Chartek. At most, a maximum of 1.0 litre (0.25 US gallons) may be used per full 20kg (44.1 lb) kit of Chartek. The solvent used for mixing should also be at room temperature (typically 20°C (68°F)) to prevent it cooling down the Chartek when added. B4.9 Mixing Procedure Kits should not be mixed until they are ready to be used. Once mixed the kit should be sprayed as soon as possible, ideally it should be loaded into the machine within a few minutes of mixing. After addition of PMA solvent into part A it should be mixed to incorporate the solvent fully within the resin. The mixing should begin slowly and speed built up gradually. When Part A has reached a smooth consistency, Part B is then poured into the Part A container, scraping the sides of the Part B container to empty it completely, ensuring correct ratio of material is mixed. Only full kits should be mixed to ensure the material is mixed in the correct ratio. Again, the mixing should begin slowly and speed built up gradually, mixing carefully until a smooth texture and uniform colour are achieved. The shearing action of mixing the material will cause the material to heat up so temperature should be checked after mixing. In addition, once the material is in a mixed state and left in the drum, the exothermic nature of the reaction will cause the material to continue to increase in temperature, greatly reducing the available pot life. If spray operations are held up for any reason then extended pot life can be achieved by emptying out mixed Chartek on to flat surfaces, spreading it out to reduce exothermic reaction and using it for trowel application. B4.10 Single Leg Airless Spray Equipment Only airless single leg spray equipment qualified by International Protective Coatings should be used. Typical equipment specification would be as follows: Pump Compression Ratio

Ratio to be a minimum of 68:1, ideally 74:1 or greater, fitted with check valve to eliminate spray fan fluctuation

Figure B6: Modified Airless Spray Unit




Air Motor Graco Premier (or equivalent) mounted on a power ram with

a follower or induction material feed plate

Fluid lines ¾” ID, 15 to 20 metres (50 to 65 feet) long, pressure rated to meet the required high pressures of the pump. Insulated if required.

Whip Line ½” ID, 4.5 metres (15 feet) long, pressure rated to meet the required high pressures of the pump

Spray Gun High pressure airless spray gun fitted with swivel.

Spray Tip 0.035” to 0.041” I.D. “reverse-a-clean” or equivalent airless spray tips. For smaller structural steel a narrow spray fan pattern should be used, e.g. size 3 or 4 thou tip. For larger structures and fire divisions a wider spray fan pattern may be used, e.g. size 5 or 6 thou tip.

Figure B7: High Pressure Spray Gun

Notes on Spraying: There should be sufficient area available to spray and enough manpower to service the application, operate the unit and mixing of material. Frequently shutting down the spray unit will causes wasted time and material. During production if the machine starts to require more pressure and the spray fan diminishes, then this is a good indication that cleaning or flush of the machine is necessary. International Protective Coatings’ GTA007 solvent is recommended for cleaning and flushing of equipment. Flushing the pump with cold solvent will cause the internals of the machine to be cooled down, again this cooling effect will affect the sprayability of the Chartek when it is reintroduced into the pump. It is therefore recommended that the solvent used for flushing should also be at room temperature (typically 20°C (68°F)). The addition of more solvent or increasing the pressure will not solve the problem but will only reduce film build up and take the machine passed its safe working parameters. The follower plate situated at the base of the leg should be removed prior to the unit being introduced into solvent. Inside every single leg spray unit there are areas known as “black spots”. Black spots accumulate mixed material which cannot be dislodged with the flow of freshly mixed material, these black spots are a function of the machine design and this problem is not unique to Chartek. Even with the system being flushed with thinners every sixth or seventh kit, these areas will still have traces of material trapped, this material will start to cure and restrict the movement of the leg’s shaft. It is therefore highly recommended that the leg be fully striped and dismantled at the end of each working shift and all moving parts be thoroughly cleaned either by steam cleaning or with solvent.




During stoppages in the day’s production (lunch breaks, etc.) the machine must be circulated with solvent (GTA007) and the spray gun and tip must also be removed and immersed in solvent. B4.11 Single Leg Spray Application Method In order to ensure trouble free operation of this type of pump the material must be maintained at the correct temperature. It is therefore necessary to provide controlled heated storage for the Chartek and advisable to place the machine in a modified insulated container for work at low air temperatures. There should be sufficient area available to spray and enough manpower to keep up with the gun. Frequently shutting down spray machines causes wasted time and material spent cleaning and causes pressure build up in the material lines and spray gun, which may represent a safety hazard. The first coat of Chartek is sprayed and quickly trowelled into the surface to ensure good wetting and even thickness. Trowelling also helps to thoroughly encapsulate any pre-installed mesh and reduces the formation of air pockets. With airless spray applications using qualified equipment and where HK-1TM or no mesh is being used, trowelling the first coat may be eliminated. In these instances it is essential that there is thorough atomisation achieving consistent even spray fan (no fingering) and 100% wetting of the surface. If trowelled, trowel marks and high points are knocked down with a short nap roller dampened with PMA solvent. The real purpose of this rolling is to achieve a uniform thickness of the coat, which allows uniform build up of subsequent coats and ultimately the correct final thickness. Rolling also serves to produce a smooth surface finish, when required. Two precautions to take with rolling are:

1. If the Chartek has not gelled (started to cure) sufficiently, it can sag or slump. 2. Too much solvent on the roller can reduce the cure rate if it is forced into the wet Chartek.

For subsequent coats, sufficient time must pass for the applied Chartek to gel (“set up” or partially cure) in order to support the weight of the additional material. Preferably, subsequent coats should be applied when the previous coat is still tacky. Where practicalities prevent “wet on wet” application, overcoating time should be reduced to a minimum. When the overcoating time is longer than 24 hours, a sprayed holding coat should be applied to leave the Chartek with a good key to improve the adhesion of the next coat. The holding coat is produced by raising the pump output pressure to give a wide fan and increased atomisation. The spray pass is much faster than normal and the result is a coarse finish that promotes good bonding with subsequent coats.




Beyond 24 hours, surfaces must be suitably washed with one of the approved methods described in Section A2. It is imperative that surfaces are clean and thoroughly dry before additional coats of Chartek are applied. When using HK-1 mesh and more than 24 hours is expected before overcoating, it is a requirement that a sprayed holding coat is applied over the HK-1 mesh to prevent contamination entrapment. The final coat, when applied to a ‘wet’ surface, should be sufficiently thick to allow good ‘flowing out’ and to minimise surface roughness and to achieve the specified final thickness. In applying a final coat to a hardened surface the thickness should be no less than 3mm (1/8”) to ensure adequate adhesion to the hardened surface. When spraying in cold conditions, the pump should be located in a heated area, ideally the same area that is used to store the Chartek at a sprayable temperature. Hoses may be insulated and ambient temperature parameters must be frequently checked and maintained. In hot conditions, the spray unit and Chartek must be located in an air-conditioned environment. Hoses should be insulated and wrapped with heat reflecting tape. It may also be necessary to raise hoses above the ground in extremely hot environments. High substrate temperatures should be avoided by providing suitable shade cover and air-conditioning of the area immediately surrounding the workface may also be necessary. B4.12 Water Contamination CAUTION: If rain or condensation occurs during application or shortly thereafter, moisture may be absorbed into the uncured material. In addition, an amine bloom may form on the Chartek surface. These conditions will affect intercoat adhesion. Take the following action if water contamination occurs: Contamination Action Cured Chartek (fresh water): Dry and solvent wipe Cured Chartek (salt water): Warm water wash - maximum 60°C (140°F)

Dry and solvent wipe Uncured Chartek: Remove source of moisture

Allow Chartek to cure Dry and solvent wipe Remove and replace all uncured material

B4.13 Surface Finish Discontinuities, pinholes, voids or isolated deposits of excess thickness in the coating are not acceptable. Where there is the risk of water ponding on horizontal surfaces, the Chartek should be sloped sufficiently to avoid ponding.




Samples of the surface finish acceptable to the client, a reference area, must be prepared by the applicator prior to project start-up. See the Quality Control Manual for Chartek Fireproofing Systems Application for further details. B4.14 Terminations Caulking or sealing of free edges and terminations is not required for Chartek fireproofing.




B5.0 CHARTEK APPLICATION WITH PLURAL SPRAY EQUIPMENT B5.1 Ambient Conditions Suitable application conditions are of critical importance for the successful application of Chartek. Consequently, Chartek should only be applied when the ambient conditions are within the following parameters:

• Air temperature: minimum 10°C (50°F) • Relative humidity: maximum 85% • Surface temperature: at least 3°C (5°F) above dew point temperature

However, Chartek may be applied at an air temperature minimum 5°C (41°F) using plural spray equipment only, recognising that the time to cure will in such applications be extended. Additionally, there may also be a higher propensity for amine bloom formation which would affect overcoating with further layers of Chartek, where required, and may affect overcoating with topcoats. For such low air temperature applications, plural equipment is the only recommended dispensing method. B5.2 Surface Cleanliness To ensure proper adhesion of Chartek to the primed substrate, the surfaces to be coated must be dry and free from oil, grease, dirt or any other contaminants that have been deposited since surface preparations were completed. It is the applicator’s responsibility to inspect all surfaces to be coated and clean them if necessary (see the notes on degreasing in Section A2.2). Ambient conditions are of critical importance for a successful application. If they cannot be kept within the above parameters, Chartek application may only proceed if adequate environmental protection is provided. B5.3 Primer and Surface Preparation It is the applicator’s responsibility to verify that the correct primer type (included in the list of qualified primers), thickness (as specified in Section A2.0, Table A1: Chartek Surface Preparation Requirements) requirements are complied with. It is also the applicator’s responsibility to ensure that the preparation of the surface which is to be overcoated with Chartek is in accordance with the requirements of this Application Manual and other documents that may be applicable. For acceptance of the primed surface, checks shall include, but not be limited to, the following: a) The surface profile is in accordance with this Application Manual and other documents that









It is the applicator’s responsibility to ensure that the primed surface and the primer itself are in an acceptable condition for overcoating with Chartek. Such factors as ageing of the primer (degradation and surface chalking), contamination, rust bloom, etc. shall be considered when determining a surface’s suitability before overcoating with Chartek. Where there is any doubt as to a primer’s acceptance, the primer manufacturer should be consulted and International Protective Coatings advised. NB: Overcoating a primer system with a 100% solids epoxy material such as Chartek is different to overcoating with further layers of material, especially solvented materials. Consequently, it is important that the primer manufacturer should be fully informed of the overcoating system and purpose of that system when directing any questions to the manufacturer concerning overcoating. International should be consulted where any doubt exists. B5.4 Material Preparation for Plural Component Spray Application Prior to spraying Chartek with plural component spray equipment, the material should be preheated to the following requirement: • 30 to 34°C (86 to 93°F) for 24 hours (maximum 48 hours) prior to use WARNING: Accelerated methods of heating the Chartek containers, such as electrical heaters in direct contact with the containers or hot water baths, are not permitted. Such methods can cause overheating of the outer layers of Chartek in the container, which may produce undesirable changes to its properties (including shorter pot life). B5.5 Plural Component Spray Equipment As Chartek is a thixotropic material, it is most efficiently applied with purpose built hot spray plural component pumps, which have the advantage of not requiring any premixing of the two parts. Parts A and B of Chartek are pumped into separate pressurised heated tanks, equipped with high torque paddle mixers, where they are brought up to temperature. From here, the separate parts are drawn into a fixed ratio displacement pump that establishes the correct ratio in volume. The two parts, still separate, are then pumped through electric in-line heaters and on through heated insulated hoses to an in-line static mixer (“worm”). As the two parts are pushed through the worm they are intimately mixed, then fed through a short whip line, typically 4.5 metres (15ft) long, to the high pressure (minimum 500 bar (7250 psi)) airless spray gun. Too cool a gun exit temperature may result in fingering of the spray pattern due to insufficient atomisation, while too hot a temperature will produce too rapid a cure and make trowelling difficult.




In order to ensure trouble free operation of this type of pump the material must be maintained at the correct temperature. It is therefore necessary to provide controlled heated storage for the Chartek and advisable to place the machine in a modified insulated container for work at low air temperatures. The importance of keeping all spray equipment clean and efficient cannot be overstated, as down time is very costly. For this reason a skilled and experienced machine operator is a vital component of the team. Machines built to spray Chartek are supplied by a number of companies. Each supplier provides instructions on machine operation and maintenance. International Protective Coatings should always be consulted regarding the suitability of spray equipment. Because of the larger volume of material delivered by these machines, crew sizes are larger to keep up with the gun. The material is delivered hot and therefore must be worked more quickly than conventional spray

Table B3: Operating Parameters for Plural Component Spray Machines

Operating Parameters Storage tank temperatures Part A: max. 60°C (140°F )

Part B: max. 50°C (122°F ) In-line heater temperatures Part A: 60 to 70°C (140 to 158°F )

Part B: 45 to 55°C (113 to 131°F ) Hose heater temperature 60 to 70°C (140 to 158oF)

Gun exit temperature 57 to 63°C (135 to 145°F ) Storage tank pressures Part A: 5 bar (70 psi)

Part B: 4 bar (60 psi) Tank stirrer speed Part A: 20rpm minimum

Part B: 15rpm minimum Displacement pump pressure 175 to 240 bar (2500 to 3500 psi)

Fluid lines: ¾” I.D. fluid lines for Part A and ½” I.D. fluid lines for Part B. Spray tips: 0.035” to 0.041” I.D. “reverse-a-clean” or equivalent airless spray tips. For smaller structural steel a narrow spray fan pattern should be used, e.g. size 3 or 4 thou tip. For larger structures and fire divisions a wider spray fan pattern may be used, e.g. size 5 or 6 thou tip.




B5.6 Ratio Checks It is important that the delivery ratio of plural spray pumps is regularly checked. As a minimum, a ratio check by weight should be performed at the start up of each day’s production and again if the machine is shut down and restarted for any reason. Use the following procedure for ratio checks by weight: 1. Weigh clean empty Parts A and B containers and note the respective weights. 2. Place the containers under the ratio check valves located on the mixing block and open the

valves at exactly the same time. 3. Close the valves when the containers are at least half full at exactly the same time. 4. Find the net weight of each part by subtracting the weight of the containers. 5. Calculate the ratio of Part A to Part B as a percentage of the total weight.

In addition to the ratio checks, constant checking of the displacement pump pressure gauges and the colour of the mixed Chartek should be carried out by the machine operator and sprayer respectively. Example Calculation Part A empty container weight 2.3kg (5.0lb)

Part B empty container weight 1.2kg (2.6lb)

Part A full container weight 9.4kg (20.7lb)

Part B full container weight 4.1kg (9.0lb)

Part A net weight 7.1kg (15.7lb)

Part B net weight 2.9kg (6.4lb)

Calculated Parts A:B as a ratio of total weight 2.45:1

The acceptable ratio range of Part A to Part B 2.32:1 Minimum 2.56:1 Maximum

Calculated ratio A:B as a percentage of total weight 71.0:29.0 (Total combined = 100%)

The acceptable ratio range as a percentage Part A – 70% to 72% Part B – 30% to 28%

B5.7 Plural Spray Application Method In order to ensure trouble free operation of this type of pump the material must be maintained at the correct temperature. It is therefore necessary to provide controlled heated storage for the Chartek and spray pump. When spraying in cold conditions, the spray pump should be located in a heated area, ideally the same area that is used to store the Chartek at a sprayable temperature. Hoses should be insulated and heated and ambient temperature parameters must be frequently checked and maintained.




In hot conditions, the spray pump and Chartek must be located in an air-conditioned environment. Hoses should be insulated and wrapped with heat reflecting tape. It may also be necessary to raise hoses above the ground in extremely hot environments. High substrate temperatures should be avoided by providing suitable shade cover and air-conditioning of the area immediately surrounding the workface may also be necessary. There should be sufficient area available to spray and enough manpower to keep up with the gun. Frequently shutting down spray machines causes wasted time and material spent cleaning and causes pressure build up in the material lines and spray gun, which may represent a safety hazard. The first coat of Chartek is sprayed and quickly trowelled into the surface to ensure good wetting and even thickness. With plural spray equipment applications and where HK-1TM or no mesh is being used, trowelling the first coat may be eliminated provided there is thorough atomisation achieving consistent even spray fan (no fingering) and 100% wetting of the surface. Trowelling also helps to thoroughly encapsulate any pre-installed mesh and reduces the formation of air pockets. If trowelled, trowel marks and high points are knocked down with a short nap roller dampened with PMA solvent. Rolling achieves a uniform thickness of the coat, which allows uniform build up of subsequent coats and ultimately the correct final thickness. Rolling also serves to produce a smoother surface finish, reducing high spots and stippled finish. Two precautions to be taken with rolling are: 1. If the Chartek has not gelled (started to cure) sufficiently, it can sag or slump. 2. Too much solvent on the roller can reduce the cure rate if it is forced into the wet Chartek. For subsequent coats, sufficient time must pass for the applied Chartek to gel (“set up” or partially cure) in order to support the weight of the additional material. Preferably, subsequent coats should be applied when the previous coat is still tacky. Where practicalities prevent “wet on wet” application, overcoating time should be reduced to a minimum and a sprayed holding coat should be applied to leave the Chartek with a good key to improve the adhesion of the next coat. In addition, a sprayed holding coat is applied over HK-1TM mesh to prevent contamination entrapment when extended overcoating intervals are expected. The holding coat is produced by boosting the Chartek temperature (in the plural component spray equipment) and/or raising the pump output pressure to give a wide fan and increased atomisation. The spray pass is much faster than normal and the result is a coarse finish that promotes good bonding with subsequent coats. Before spraying subsequent coats onto cured surfaces, they should be checked for cleanliness and, if required, suitably cleaned with one of the approved methods described in Section A2.0 “Surface Preparation”. It is imperative that surfaces are clean and thoroughly dry before additional coats of Chartek are applied.




The final coat, when applied to a ‘wet’ surface, should be sufficiently thick to allow good ‘flowing out’ and to minimise surface roughness and to achieve the specified final thickness. In applying a final coat to a hardened surface the thickness should be no less than 3mm (1/8”) to ensure adequate adhesion to the hardened surface. B5.8 Water Contamination CAUTION: If rain or condensation occurs during application or shortly thereafter, moisture may be absorbed into the uncured material. In addition, an amine bloom may form on the Chartek surface. These conditions will affect intercoat adhesion. Take the following action if water contamination occurs: Contamination Action Cured Chartek (fresh water): Dry and solvent wipe Cured Chartek (salt water): Warm water wash - maximum 60°C (140°F)



B5.9 Surface Finish Discontinuities, pinholes, voids or isolated deposits of excess thickness in the coating are not acceptable. Where there is the risk of water ponding on horizontal surfaces, the Chartek should be sloped sufficiently to avoid ponding. Samples of the surface finish acceptable to the client, a reference area, must be prepared by the applicator prior to project start-up. See the Quality Control Manual for Chartek Fireproofing Systems Application for further details. B5.10 Terminations Caulking or sealing of free edges and terminations is not required for Chartek fireproofing.




B6.0 HAND TROWEL APPLICATION B6.1 Ambient Conditions Suitable application conditions are of critical importance for the successful application of Chartek. Consequently, Chartek should only be applied when the ambient conditions are within the following parameters:


However, Chartek may be applied at an air temperature minimum 5°C (41°F) using plural spray equipment only, recognising that the time to cure will in such applications be extended. Additionally, there may also be a higher propensity for amine bloom formation which would affect overcoating with further layers of Chartek, where required, and may affect overcoating with topcoats. For such low air temperature applications, plural equipment is the only recommended dispensing method. B6.2 Surface Cleanliness To ensure proper adhesion of Chartek to the primed substrate, the surfaces to be coated must be dry and free from oil, grease, dirt or any other contaminants that have been deposited since surface preparations were completed. It is the applicator’s responsibility to inspect all surfaces to be coated and clean them if necessary (see the notes on degreasing in Section A2.2). Ambient conditions are of critical importance for a successful application. If they cannot be kept within the above parameters, Chartek application may only proceed if adequate environmental protection is provided. B6.3 Primer and Surface Preparation It is the applicator’s responsibility to verify that the correct primer type (included in the list of qualified primers), thickness (as specified in Section A3.0) requirements are complied with. It is also the applicator’s responsibility to ensure that the preparation of the surface which is to be overcoated with Chartek is in accordance with the requirements of this Application Manual and other documents that may be applicable. For acceptance of the primed surface, checks shall include, but not be limited to, the following: (a) The surface profile is in accordance with this Application Manual and other documents that


cleanliness and presence of surface contaminants. (c) That the primer is qualified by International for use with Chartek. (d) That the applicator has access to, and is familiar with, the primer manufacturer’s application

data, and that the application process and environmental conditions are in compliance with the primer manufacturer’s requirements.






It is the applicator’s responsibility to ensure that the primed surface and the primer itself are in an acceptable condition for overcoating with Chartek. Such factors as ageing of the primer (degradation and surface chalking), contamination, rust bloom, etc. shall be considered when determining a surface’s suitability before overcoating with Chartek. Where there is any doubt as to a primer’s acceptance, the primer manufacturer should be consulted and International Protective Coatings advised. NB: Overcoating a primer system with a 100% solids epoxy material such as Chartek is different to overcoating with further layers of material, especially solvented materials. Consequently, it is important that the primer manufacturer should be fully informed of the overcoating system and purpose of that system when directing any questions to the manufacturer concerning overcoating. International should be consulted where any doubt exists. B6.4 Material Preparation for Hand Trowel Application Prior to applying Chartek by hand trowel, the material should be preheated to the following requirement: • Warm enough to mix, typically 20 to 25oC (68 to 77°F) Note: The higher the temperature the shorter the working pot life. Pot life durations are published on the product data sheets Accelerated methods of heating the Chartek containers, such as electrical heaters in direct contact with the containers or hot water baths, are not permitted. Such methods can cause overheating of the outer layers of Chartek in the container, which may produce undesirable changes to its properties (including shorter pot life). B6.5 Mixing For hand application Chartek must be premixed. A small amount of PMA (propylene methoxyacetate) thinner is added to Part A to reduce viscosity for mixing and application International’s thinner GTA123 or GTA822 is recommended for this purpose. The amount required varies with initial material temperature but up to 0.5 litres (0.13 US gallons) may be used per full kit of Chartek. When Part A has reached a smooth consistency, the Part B is then poured into the Part A container, scraping the sides of the Part B container to empty it completely. The two parts are thoroughly mixed together with a high torque variable speed paddle mixer, minimum 5 HP air motors (or 1000W/110V electric motor minimum) equipped with 250mm (10”) paddles. Mixing should continue until a uniform colour is achieved




For best results, the mixer should be mounted on a power ram base to ease the effort required and to allow vertical movement of the paddle blade. The mixing should begin slowly and speed built up gradually. Mix carefully until a smooth texture and uniform colour are achieved. For a full kit this is approximately 4 minutes. Kits should not be mixed until they are ready to be used. B6.6 Hand Trowel Application Method Chartek may be applied using plasterer’s trowels, which has the advantage of very little waste and virtually eliminates the need for masking. After a kit has been mixed, it may be spread out on flat clean boards or surfaces for each applicator to work with. This prevents the material from curing too quickly and allows sufficient working time. Alternatively the material may be applied directly from the pail. Trowel marks and high points are knocked down with a short nap roller dampened with PMA solvent. Rolling achieves a uniform thickness of the coat, which allows uniform build up of subsequent coats and ultimately the correct final thickness. Rolling also serves to produce a smoother surface finish, reducing high spots and stippled finish. Two precautions to be taken with rolling are: 1. If the Chartek has not gelled (started to cure) sufficiently, it can sag or slump. 2. Too much solvent on the roller can reduce the cure rate if it is forced into the wet Chartek. For subsequent coats, sufficient time must pass for the applied Chartek to gel (“set up” or partially cure) in order to support the weight of the additional material. Preferably, subsequent coats should be applied when the previous coat is still tacky. Where practicalities prevent “wet on wet” application, overcoating time should be reduced to a minimum. In addition, an encapsulating coat is applied over HK-1TM mesh to prevent contamination entrapment when extended overcoating intervals are expected B6.7 Mixing of Partial Kits Often trowel application will require less than a full kit of Chartek. In these cases, the required amounts of Parts A and B should be accurately weighed out into a clean container and thoroughly mixed. The correct ratio by weight for Chartek is as follows: When complete kits are to be split down the following method of calculation may be used:




Worked Example Parts A:B as a ratio of total weight:

2.45:1

The acceptable ratio range of Part A to Part B is:

2.32: 1 Minimum 2.56: 1 Maximum

Required Weight of Part B calculated as follows:

Measured Weight of Part A ÷ 2.45 (the Chartek 7 weight ratio) e.g. 8kgs of Part A ÷ 2.45 = 3.27kgs of Part B Therefore the required amount of Part B to be weighed out and added to the 8kgs of Part A is 3.27kgs.

B6.8 Water Contamination CAUTION: If rain or condensation occurs during application or shortly thereafter, moisture may be absorbed into the uncured material. In addition, an amine bloom may form on the Chartek surface. These conditions will affect intercoat adhesion. Take the following action if water contamination occurs: Contamination Action Cured Chartek (fresh water): Dry and solvent wipe Cured Chartek (salt water): Warm water wash - maximum 60°C (140°F)



B6.9 Surface Finish For trowel application a smooth, even and rolled finish should be achieved. Discontinuities, pinholes, voids or isolated deposits of excess thickness in the coating are not acceptable. Where there is the risk of water ponding on horizontal surfaces, the Chartek should be sloped sufficiently to avoid ponding. Samples of the surface finish acceptable to the client, a reference area, must be prepared by the applicator prior to project start-up. See the Quality Control Manual for Chartek Fireproofing Systems Application for further details. B6.10 Terminations Caulking or sealing of free edges and terminations is not required for Chartek fireproofing.




APPENDICES




APPENDIX A – HK-1TM Meshing Arrangements




APPENDIX B – Metal Meshing Arrangements




APPENDIX C – Certified Thicknesses - Bulkheads and Decks


Chartek® 7

Certified Reinforcement and Thickness Arrangements for Bulkhead and Decks

TABLE 1: BULKHEADS

Chartek 7 Reinforcement and Thickness

(mm) Design

Lloyd’s Register Det Norske Veritas American Bureau of Shipping

A-60 class (Insulated backface)

5.0 HK-1 Mesh NC NC

H-0 class (400°C) 5.0 HK-1 mesh

5.0 HK-1 mesh

6.5 HK-1 mesh

H-30 class 7.0 HK-1 mesh NC NC

H-60 class (Insulated backface)

5.0 HK-1 Mesh NC 5.1

HK-1 mesh

H-60 class 10.0 HK-1 mesh

9.0 HK-1 mesh

10.0 HK-1 mesh

H-120 class (Insulated backface) NC NC NC


13.0 HK-mesh

14.0 HK-1 mesh


TABLE 2: DECKS

Chartek® 7 Reinforcement and Thickness

(mm) Design


A-60 class 8.0 HK-1 mesh

8.0 HK-1 mesh NC

H-0 class (400°C) 5.0 HK-1 Mesh

5.0 HK-1 Mesh

6.5 HK-1 mesh

H-30 class 7.0 HK-1 mesh NC NC



9.0 HK-1 mesh

10.0 HK-1 mesh



15.0 HK-1 mesh NC

NC = Not Certified


ADDITIONAL THICKNESS FOR JET FIRES: Notes: The thickness of coating Chartek® for jet fire exposure may determined by adding a “jet fire erosion thickness” as shown in Tables 3 or 4 (dependent on mesh type used) to the thickness required by hydrocarbon testing as shown in Tables 1 and 2. In all instances the mesh type, position and overlaps shall be strictly in accordance with the Chartek Application Manual and relevant certification. Table 3: Jet Fire Erosion Thickness – HK-1 Mesh

Additional Chartek 7 Thickness (mm) Jet Fire Duration


No Jet Fire +0 +0 NC

Up to 20 minutes jet fire +2 +1 NC

21 to 30 minutes jet fire +2 +2.5 NC



61 to 90 minutes jet fire +4 NC NC

91 to 120 minutes jet fire +5 NC NF

NC = Not Certified


Table 4: Jet Fire Erosion Thickness – Stainless Steel Mesh

Additional Chartek® 7 Thickness (mm) Jet Fire Duration


No Jet Fire +0 0 NC

Up to 20 minutes jet fire +1 +1 NC

21 to 30 minutes jet fire +1 +2 NC





NC = Not Certified




APPENDIX D – Typical Standards of Finish and Mesh Overlap Photographic Reference


Standards of Application Finish

Typical standard of uniform spray finish, additionally showing clean, straight, free

edge terminations

Material left in trowelled but unrolled finish


Poor standard of surface finish showing unacceptable heavy spray and sags


Mesh Overlaps

HK-1TM mesh 50mm overlap

HK-1 mesh 150mm overlap for specific jet fire applications




APPENDIX E – Chartek Checklist

1. Clean surface

Blast to Sa 2½. Record profile

2. Prime surface

Apply 50-75 microns (2-3 mils)of qualified primer

3. Inspect

4. Wetting coat of Chartek

2-3mm (70-110 mils) trowel in well. Trowelling is not required if spray

thoroughly wets surface

5. Build up to mesh depth

Chartek 7 - Basic Installation Checklist

6. Inspect for thickness and uniformity 7. Install HK-1 mesh on wet surface

Wet gauge or drill Ensure fibre orientation and overlaps

8. Cover mesh with Chartek 9. Build up to final thickness

10. Final inspection for uniformity of thickness

11. Document measurements

12. Finish with recommended topcoat as required. Record

type and QA details

For full details refer to the current Chartek Application Manual.

Record QA details. i.e. weather, type

of primer, etc

1 October 2005_Rev.1

Where mesh reinforcement is

required

For alternative primers and topcoat, please contact International Paint



APPENDIX F – Procedure for Inspection, Test and Replacement of Failed Fire Protection

Technical Note TN/F/077_Rev.0_130203


1

Procedure for Inspection, Test and Replacement

(PITR)

FAILED FIRE PROTECTION Introduction Based on the understanding that the previously applied passive fire protection (pfp) material is to be thoroughly removed prior to reinstatement with Chartek® 7, the following is the recommended inspection, test and replacement procedure to be implemented. Inspection and Test Plan (ITP) An Inspection and Test Plan (ITP) should be developed based upon this document and other documentation/specifications relating to the structure in question. The ITP should include clear details of each stage of the process and ‘hold’ points for acceptance of critical items. 1. Material Removal 1.1. The existing passive fire protection material must be completely removed from

the surface revealing clean and sound primer system prior to overcoating with Chartek. Method of removal to be advised to International prior to work commencing. Typically methods include hand tools, high pressure water jetting and other mechanical methods.

2. Reinstatement of Existing Primer System 2.1 Generally it is anticipated that the primer system under the failing material will be

sufficiently degraded that full surface preparation and reinstatement of primer system will be required. However, in the event of early failure (disbondment) of a fire protection system, it may be that a sound primer system can be revealed. In this situation the following procedure applies.

2.2 The cleanliness, condition, thickness and general soundness of the primer is

critical to the ultimate adhesion of the Chartek fireproofing and consequently procedures relating to inspection and evaluation of primer soundness must be thoroughly followed for the full surface area.

2.3 Dependent upon the method of removal of the failing fire protection material, the

inspection after treatment of the primer system may vary. Any departure or change from the procedure recommended in this document must be reported to International Paint for review and acceptance prior to the change being implemented. Method used to be advised to International prior to work commencing.



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2.4 Damage to the primer system during removal of the failed pfp material must be

repaired by appropriate means (approved by International) to result in a sound surface prior to Chartek® application. Generally this will require surface treatment to ISO 8501-1 St 3 or SSPC-SP3 for limited areas of damage.

2.5 Key criteria for acceptance of the existing primer system are as follows:

• The primer system is of known origin and approved by International Paint for use under Chartek fireproofing. The primer system must be a recognised primer in accordance with the current acceptable primers list for use with Chartek fireproofing, obtainable from International Paint, Fire & Insulation Products.

• The primer thickness must be within the tolerable levels indicated in the

Chartek Application Manual, Section 4, a synopsis of which is as follows:

The maximum allowable primer system DFTs are summarized in the following table. Table 2. Primer system maximum DFTs

DRY FILM THICKNESS PRIMER SYSTEM

Normal Areas Overlap Areas Epoxy primer 50–75 microns

(2–3 mils) 100 microns

(4 mils) Epoxy zinc primer 50–75 microns

(2–3 mils) 100

(4 mils) Epoxy zinc primer plus tie-coat 75–110 microns

(3–4.4 mils)

125 microns (5 mils)

2.6 The primer system must be sound with no evidence of breakdown, flaking, rust

breakthrough, contamination, or other defective condition which would indicate that the primer may not be suitable for overcoating with Chartek fireproofing in accordance with the Chartek 7 Fireproofing Application Manual.

2.6 Final cleaning and preparation of sound primer system will be obtained by high

pressure fresh water washing or, if required, solvent cleaning to SSPC SP1. 2.7 Test for the presence of soluble chloride salts using a method approved by

International Paint.



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2.8 Adhesion and cohesive strength of the primer system are critical to the longevity

of the fire protection system. Consequently, random dolly pull-off tests in accordance with ISO 4624 must be carried out at a frequency one test per 3m2. The minimum acceptable pull-off value utilising this test procedure is:

Hydraulic PAT adhesion test: 10MPa Elcometer 106 adhesion test: 5MPa Pull-off results at less than the minimum acceptable level will require that the surface is abrasive blasted to achieve a minimum Sa 2½ standard of surface cleanliness prior to application of new primer system. The primer must be as approved on the aforementioned reference list.

2.9 It is the responsibility of the Chartek® fireproofing Qualified Applicator carrying

out the installation of fire protection to review all procedures utilised on the foregoing 1.1 to 2.8 and to accept the surface as suitable for overcoating with Chartek fireproofing. This may require obtaining acceptance of the owner or the owner’s designated contractor.

3. Method to be Used for Surface Repreparation and/or Primer Replacement is

Required 3.1 In certain circumstances the inspection of the steel surface after removal of the

pfp material may reveal that a more thorough remedial treatment is required. Typical situations include:

• the primer or coating system does not appear on the Chartek fireproofing

qualified primers list • the thickness of the primer system is unacceptable • the primer system is degraded to the point where significant corrosion is

present • the general condition of the surface is such that anything other than full

surface treatment will not result in a surface that is acceptable for Chartek application

3.2 The most acceptable form of surface repreparation is open abrasive blasting. It

is recognised that in certain situations, particularly on offshore installations, open abrasive blasting is not permissible. Consequently, alternative methods of preparation may be found including wet blasting and high pressure water jetting. Methods which do not develop or reveal a surface profile are generally unacceptable. Power tool cleaning is acceptable but only for limited areas.

NB: Methods used must be advised to International Paint and approved prior to commencement of work.



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3.3 Once the appropriate surface preparation method has been determined and

carried out, utilisation of an appropriate primer system should be employed. This may include application of a specific primer system relevant to the surface preparation method. Any new primer system used must be listed on the Chartek® fireproofing qualified primers list.

3.4 Chartek fireproofing material must be installed by a Qualified Applicator using

equipment approved by International Paint and personnel who have been trained at the Chartek fireproofing applicator school and who are in possession of a certificate attesting to the fact that they have attended training.

3.5 Chartek fireproofing must be installed in strict accordance with the Chartek 7

Fireproofing Application Manual. Particular attention should be paid to the environmental conditions during application of material.

3.6 Chartek material is to be installed to the correct thickness in accordance with the

specified material thickness to meet the installation’s fire criteria. It is the responsibility of the Chartek fireproofing Qualified Applicator to ensure that the correct thickness is applied to the specific area of the structure being fire protected. Should there be doubt with reference to specified thicknesses, these should be checked with the owner or the owner’s designated representative and International Paint.

3.7 Application of Chartek fireproofing should not commence until acceptance for

overcoating of the prepared surface has been given as in 2.9 above. Where required this will include acceptance by the Chartek fireproofing Field Service Engineer as part of the fire protection installation audit procedure conducted by International Paint.

NB: It is the responsibility of the International Paint’s Technical Service Engineer to carry out an audit of the installation process. He is not responsible for the daily inspection activities, which should be carried out by the Chartek fireproofing Qualified Applicator.

4. Acceptance of Installed Surface and Topcoating 4.1 The Chartek fireproofing Qualified Applicator is responsible for obtaining

acceptance by the owner or the owner’s designated representative that the installation is completed to the required standard and thicknesses prior to application of topcoat.

4.2 Topcoating should be applied in accordance with the Chartek 7 Fireproofing

Application Manual in a timely fashion.




APPENDIX G – Technical Note TN/F/083 “Overcoating of aged and zinc primers”

Technical Note

TN/F/083_Rev.1_040205


1

Overcoating of Aged Primers and Zinc Primers

with Chartek® Fireproofing Background As a general rule it is good practice to overcoat primers used with Chartek as soon as the primer is sufficiently cured to accept overcoating. Overcoating of primers in a timely fashion reduces the risk of contamination prior to overcoating and risk of poor adhesion due to deterioration of the primer generally. At all times the following shall be strictly followed: 1. The primer manufacturer’s recommendation for overcoating of the primer in question with

a thick film epoxy fireproofing. 2. International Paint’s recommendations. 3. Project specifications and the Chartek Application Manual, primers section. 4. The primer or primer system is listed on the Chartek Qualified Primer Systems list, latest

edition. Aged Primers As primers age due to a number of factors there is no definitive rule as to maximum time that a primer can be left prior to overcoating with Chartek. Factors such as UV exposure, humidity and general environmental conditions can cause a wide variation in acceptability. UV exposure in particular can cause surface chalking and crazing. • In all cases the condition of the primer must be closely examined and the

recommendations of the primer manufacturer adhered to. Generally primer manufacturers specify the recommended overcoating times in product data sheets, or the manufacturer should be consulted for the overcoating limits. High UV exposure can decrease these times considerably, emphasising the need for close inspection prior to Chartek application.

NB: When consulting the primer manufacturer, they must be made aware that the product being applied is a thick film (i.e. millimetres rather than microns) 100% solids epoxy system, i.e. Chartek. It is likely that the manufacturer will consider overcoating with thick film epoxy differently to overcoating with thin film solvented systems. As the Chartek Qualified Applicator is responsible for the installation it is normally his responsibility to accept or not accept the primed surface. International strongly encourages other parties, such as the owner, engineer and fabricator, to require attention to condition of primer and to ensure that project specifications, QA/QC and other relevant documents correctly address these issues.

Technical Note

TN/F/083_Rev.1_040205


2

Zinc Primers Two types of zinc primers are used with Chartek®, they are (overcoating time typically within 5 days and 21 days with a tie coat): • Inorganic Zinc Silicate • Zinc Rich Epoxy Zinc silicate primers are generally discouraged due to inconsistency in the surface film after application. However, several zinc silicates are qualified for use with Chartek and may be used in accordance with the Chartek application manual. Use of zinc silicate primers without an epoxy tie coat is strongly discouraged due to the likelihood of zinc salts formation which can reduce the bond of the overcoating material, e.g. Chartek. Zinc salts are more likely to form in humid conditions and can be very difficult to remove without sweep blasting the surface. The cured inorganic zinc silicate primer coating condition prior to overcoating is critical to performance and attention must be paid to the state of cure of the primer. In this respect, reference should be made to the manufacturer’s recommendations. It is strongly recommended that the state of cure of zinc silicate primers is checked by a basic solvent rub test and, preferably, dolly pull-off test. Whilst epoxy zinc primers are less susceptible to zinc salts formation they are not eliminated form the possibility of salts and must be closely scrutinised for this condition. Again it is not recommended that zinc epoxies are used without tie coat unless it can be guaranteed that overcoating will take place well before the possibility of salts formation. Remedial action in the event of salts formation is sweepblasting. Additionally, epoxy primers that have been exposed to elevated temperatures may result in a hard glossy surface. Remedial action shall be sweepblasting. Epoxy Primers (Overcoating time typically within 21 days) Twin pack epoxy primers such as an epoxy polyamide and epoxy zinc phosphate are less susceptible to variations in application conditions and cure. Nevertheless, attention should be paid to ensure that primer thicknesses are within the tolerances allowed in the Chartek Application Manual and that the primer has not degraded in the fashion indicated for zinc primers above. UV exposure, age and elevated temperatures again being conditions which can lead to primer deterioration resulting in poor adhesion of the Chartek fireproofing. Summary Whilst the adhesion of Chartek fireproofing to most substrates is exceptionally strong, incorrect use of primers or deterioration of primers and coatings used under the material can lead to inadequate adhesion and this situation must be avoided. Contact with the primer manufacturer noting that their materials are to be overcoated with a 100% solids thick film epoxy coating in any case of doubt is recommended, as is contact with International Paint for

Technical Note

TN/F/083_Rev.1_040205


3

additional comment and advice. It should also be noted that the primers listed as qualified for use with Chartek® fireproofing are qualified by their country of origin and additional care is needed when utilising primers of the same designation from alternative locations. Contact should be made with International Paint in these circumstances.




APPENDIX H – Technical Note TN/F/101 “Disposal of Chartek”

Technical Note TN/F/101_121104


1

Disposal of Chartek®

Mixed (Cured) Material This Technical Note addresses the procedure for the disposal of Chartek Parts A and B when mixed, that is cured material. In the first instance, the local authorities under whose jurisdiction the disposal of waste materials fall should be consulted as local regulations may differ in various parts of the world and within different regions of a country. Additionally, disposal regulations are constantly being changed or amended and the following can only be considered a guide. Mixed, that is when cured, Chartek material may be incinerated and disposed of in a land-fill site. Chartek’s constituent components Parts A and B when mixed and cured are classified as non-flammable and non-hazardous, and contain no toxins that would prevent land-fill disposal. Should there be components of Parts A and B they should be mixed together and allowed to cure. All excess of each component should be removed from containers and the work site. The solid material is classified as non-flammable and non-hazardous. After a fire charred material may also be treated in the same way, as above. There are no specific requirements for protective clothing. However, it is recommended that as a precaution, during disposal, personnel wear overalls, gloves and a mask.




APPENDIX I – Definitions and Abbreviations

Definit ions and Abbreviat ions

TO L E R A N C E S

GL O S S LE V E L

DR Y FI L M TH I C K N E S S(DFT)WE T FI L M TH I C K N E S S(WFT)VO L U M E SO L I D S

DRY I N G TI M E

The numerical information quoted in this data manual has been derived fromlaboratory test data obtained under controlled conditions for the productsdescribed. Whilst every effort has been made to ensure accuracy, this informationwill be subject to minor variations obtained in normal manufacturing tolerances,and any fluctuations in ambient conditions during the application and curingperiods.

Typical gloss values have been determined in accordance with ISO 2813:1978 using a60° gloss head. The categories used in the data sheet are:

Finish (Sheen) Gloss (60° Head)

Matt 0-15Eggshell 16-30Semi-Gloss 31-60Gloss 61-85High Gloss >85

In practice, the level of sheen and surface finish will be dependent upon a numberof factors, including application and the condition of the surface to be overcoated.

The measured thickness of the final dried film applied to the substrate.

The initial thickness of the wet coating applied to the substrate.

The volume solids figure given on the product data sheet is the percentage of thewet film, which remains as the dry film, and is obtained from a given wet filmthickness under specified application method and conditions. These figures havebeen determined under laboratory conditions using the test method described inthe Oil & Colour Chemists (OCCA) Monograph No. 4 - Determination of the SolidContent of Paint (by Volume). This method is a modification of ASTM D-2697which determines the volume solids of a coating using the recommended dry filmthickness of the coating quoted on the product data sheet, and a specified dryingschedule at ambient temperature, i.e. 7 days at 23°C ± 1°C.

The drying times quoted in the product data sheet have been determined in thelaboratory using a typical dry film thickness, the ambient temperature quoted in therelevant product data sheet, and the appropriate test method, i.e.

Touch Dry (ISO 1517-73) - The surface drying state of a coating when Ballotini (small glass spheres) can be lightly brushed away without damaging the surface of the coating.

Hard Dry (ISO 9117-90) - The condition of the film in which it is dry throughout its thickness, as opposed to that condition in which the surface of the film is dry but the bulk of the coating is still mobile.

This through drying state is determined by the use of a “mechanical thumb” devicewhich, when applied using a specified gauge, under specified pressure, torsion andtime, does not mark or damage the film.

The drying times achieved in practice may show some slight fluctuation, particularlyin climatic conditions where the substrate temperature differs significantly from theambient air temperature.

The product data sheet gives both a “minimum” and a “maximum” overcoatinginterval and the figures quoted at the various temperatures are intended asguidelines, consistent with good painting practices. Certain terms requireelaboration as follows:

Minimum

The “minimum overcoating time” quoted is an indication of the time required forthe coating to attain the necessary state of dryness and hardness to allow theapplication of a further coat of paint. It assumes:

OV E R C O AT I N G

IN T E RVA L

Protective Coatings® bcdefg ®a


(i) the coating has been applied at the normal recommended thickness.

(ii) environmental conditions both during and after application were as recommended for that particular coating, especially in respect of temperature, relative humidity and ventilation.

(iii) the paint used for overcoating is suitable for that purpose.

(iv) an understanding of the “method of application”. For example, if a coating canbe applied by both brush or spray it is expected that overcoating may be carried out more rapidly if sprayed and it is the “lowest” figure that is quoted.

If the above conditions are not met, the quoted minimum overcoating times areliable to variation and will invariably have to be extended.

Maximum

The “maximum overcoating time” indicates the allowable time period within whichovercoating should take place in order to ensure acceptable intercoat adhesion isachieved.

Extended

Where an “extended” overcoating time is stated, the anticipated level of intercoatadhesion can only be achieved if:

(i) the coating has been applied in accordance with good painting practices and at the specified film thickness.

(ii) the aged coating has the “intended” surface characteristics required for long term overcoatability. For example, an over-applied epoxy MIO may not have its usual “textured” surface and will no longer be overcoatable after ageing unless it is abraded.

(iii) the condition of the coating to be overcoated must be in intact, tightly adherent, clean, dry and free from all contaminants. For example, the rough textured surface of an MIO may require “extensive” cleaning, especially in an industrial and/or coastal environment.

(iv) coatings having a glossy surface which could have a detrimental effect on the adhesion of subsequent coats should be treated by light surface abrasion, sweep blasting, or other suitable processes which will not cut through or detract from the performance of the underlying coating.

It should be recognised that the level of intercoat adhesion obtained is alsodependent upon the chemistry of the “topcoat”. By their nature, primers orundercoats with acceptable pigment levels will have inherently better adhesion thanfinish coats with lower pigment contents.

The measurement of ultimate “adhesive strength” can often be a difficult process,and interpretation of results can be subjective. Excellent adhesion does notnecessarily mean good performance, nor does relatively poor adhesion necessarilymean poor performance.

Although the adhesion of coatings applied to aged/cured coatings may be deemedsatisfactory for the specified end use, actual numerical values obtained for adhesionmay be less than with coatings applied within “minimum/short” overcoatingintervals. For further additional information on individual products, or coatingschemes, consult International Protective Coatings.


FL A S H PO I N T

WO R K I N G PO T LI F E

The minimum temperature at which a product, when confined in a Setaflash closed cup,must be heated for the vapours emitted to ignite momentarily in the presence of a flame(ISO 3679:1983).

Volatile Organic Content (VOC) is the weight of organic solvent per litre of paint.

Legislative requirements differ from country to country, and from region to region, andare constantly being reviewed. Two values are quoted for VOC on the product data sheetwhich have been determined practically in the laboratory using the following publishedtest methods:-

UK - PG6/23(92), Appendix 3

This test method was published in February 1992, by the UK Department of theEnvironment as part of the Secretary of State’s Guidance Note (PG6/23(92)), issued as aguide to local authorities on the appropriate techniques to control air pollution, in orderto achieve the objectives laid down in the Environmental Protection Act 1990. Themethod described in Appendix 3 includes guidance on the method of measuring VOC ofcoatings, as applied to demonstrate compliance with Clause 19 of the Guidance Note.

USA - EPA Federal Reference Method 24

The Environmental Protection Agency (EPA), published procedures for demonstrationof compliance with VOC limits under Federal Reference Method 24 “The Determinationof Volatile Matter Content, Density, Volume Solids and Weight Solids of SurfaceCoatings”. This method was originally published in the Federal register in October 1980,and coded 40 CFR, Part 60, Appendix A, and amended in 1992 to incorporateinstructions for detailing with multi-component systems, and a procedure for thequantitative determination of VOC exempt solvent.

It is recommended that users check with local agencies for details of current VOCregulations, to ensure compliance with any local legislative requirements when proposingthe use of any coating.

The maximum time during which the product supplied as separate components should beused after they have been mixed together at the specified temperature (ISO 9514:1922).

The values quoted have been obtained from a combination of laboratory tests, andapplication trials, and refer to the time periods under which satisfactory coatingperformance will be achieved.

Application of any product after the working pot life has been exceeded will lead toinferior product performance, and must NOT be attempted, even if the material inquestion appears liquid in the can.

The shipping weights quoted refer to the total weight of the product supplied plus theweight of the can. These weights are quoted for individual components, and do not takeinto account any additional packaging weight attributable to cartons, etc.

The shelf life quoted on the product data sheets is generally a conservative value, and it isprobable that the coating can be applied without any deterioration in performance afterthis period has elapsed. However, if the specified shelf life has been exceeded, it isrecommended that the condition of the material is checked before any large scaleapplication is undertaken using materials beyond the quoted shelf life.

For further information consult International Protective Coatings.

SH I P P I N G WE I G H T

SH E L F LI F E

VO L AT I L E OR G A N I C

CO N T E N T (VOC)

DisclaimerThe information given in this manual is for general guidance only and is not guaranteed as being wholly accurate or complete. Unless otherwise agreed in writing,all products supplied and technical advice given by us are subject to our standard conditions of sale, a copy of which is available upon request.





SECTION C – CHARTEK 8




C1.0 CHARTEK PACKAGING AND STORAGE C1.1 50kg (110lb) Kit For plural component spray equipment, Chartek is supplied in a 50kg (110lb) kit comprising of two drums of grey coloured resin (Part A) and one drum of light coloured hardener (Part B). Part A (2 Drums)

35.7 kg (78.7 lb)

Part B (1 Drum)

14.3 kg (31.5 lb)

Total 50 kg 110.2 lb NOTE: 50kg (110lb) kits are only suitable for use with plural spray equipment. C1.2 20kg (44.1lb) Kit For single component pumps and trowel application, Chartek is supplied in a 20kg (44.1lb) kit comprising of one part filled drum of grey coloured resin (Part A) and one plastic pail of light coloured hardener (Part B). This allows the hardener to be decanted into the Part A resin for mixing. Part A 14.3kg (31.5lb)Part B 5.7kg (12.6lb)Total 20.0kg (44.1lb) NOTE: 20kg (44.1lb) kits can also be used with plural spray equipment. C1.3 Cast Grade For casting work a less viscous version, Chartek cast grade, is available. For further details contact International Protective Coatings. C1.4 Storage Conditions for Chartek Chartek should be stored dry, indoors and out of direct sunlight. The following storage temperature ranges must be maintained:

• Minimum 1°C (34°F), maximum 30°C (86°F)




C2.0 CARBON FIBRE MESH REINFORCEMENT C2.1 Meshing Designs The meshing requirements are given below. Particular attention should be paid to the Chartek type and thickness, and fire type. Refer to Appendix A for HK-1TM mesh design drawings. Table C1: Mesh Requirements Use Hydrocarbon (Pool) Fires Jet Fires

Structural Steel I and Open Sections

For certified thicknesses over 7.2mm (284 mils) HK-1 mesh installed at mid film thickness with 50mm (2”) overlaps and with 100% coverage. For certified thicknesses below 7.2mm (284 mils) no mesh required. Beams and columns with webs less than 250mm (10”) deep do not require mesh on webs.

Not suitable for Jet Fire designs, use Chartek 7.

Structural Steel Hollow Sections For certified thicknesses over 7.2mm (284 mils) HK-1 mesh installed at mid film thickness with 50mm (2”) overlaps and with 100% coverage. For certified thicknesses below 7.2mm (284 mils) no mesh required.


Tanks, Vessels and Pipework For certified thicknesses over 7.2mm (284 mils) HK-1 mesh installed at mid film thickness with 50mm (2”) overlaps and with 100% coverage. For certified thicknesses below 7.2mm (284 mils) no mesh required.


Divisions – Bulkheads and Decks No HK-1 mesh required for certified thicknesses on Bulkheads and Divisions.


C2.2 HK-1TM and HK-1 (M)TM Carbon Fibre Mesh Reinforcement HK-1 and HK-1 (M) carbon fibre meshes are knitted cloth of carbon filaments and glass thread. Both meshes are equivalent to each other with respect to their construction and constituent materials, and their performance. The designation of HK-1 and HK-1 (M) relates only to their manufacturing source. C2.3 Packaging of HK-1 and HK-1 (M) Carbon Fibre Mesh Reinforcement HK-1 and HK-1 (M) are available from International Protective Coatings in 165m2 (1776ft2) and 167.3m2 (1800 ft2) rolls respectively. C2.4 General Rules for Meshing 1. Cut mesh to required sizes before starting Chartek application. 2. Apply mesh to wet Chartek at approximately mid thickness. 3. Roll the mesh thoroughly into the wet Chartek with short nap rollers dampened with PMA

solvent.




4. Overlap adjacent pieces of mesh by at least 50mm (2”). For jet fire applications, overlap by at least 150mm (6”).

5. To minimise waste the straight carbon (black) fibres are parallel to flange edges and the axis of hollow sections.

6. After installing HK-1, either continue to build up the required thickness or spray a light coat of Chartek over the mesh to leave a good key for subsequent coats.

7. For jet fire applications the minimum overlap shall be 150mm (6”) and the HK-1 shall cover all surfaces (i.e. 100% coverage without any gaps) of the member regardless of dimensions.

NOTE: For certified thickness values of 7.2mm (284 mils) and below, no mesh reinforcement is required. For certified thickness values above 7.2mm (284 mils) mesh reinforcement is required. When Chartek is applied in excess of 7.2mm (284 mils) and the design or certified thickness is 7.2mm (284 mils) or less, no mesh is required. However, the applied thickness of Chartek without mesh shall not exceed 8mm.




C3.0 APPLICATION WITH SINGLE LEG AIRLESS SPRAY EQUIPMENT C3.1 Ambient Conditions Suitable application conditions are of critical importance for the successful application of Chartek. Consequently, Chartek should only be applied when the ambient conditions are within the following parameters: • Air temperature: minimum 10°C (50°F) • Relative humidity: maximum 85% • Surface temperature: at least 3°C (5°F) above dew point temperature However, Chartek may be applied at an air temperature minimum 5°C (41°F) using plural spray equipment only, recognising that the time to cure will in such applications be extended. Additionally, there may also be a higher propensity for amine bloom formation which would affect overcoating with further layers of Chartek, where required, and may affect overcoating with topcoats. For such low air temperature applications, plural equipment is the only recommended dispensing method. C3.2 Surface Cleanliness To ensure proper adhesion of Chartek to the primed substrate, the surfaces to be coated must be dry and free from oil, grease, dirt or any other contaminants that have been deposited since surface preparations were completed. It is the applicator’s responsibility to inspect all surfaces to be coated and clean them if necessary (see the notes on degreasing in Section A2.2). Ambient conditions are of critical importance for a successful application. If they cannot be kept within the above parameters, Chartek application may only proceed if adequate environmental protection is provided. C3.3 Primer and Surface Preparation It is the applicator’s responsibility to verify that the correct primer type (included in the list of qualified primers), thickness (as specified in Section A3.0) requirements are complied with. It is also the applicator’s responsibility to ensure that the preparation of the surface which is to be overcoated with Chartek is in accordance with the requirements of this Application Manual and other documents that may be applicable. For acceptance of the primed surface, checks shall include, but not be limited to, the following: (a) The surface profile is in accordance with this Application Manual and other documents that










C3.4 Kit Size For single leg airless spray pump application, Chartek is supplied in a 20kg (44.1 lb) kit comprising of one part-filled drum of grey coloured resin (Part A) and one plastic pail of light coloured hardener (Part B). Use of this kit size ensures provides sufficient space in the drum to allow the Part B hardener to be decanted into the Part A resin for mixing. Only full kits should be mixed to ensure the material is mixed in the correct ratio. C3.5 Material Preparation for Single Leg Airless Spray Application Material preparation for single leg airless spray application requires the Chartek to be brought up to the ideal temperature for spraying. Temperature is critical to ensure the correct viscosity to allow good spray application to be achieved. This needs to be carefully monitored, too cold and the material will not atomise and spray, too hot and the pot life will be reduced and there will be the risk of blockages and curing of materials in the lines. For guidance on working pot life see the following table:

Figure C1: 20kg (44.1 lb) Kit




25°C (77°F) 30°C (86°F)

40 minutes 30 minutes Note: Pot life is a guide to the time from mixing of the kit to the complete spray-out of the mixed kit and ability to trowel and roll the material once applied to the steel. It is not a measure of time for mixing to start of spraying. Once a kit is mixed, spraying of the kit should commence as soon as possible, ideally within a few minutes, as the exothermic reaction of the mixed material in the drum will cause the temperature to rise and pot life to be dramatically reduced. Prior to spraying Chartek with single leg airless spray equipment, the material should be brought to a temperature of 25 to 30°C (77 to 86°F) for a minimum of 24 hours prior to use. Material temperature should be measured using a thermometer (such as a digital temperature probe type). Best spray results will be achieved when the material temperature is within the following range: Material Optimum mixed temperature

oC Chartek 7 30 to 35 Chartek 1709 25 to 30

Accelerated methods of heating the Chartek containers, such as electrical heaters in direct contact with the containers or hot water baths, are not permitted. Such methods can cause overheating of the outer layers of Chartek in the container, which may produce undesirable changes to its properties (including shorter pot life). C3.6 Heated Storage Units To achieve the correct temperatures it may be necessary to use heated storage units, especially in cold and temperate climates. Such storage units are typically built from standard site storage containers. The container will generally be lined with thermal insulation (see photographs below) and should be suitably ventilated.

Figure C2: Digital thermometer and probe.




Figure C3: Typical storage container, showing insulation on inside In addition the container will normally require to be fitted with a thermostatically controlled heater. Heater and electrical installation should be carried out by a qualified electrician to meet prevailing regulatory requirements. Heaters should be protected by guards to prevent accidental damage and also to prevent Chartek drums being placed directly against the heaters. Alternatively heaters may be installed under a grated floor allowing the heat to rise through stacked drums of Chartek. Figure C4: Example fin tube heaters (heater type dependent on local regulations) The number of heaters used and their power rating will depend on the size of container used, local climate conditions and amount of insulation fitted. Heater manufacturer should be consulted for advice. For smaller projects, or where greater portability is required, custom made hot boxes can be used, these should be of adequate size and number to allow sufficient material to be held at the correct temperature for the work to progress smoothly. QA/QC measurement of storage conditions should be maintained. It should also be noted in tropical or desert climates it may be required to fit refrigeration equipment to ensure the material does not become too hot. C3.7 Mixing Equipment There are two critical aspects to mixing Chartek, firstly to ensure that the two components are thoroughly mixed and secondly to undertake the mixing operation as quickly as possible to ensure maximum working pot life is maintained.





Proprietary Chartek mixing equipment is available from a number of manufacturers. C3.8 Use of Solvent If a single leg airless spray pump application is utilised, the Chartek must be premixed and generally will require the use of solvent to reduce viscosity for mixing and spraying and to extend the working pot life of the material. Propylene Methoxyacetate (PMA) solvent is the approved solvent type for use with Chartek. It is essential that the solvent is of high quality, clean and not contaminated with water or other contaminants. It must be of “Virgin”, “Technical”, “Laboratory” or “A1” grade and with certified water content less than 100ppm. It should be stored in drums/containers that are airtight and re-sealable. Under no circumstances should recycled or reclaimed solvents be used or old, used containers refilled. International Protective Coatings’ product GTA123 is recommended.

Figure C5: Suitable Chartek mixing equipment




The solvent is added to Part A (resin) of the Chartek kit. The amount of PMA solvent required varies with initial material temperature but typically will be 0.5 litres (1 pint) per full 20kg (44.1 lb) kit of Chartek. At most, a maximum of 1.0 litre (0.25 US gallons) may be used per full 20kg (44.1 lb) kit of Chartek. The solvent used for mixing should also be at room temperature (typically 20°C (68°F)) to prevent it cooling down the Chartek when added. C3.9 Mixing Procedure Kits should not be mixed until they are ready to be used. Once mixed the kit should be sprayed as soon as possible, ideally it should be loaded into the machine within a few minutes of mixing. After addition of PMA solvent into part A it should be mixed to incorporate the solvent fully within the resin. The mixing should begin slowly and speed built up gradually. When Part A has reached a smooth consistency, Part B is then poured into the Part A container, scraping the sides of the Part B container to empty it completely, ensuring correct ratio of material is mixed. Only full kits should be mixed to ensure the material is mixed in the correct ratio. Again, the mixing should begin slowly and speed built up gradually, mixing carefully until a smooth texture and uniform colour are achieved. The shearing action of mixing the material will cause the material to heat up so temperature should be checked after mixing. In addition, once the material is in a mixed state and left in the drum, the exothermic nature of the reaction will cause the material to continue to increase in temperature, greatly reducing the available pot life. If spray operations are held up for any reason then extended pot life can be achieved by emptying out mixed Chartek on to flat surfaces, spreading it out to reduce exothermic reaction and using it for trowel application. C3.10 Single Leg Airless Spray Equipment Only airless single leg spray equipment qualified by International Protective Coatings should be used. Typical equipment specification would be as follows: Pump Compression Ratio


Figure C6: Modified Airless Spray Unit










Figure C7: High Pressure Spray Gun





During stoppages in the day’s production (lunch breaks, etc.) the machine must be circulated with solvent (GTA007) and the spray gun and tip must also be removed and immersed in solvent. C3.11 Single Leg Spray Application Method In order to ensure trouble free operation of this type of pump the material must be maintained at the correct temperature. It is therefore necessary to provide controlled heated storage for the Chartek and advisable to place the machine in a modified insulated container for work at low air temperatures. There should be sufficient area available to spray and enough manpower to keep up with the gun. Frequently shutting down spray machines causes wasted time and material spent cleaning and causes pressure build up in the material lines and spray gun, which may represent a safety hazard. The first coat of Chartek is sprayed and quickly trowelled into the surface to ensure good wetting and even thickness. Trowelling also helps to thoroughly encapsulate any pre-installed mesh and reduces the formation of air pockets. With airless spray applications using qualified equipment and where HK-1TM or no mesh is being used, trowelling the first coat may be eliminated. In these instances it is essential that there is thorough atomisation achieving consistent even spray fan (no fingering) and 100% wetting of the surface. If trowelled, trowel marks and high points are knocked down with a short nap roller dampened with PMA solvent. The real purpose of this rolling is to achieve a uniform thickness of the coat, which allows uniform build up of subsequent coats and ultimately the correct final thickness. Rolling also serves to produce a smooth surface finish, when required. Two precautions to take with rolling are:






Beyond 24 hours, surfaces must be suitably washed with one of the approved methods described in Section A2. It is imperative that surfaces are clean and thoroughly dry before additional coats of Chartek are applied. When using HK-1 mesh and more than 24 hours is expected before overcoating, it is a requirement that a sprayed holding coat is applied over the HK-1 mesh to prevent contamination entrapment. The final coat, when applied to a ‘wet’ surface, should be sufficiently thick to allow good ‘flowing out’ and to minimise surface roughness and to achieve the specified final thickness. In applying a final coat to a hardened surface the thickness should be no less than 3mm (1/8”) to ensure adequate adhesion to the hardened surface. When spraying in cold conditions, the pump should be located in a heated area, ideally the same area that is used to store the Chartek at a sprayable temperature. Hoses may be insulated and ambient temperature parameters must be frequently checked and maintained. In hot conditions, the spray unit and Chartek must be located in an air-conditioned environment. Hoses should be insulated and wrapped with heat reflecting tape. It may also be necessary to raise hoses above the ground in extremely hot environments. High substrate temperatures should be avoided by providing suitable shade cover and air-conditioning of the area immediately surrounding the workface may also be necessary. C3.12 Water Contamination CAUTION: If rain or condensation occurs during application or shortly thereafter, moisture may be absorbed into the uncured material. In addition, an amine bloom may form on the Chartek surface. These conditions will affect intercoat adhesion. Take the following action if water contamination occurs: Contamination Action Cured Chartek (fresh water): Dry and solvent wipe Cured Chartek (salt water): Warm water wash - maximum 60°C (140°F)



C3.13 Surface Finish Discontinuities, pinholes, voids or isolated deposits of excess thickness in the coating are not acceptable. Where there is the risk of water ponding on horizontal surfaces, the Chartek should be sloped sufficiently to avoid ponding.




Samples of the surface finish acceptable to the client, a reference area, must be prepared by the applicator prior to project start-up. See the Quality Control Manual for Chartek Fireproofing Systems Application for further details. C3.14 Terminations Caulking or sealing of free edges and terminations is not required for Chartek fireproofing.




C4.0 CHARTEK APPLICATION WITH PLURAL SPRAY EQUIPMENT C4.1 Ambient Conditions Suitable application conditions are of critical importance for the successful application of Chartek. Consequently, Chartek should only be applied when the ambient conditions are within the following parameters:


However, Chartek may be applied at an air temperature minimum 5°C (41°F) using plural spray equipment only, recognising that the time to cure will in such applications be extended. Additionally, there may also be a higher propensity for amine bloom formation which would affect overcoating with further layers of Chartek, where required, and may affect overcoating with topcoats. For such low air temperature applications, plural equipment is the only recommended dispensing method. C4.2 Surface Cleanliness To ensure proper adhesion of Chartek to the primed substrate, the surfaces to be coated must be dry and free from oil, grease, dirt or any other contaminants that have been deposited since surface preparations were completed. It is the applicator’s responsibility to inspect all surfaces to be coated and clean them if necessary (see the notes on degreasing in Section A2.2). Ambient conditions are of critical importance for a successful application. If they cannot be kept within the above parameters, Chartek application may only proceed if adequate environmental protection is provided. C4.3 Primer and Surface Preparation It is the applicator’s responsibility to verify that the correct primer type (included in the list of qualified primers), thickness (as specified in Section A2.0, Table A1: Chartek Surface Preparation Requirements) requirements are complied with. It is also the applicator’s responsibility to ensure that the preparation of the surface which is to be overcoated with Chartek is in accordance with the requirements of this Application Manual and other documents that may be applicable. For acceptance of the primed surface, checks shall include, but not be limited to, the following: a) The surface profile is in accordance with this Application Manual and other documents that









It is the applicator’s responsibility to ensure that the primed surface and the primer itself are in an acceptable condition for overcoating with Chartek. Such factors as ageing of the primer (degradation and surface chalking), contamination, rust bloom, etc. shall be considered when determining a surface’s suitability before overcoating with Chartek. Where there is any doubt as to a primer’s acceptance, the primer manufacturer should be consulted and International Protective Coatings advised. NB: Overcoating a primer system with a 100% solids epoxy material such as Chartek is different to overcoating with further layers of material, especially solvented materials. Consequently, it is important that the primer manufacturer should be fully informed of the overcoating system and purpose of that system when directing any questions to the manufacturer concerning overcoating. International should be consulted where any doubt exists. C4.4 Material Preparation for Plural Component Spray Application Prior to spraying Chartek with plural component spray equipment, the material should be preheated to the following requirement: • 30 to 34°C (86 to 93°F) for 24 hours (maximum 48 hours) prior to use WARNING: Accelerated methods of heating the Chartek containers, such as electrical heaters in direct contact with the containers or hot water baths, are not permitted. Such methods can cause overheating of the outer layers of Chartek in the container, which may produce undesirable changes to its properties (including shorter pot life). C4.5 Plural Component Spray Equipment As Chartek is a thixotropic material, it is most efficiently applied with purpose built hot spray plural component pumps, which have the advantage of not requiring any premixing of the two parts. Parts A and B of Chartek are pumped into separate pressurised heated tanks, equipped with high torque paddle mixers, where they are brought up to temperature. From here, the separate parts are drawn into a fixed ratio displacement pump that establishes the correct ratio in volume. The two parts, still separate, are then pumped through electric in-line heaters and on through heated insulated hoses to an in-line static mixer (“worm”). As the two parts are pushed through the worm they are intimately mixed, then fed through a short whip line, typically 4.5 metres (15ft) long, to the high pressure (minimum 500 bar (7250 psi)) airless spray gun. Too cool a gun exit temperature may result in fingering of the spray pattern due to insufficient atomisation, while too hot a temperature will produce too rapid a cure and make trowelling difficult.




In order to ensure trouble free operation of this type of pump the material must be maintained at the correct temperature. It is therefore necessary to provide controlled heated storage for the Chartek and advisable to place the machine in a modified insulated container for work at low air temperatures. The importance of keeping all spray equipment clean and efficient cannot be overstated, as down time is very costly. For this reason a skilled and experienced machine operator is a vital component of the team. Machines built to spray Chartek are supplied by a number of companies. Each supplier provides instructions on machine operation and maintenance. International Protective Coatings should always be consulted regarding the suitability of spray equipment. Because of the larger volume of material delivered by these machines, crew sizes are larger to keep up with the gun. The material is delivered hot and therefore must be worked more quickly than conventional spray

Table C2: Operating Parameters for Plural Component Spray Machines

Operating Parameters Storage tank temperatures Part A: max. 60°C (140°F )

Part B: max. 50°C (122°F ) In-line heater temperatures Part A: 55 to 65°C (131 to 149°F )

Part B: 45 to 55°C (113 to 131°F ) Hose heater temperature 55 to 65°C (131 to 149oF)

Gun exit temperature 50 to 55°C (122 to 131°F ) Storage tank pressures Part A: 5.5 bar (80 psi)

Part B: 2.72 bar (40 psi) Tank stirrer speed Part A: 10rpm minimum






C4.6 Ratio Checks It is important that the delivery ratio of plural spray pumps is regularly checked. As a minimum, a ratio check by weight should be performed at the start up of each day’s production and again if the machine is shut down and restarted for any reason. Use the following procedure for ratio checks by weight: 1. Weigh clean empty Parts A and B containers and note the respective weights. 2. Place the containers under the ratio check valves located on the mixing block and open the





Part B full container weight 4.05kg (8.91lb)







C4.7 Plural Spray Application Method In order to ensure trouble free operation of this type of pump the material must be maintained at the correct temperature. It is therefore necessary to provide controlled heated storage for the Chartek and spray pump. When spraying in cold conditions, the spray pump should be located in a heated area, ideally the same area that is used to store the Chartek at a sprayable temperature. Hoses should be insulated and heated and ambient temperature parameters must be frequently checked and maintained.




In hot conditions, the spray pump and Chartek must be located in an air-conditioned environment. Hoses should be insulated and wrapped with heat reflecting tape. It may also be necessary to raise hoses above the ground in extremely hot environments. High substrate temperatures should be avoided by providing suitable shade cover and air-conditioning of the area immediately surrounding the workface may also be necessary. There should be sufficient area available to spray and enough manpower to keep up with the gun. Frequently shutting down spray machines causes wasted time and material spent cleaning and causes pressure build up in the material lines and spray gun, which may represent a safety hazard. The first coat of Chartek is sprayed and quickly trowelled into the surface to ensure good wetting and even thickness. With plural spray equipment applications and where HK-1TM or no mesh is being used, trowelling the first coat may be eliminated provided there is thorough atomisation achieving consistent even spray fan (no fingering) and 100% wetting of the surface. Trowelling also helps to thoroughly encapsulate any pre-installed mesh and reduces the formation of air pockets. If trowelled, trowel marks and high points are knocked down with a short nap roller dampened with PMA solvent. Rolling achieves a uniform thickness of the coat, which allows uniform build up of subsequent coats and ultimately the correct final thickness. Rolling also serves to produce a smoother surface finish, reducing high spots and stippled finish. Two precautions to be taken with rolling are: 1. If the Chartek has not gelled (started to cure) sufficiently, it can sag or slump. 2. Too much solvent on the roller can reduce the cure rate if it is forced into the wet Chartek. For subsequent coats, sufficient time must pass for the applied Chartek to gel (“set up” or partially cure) in order to support the weight of the additional material. Preferably, subsequent coats should be applied when the previous coat is still tacky. Where practicalities prevent “wet on wet” application, overcoating time should be reduced to a minimum and a sprayed holding coat should be applied to leave the Chartek with a good key to improve the adhesion of the next coat. In addition, a sprayed holding coat is applied over HK-1TM mesh to prevent contamination entrapment when extended overcoating intervals are expected. The holding coat is produced by boosting the Chartek temperature (in the plural component spray equipment) and/or raising the pump output pressure to give a wide fan and increased atomisation. The spray pass is much faster than normal and the result is a coarse finish that promotes good bonding with subsequent coats. Before spraying subsequent coats onto cured surfaces, they should be checked for cleanliness and, if required, suitably cleaned with one of the approved methods described in Section A2.0 “Surface Preparation”. It is imperative that surfaces are clean and thoroughly dry before additional coats of Chartek are applied.




The final coat, when applied to a ‘wet’ surface, should be sufficiently thick to allow good ‘flowing out’ and to minimise surface roughness and to achieve the specified final thickness. In applying a final coat to a hardened surface the thickness should be no less than 3mm (1/8”) to ensure adequate adhesion to the hardened surface. C4.8 Water Contamination CAUTION: If rain or condensation occurs during application or shortly thereafter, moisture may be absorbed into the uncured material. In addition, an amine bloom may form on the Chartek surface. These conditions will affect intercoat adhesion. Take the following action if water contamination occurs: Contamination Action Cured Chartek (fresh water): Dry and solvent wipe Cured Chartek (salt water): Warm water wash - maximum 60°C (140°F)



C4.9 Surface Finish Discontinuities, pinholes, voids or isolated deposits of excess thickness in the coating are not acceptable. Where there is the risk of water ponding on horizontal surfaces, the Chartek should be sloped sufficiently to avoid ponding. Samples of the surface finish acceptable to the client, a reference area, must be prepared by the applicator prior to project start-up. See the Quality Control Manual for Chartek Fireproofing Systems Application for further details. C4.10 Terminations Caulking or sealing of free edges and terminations is not required for Chartek fireproofing.




C5.0 HAND TROWEL APPLICATION C5.1 Ambient Conditions Suitable application conditions are of critical importance for the successful application of Chartek. Consequently, Chartek should only be applied when the ambient conditions are within the following parameters:


However, Chartek may be applied at an air temperature minimum 5°C (41°F) using plural spray equipment only, recognising that the time to cure will in such applications be extended. Additionally, there may also be a higher propensity for amine bloom formation which would affect overcoating with further layers of Chartek, where required, and may affect overcoating with topcoats. For such low air temperature applications, plural equipment is the only recommended dispensing method. C5.2 Surface Cleanliness To ensure proper adhesion of Chartek to the primed substrate, the surfaces to be coated must be dry and free from oil, grease, dirt or any other contaminants that have been deposited since surface preparations were completed. It is the applicator’s responsibility to inspect all surfaces to be coated and clean them if necessary (see the notes on degreasing in Section A2.2). Ambient conditions are of critical importance for a successful application. If they cannot be kept within the above parameters, Chartek application may only proceed if adequate environmental protection is provided. C5.3 Primer and Surface Preparation It is the applicator’s responsibility to verify that the correct primer type (included in the list of qualified primers), thickness (as specified in Section A3.0) requirements are complied with. It is also the applicator’s responsibility to ensure that the preparation of the surface which is to be overcoated with Chartek is in accordance with the requirements of this Application Manual and other documents that may be applicable. For acceptance of the primed surface, checks shall include, but not be limited to, the following: (a) The surface profile is in accordance with this Application Manual and other documents that









It is the applicator’s responsibility to ensure that the primed surface and the primer itself are in an acceptable condition for overcoating with Chartek. Such factors as ageing of the primer (degradation and surface chalking), contamination, rust bloom, etc. shall be considered when determining a surface’s suitability before overcoating with Chartek. Where there is any doubt as to a primer’s acceptance, the primer manufacturer should be consulted and International Protective Coatings advised. NB: Overcoating a primer system with a 100% solids epoxy material such as Chartek is different to overcoating with further layers of material, especially solvented materials. Consequently, it is important that the primer manufacturer should be fully informed of the overcoating system and purpose of that system when directing any questions to the manufacturer concerning overcoating. International should be consulted where any doubt exists. C5.4 Material Preparation for Hand Trowel Application Prior to applying Chartek by hand trowel, the material should be preheated to the following requirement: • Warm enough to mix, typically 20 to 25oC (68 to 77°F) Note: The higher the temperature the shorter the working pot life. Pot life durations are published on the product data sheets Accelerated methods of heating the Chartek containers, such as electrical heaters in direct contact with the containers or hot water baths, are not permitted. Such methods can cause overheating of the outer layers of Chartek in the container, which may produce undesirable changes to its properties (including shorter pot life). C5.5 Mixing For hand application Chartek must be premixed. A small amount of PMA (propylene methoxyacetate) thinner is added to Part A to reduce viscosity for mixing and application International’s thinner GTA123 or GTA822 is recommended for this purpose. The amount required varies with initial material temperature but up to 0.5 litres (0.13 US gallons) may be used per full kit of Chartek. When Part A has reached a smooth consistency, the Part B is then poured into the Part A container, scraping the sides of the Part B container to empty it completely. The two parts are thoroughly mixed together with a high torque variable speed paddle mixer, minimum 5 HP air motors (or 1000W/110V electric motor minimum) equipped with 250mm (10”) paddles. Mixing should continue until a uniform colour is achieved




For best results, the mixer should be mounted on a power ram base to ease the effort required and to allow vertical movement of the paddle blade. The mixing should begin slowly and speed built up gradually. Mix carefully until a smooth texture and uniform colour are achieved. For a full kit this is approximately 4 minutes. Kits should not be mixed until they are ready to be used. C5.6 Hand Trowel Application Method Chartek may be applied using plasterer’s trowels, which has the advantage of very little waste and virtually eliminates the need for masking. After a kit has been mixed, it may be spread out on flat clean boards or surfaces for each applicator to work with. This prevents the material from curing too quickly and allows sufficient working time. Alternatively the material may be applied directly from the pail. Trowel marks and high points are knocked down with a short nap roller dampened with PMA solvent. Rolling achieves a uniform thickness of the coat, which allows uniform build up of subsequent coats and ultimately the correct final thickness. Rolling also serves to produce a smoother surface finish, reducing high spots and stippled finish. Two precautions to be taken with rolling are: 1. If the Chartek has not gelled (started to cure) sufficiently, it can sag or slump. 2. Too much solvent on the roller can reduce the cure rate if it is forced into the wet Chartek. For subsequent coats, sufficient time must pass for the applied Chartek to gel (“set up” or partially cure) in order to support the weight of the additional material. Preferably, subsequent coats should be applied when the previous coat is still tacky. Where practicalities prevent “wet on wet” application, overcoating time should be reduced to a minimum. In addition, an encapsulating coat is applied over HK-1TM mesh to prevent contamination entrapment when extended overcoating intervals are expected C5.7 Mixing of Partial Kits Often trowel application will require less than a full kit of Chartek. In these cases, the required amounts of Parts A and B should be accurately weighed out into a clean container and thoroughly mixed. The correct ratio by weight for Chartek is as follows: When complete kits are to be split down the following method of calculation may be used:





2.50:1



Required Weight of Part B calculated as follows: Measured Weight of Part A ÷ 2.50 (the Chartek 8 weight ratio)

e.g. 8kgs of Part A ÷ 2.50 = 3.20kgs of Part B Therefore the required amount of Part B to be weighed out and added to the 8kgs of Part A is 3.20kgs.

C5.8 Water Contamination CAUTION: If rain or condensation occurs during application or shortly thereafter, moisture may be absorbed into the uncured material. In addition, an amine bloom may form on the Chartek surface. These conditions will affect intercoat adhesion. Take the following action if water contamination occurs: Contamination Action Cured Chartek (fresh water): Dry and solvent wipe Cured Chartek (salt water): Warm water wash - maximum 60°C (140°F)



C5.9 Surface Finish For trowel application a smooth, even and rolled finish should be achieved. Discontinuities, pinholes, voids or isolated deposits of excess thickness in the coating are not acceptable. Where there is the risk of water ponding on horizontal surfaces, the Chartek should be sloped sufficiently to avoid ponding. Samples of the surface finish acceptable to the client, a reference area, must be prepared by the applicator prior to project start-up. See the Quality Control Manual for Chartek Fireproofing Systems Application for further details. C5.10 Terminations Caulking or sealing of free edges and terminations is not required for Chartek fireproofing.




APPENDICES




APPENDIX A – HK-1TM Meshing Detail




APPENDIX B – Not Applicable THIS APPENDIX HAS BEEN DELIBERATELY LEFT BLANK.




APPENDIX C – Certified Thicknesses - Bulkheads and Decks


Chartek® 8

Certified Reinforcement and Thickness Arrangements for Bulkhead and Decks

TABLE 1: BULKHEADS

Chartek 8 Thickness (mm)

Design Lloyd’s Register Det Norske Veritas American Bureau of

Shipping

A-60 class (Insulated backface) NC NC NC

H-0 class (400°C) 4.0 No mesh

4.0 No mesh NC

H-30 class NC NC NC


5.0 No mesh NC NC

H-60 class NC NC NC


6.0 No mesh

6.0 No mesh NC

H-120 class NC NC NC


TABLE 2: DECKS

Chartek® 8 Thickness (mm)

Design Lloyd’s Register Det Norske Veritas American Bureau of

Shipping

A-60 class NC NC NC

H-0 class (400°C) 4.5 No mesh

4.5 No mesh NC

H-30 class NC NC NC


5.0 No mesh

5.0 No mesh NC

H-60 class NC NC NC


6.0 No mesh

6.0 No mesh NC

H-120 class NC NC NC

NC = Not Certified


ADDITIONAL THICKNESS FOR JET FIRES: Notes: The thickness of coating Chartek® for jet fire exposure may determined by adding a “jet fire erosion thickness” as shown in Tables 3 or 4 (dependent on mesh type used) to the thickness required by hydrocarbon testing as shown in Tables 1 and 2. In all instances the mesh type, position and overlaps shall be strictly in accordance with the Chartek Application Manual and relevant certification. Table 3: Jet Fire Erosion Thickness – HK-1 Mesh

Additional Chartek 8 Thickness (mm) Jet Fire Duration


No Jet Fire NC NC NC

Up to 20 minutes jet fire NC NC NC

21 to 30 minutes jet fire NC NC NC





NC = Not Certified


Table 4: Jet Fire Erosion Thickness – Stainless Steel Mesh

Additional Chartek 8 Thickness Jet Fire Duration


No Jet Fire NC NC NC

Up to 20 minutes jet fire NC NC NC






NC = Not Certified

ID Rev. Date APP MAN UK







edge terminations





Mesh Overlaps







1. Clean surface 2. Prime surface*

Apply 50-75 microns (2-3 mils)of qualified primer*

3. Inspect

4. Wetting coat of Chartek 5. If HK-1 mesh required, build up to mesh depth (mid film thickness)

6. Inspect for thickness and uniformity 7. Install HK-1 mesh, if required, in wet Chartek

Wet gauge Ensure correct mesh overlaps, minimum 50mm (2”), in accordance

with Chartek Application Manual




12. Finish with recommended topcoat as required. Record

type and QA details

For full details refer to the current Chartek Application Manual.

20 March 2006_Rev.1

* For qualified primers and alternative topcoats, please contact International Paint

Clean and degrease to SSPC-SP1, blast surface

to SSPC-SP10 or ISO 8501-1 Sa 2½, profile 50-

75 microns (2-3 mils)

Record QA details. i.e. weather, blast profile,

type of primer, etc.

Apply typically 2-3mm (75-115 mils). Ensure surface is fully wetted,

trowel if required.

HK-1 mesh required where specified thickness is greater than 7.2mm (283 mils)

Installed at approximate mid film

Wet gauge or drill

©International Paint Limited, 2006This document and its contents are the copyright of International Paint Limited and may not be reproduced in whole or in part without the express permission of International Paint Limited

Chartek 8 - Basic Installation Checklist







1


(PITR)











2




• The primer system is of known origin and approved by International Paint for use under Chartek fireproofing. The primer system must be a recognised primer in accordance with the current acceptable primers list for use with Chartek fireproofing, obtainable from International Paint, Fire & Insulation Products.








(2–3 mils) 100


(3–4.4 mils)



breakthrough, contamination, or other defective condition which would indicate that the primer may not be suitable for overcoating with Chartek fireproofing in accordance with the Chartek 7 Fireproofing Application Manual.






3


















4





3.5 Chartek fireproofing must be installed in strict accordance with the Chartek 7

Fireproofing Application Manual. Particular attention should be paid to the environmental conditions during application of material.




overcoating of the prepared surface has been given as in 2.9 above. Where required this will include acceptance by the Chartek fireproofing Field Service Engineer as part of the fire protection installation audit procedure conducted by International Paint.




4.2 Topcoating should be applied in accordance with the Chartek 7 Fireproofing

Application Manual in a timely fashion.





Technical Note

TN/F/083_Rev.1_040205


1







Technical Note

TN/F/083_Rev.1_040205


2


Technical Note

TN/F/083_Rev.1_040205


3








1








TO L E R A N C E S

GL O S S LE V E L


DRY I N G TI M E















Minimum


OV E R C O AT I N G

IN T E RVA L








Maximum


Extended










FL A S H PO I N T

















SH E L F LI F E


CO N T E N T (VOC)






SECTION D – CHARTEK 1709




D1.0 CHARTEK PACKAGING AND STORAGE D1.1 50kg (110 lb) Kit For plural component spray equipment, Chartek is supplied in a 50kg (110 lb) kit comprising of two drums of grey coloured resin (Part A) and one drum of light coloured hardener (Part B). 50kg (110 lb) Kit Size Part A (2 Drums)

35.70kg (78.7 lb)

Part B (1 Drum)

14.30kg (31.5 lb)

Total 50.00kg (110.2 lb) NOTE: 50kg (110 lb) kits are only suitable for use with plural spray equipment. D1.2 20kg (44.1 lb) Kit For single component pumps and trowel application, Chartek is supplied in a 20kg (44.1 lb) kit comprising of one part filled drum of grey coloured resin (Part A) and one plastic pail of light coloured hardener (Part B). This allows the hardener to be decanted into the Part A resin for mixing. 20kg (44.1 lb) Kit Size Part A 14.3kg (31.5 lb)Part B 5.7kg (12.6 lb)Total 20.0kg (44.1 lb) NOTE: 20kg (44.1 lb) kits can also be used with plural spray equipment. D1.3 Cast Grade For casting work a less viscous version, Chartek cast grade, is available. For further details contact International Protective Coatings. D1.4 General Storage Conditions for Chartek D1.4.1 Storage Conditions Chartek should be stored dry, indoors and out of direct sunlight. The material should be protected from frost and excessive temperatures. Drums should be stored unopened and damage to drums avoided. Stock should be rotated to ensure oldest material is used first. D1.4.2 Storage Temperature Ideally the material should be stored at room temperature 20°C (68°F) and should in all circumstances be stored within the following storage temperature ranges:




• Minimum 1°C (34°F) • Maximum 30°C (86°F) Storage temperatures should be monitored and recorded as part of the QA/QC procedures. This is achieved by the use of a minimum/maximum thermometer (see photos below).

Figure D1: Example Minimum/Maximum Thermometers




D2.0 HK-1TM CARBON FIBRE MESH REINFORCEMENT D2.1 Meshing Designs The meshing requirements are given below. Particular attention should be paid to the Chartek type and thickness, and fire type. Refer to Appendix A for HK-1 mesh design drawings.

Table D1: HK-1 Mesh Requirements

Use Hydrocarbon (Pool) Fires Jet Fires

Structural Steel Tested and certified in accordance with ANSI/UL1709 standard without the use of mesh reinforcement on fire ratings up to and including 1 hour and with HK-1 mesh reinforcement only on the flanges, around tips, for fire ratings greater than 1 hour and up to 3½ hours.


D2.2 HK-1 and HK-1 (M) Carbon Fibre Mesh Reinforcement HK-1 and HK-1 (M) carbon fibre meshes are knitted cloth of carbon filaments and glass thread. Both meshes are equivalent to each other with respect to their construction and constituent materials, and their performance. The designation of HK-1 and HK-1 (M) relates only to their manufacturing source. D2.3 Packaging of HK-1TM and HK-1 (M)TM Carbon Fibre Mesh Reinforcement HK-1 and HK-1 (M) are available from International Protective Coatings in 165m2 (1776ft2) and 167.3m2 (1800 ft2) rolls respectively. D2.4 General Rules for HK-1 Meshing (where required*) 8. Cut mesh to required sizes before starting Chartek application. 9. Apply mesh to wet Chartek at approximately mid thickness. 10. Roll the mesh thoroughly into the wet Chartek with short nap rollers dampened with PMA

solvent. 11. Overlap adjacent pieces of mesh by at least 50mm (2”). For jet fire applications, overlap

by at least 150mm (6”). 12. To minimise waste the straight carbon (black) fibres are parallel to flange edges and the axis of

hollow sections. 13. After installing HK-1, either continue to build up the required thickness or spray a light coat of

Chartek over the mesh to leave a good key for subsequent coats. *NOTE: Chartek 1709 is tested and certified in accordance with ANSI/UL1709 standard without the use of mesh reinforcement on fire ratings up to and including 1 hour and with HK-1 mesh reinforcement only on the flanges, around tips, for fire ratings greater than 1 hour and up to 3½ hours.




D3.0 METAL MESH REINFORCEMENT D3.1 Metal Mesh Reinforcement Requirements Extensive fire testing has demonstrated the effectiveness of HK-1TM carbon fibre mesh reinforcement for use with Chartek 1709. Chartek 1709 is also certified for use with HK-1,and in some cases without the need for mesh reinforcement at all (as indicated on the certification and detailed within this Manual). However, there are occasions when owners, specifiers or approval authorities may insist on the use of metal mesh reinforcement over and above the requirements of the fire testing and certification, particularly in Norway where NORSOK M-501 standard requirements may be strictly enforced. NORSOK M-501, prescriptively, requires pins and metal mesh reinforcement. For projects where metal mesh reinforcement is required please contact International Protective Coatings’ Regional Technical Manager for guidance.




D4.0 APPLICATION WITH SINGLE LEG AIRLESS SPRAY EQUIPMENT D4.1 Ambient Conditions Suitable application conditions are of critical importance for the successful application of Chartek. Consequently, Chartek should only be applied when the ambient conditions are within the following parameters: • Air temperature: minimum 10°C (50°F) • Relative humidity: maximum 85% • Surface temperature: at least 3°C (5°F) above dew point temperature However, Chartek may be applied at an air temperature minimum 5°C (41°F) using plural spray equipment only, recognising that the time to cure will in such applications be extended. Additionally, there may also be a higher propensity for amine bloom formation which would affect overcoating with further layers of Chartek, where required, and may affect overcoating with topcoats. For such low air temperature applications, plural equipment is the only recommended dispensing method. D4.2 Surface Cleanliness To ensure proper adhesion of Chartek to the primed substrate, the surfaces to be coated must be dry and free from oil, grease, dirt or any other contaminants that have been deposited since surface preparations were completed. It is the applicator’s responsibility to inspect all surfaces to be coated and clean them if necessary (see the notes on degreasing in Section A2.2). Ambient conditions are of critical importance for a successful application. If they cannot be kept within the above parameters, Chartek application may only proceed if adequate environmental protection is provided. D4.3 Primer and Surface Preparation It is the applicator’s responsibility to verify that the correct primer type (included in the list of qualified primers), thickness (as specified in Section A3.0) requirements are complied with. It is also the applicator’s responsibility to ensure that the preparation of the surface which is to be overcoated with Chartek is in accordance with the requirements of this Application Manual and other documents that may be applicable. For acceptance of the primed surface, checks shall include, but not be limited to, the following: (a) The surface profile is in accordance with this Application Manual and other documents that










D4.4 Kit Size For single leg airless spray pump application, Chartek is supplied in a 20kg (44.1 lb) kit comprising of one part-filled drum of grey coloured resin (Part A) and one plastic pail of light coloured hardener (Part B). Use of this kit size ensures provides sufficient space in the drum to allow the Part B hardener to be decanted into the Part A resin for mixing. Only full kits should be mixed to ensure the material is mixed in the correct ratio. D4.5 Material Preparation for Single Leg Airless Spray Application Material preparation for single leg airless spray application requires the Chartek to be brought up to the ideal temperature for spraying. Temperature is critical to ensure the correct viscosity to allow good spray application to be achieved. This needs to be carefully monitored, too cold and the material will not atomise and spray, too hot and the pot life will be reduced and there will be the risk of blockages and curing of materials in the lines. For guidance on working pot life see the following table:

Figure D1: 20kg (44.1 lb) Kit




25°C (77°F) 30°C (86°F)

40 minutes 30 minutes Note: Pot life is a guide to the time from mixing of the kit to the complete spray-out of the mixed kit and ability to trowel and roll the material once applied to the steel. It is not a measure of time for mixing to start of spraying. Once a kit is mixed, spraying of the kit should commence as soon as possible, ideally within a few minutes, as the exothermic reaction of the mixed material in the drum will cause the temperature to rise and pot life to be dramatically reduced. Prior to spraying Chartek with single leg airless spray equipment, the material should be brought to a temperature of 25 to 30°C (77 to 86°F) for a minimum of 24 hours prior to use. Material temperature should be measured using a thermometer (such as a digital temperature probe type). Best spray results will be achieved when the material temperature is within the following range:

Optimum mixed temperature oC

25 to 30 Accelerated methods of heating the Chartek containers, such as electrical heaters in direct contact with the containers or hot water baths, are not permitted. Such methods can cause overheating of the outer layers of Chartek in the container, which may produce undesirable changes to its properties (including shorter pot life). D4.6 Heated Storage Units To achieve the correct temperatures it may be necessary to use heated storage units, especially in cold and temperate climates. Such storage units are typically built from standard site storage containers. The container will generally be lined with thermal insulation (see photographs below) and should be suitably ventilated.

Figure D2: Digital thermometer and probe.




Figure D3: Typical storage container, showing insulation on inside In addition the container will normally require to be fitted with a thermostatically controlled heater. Heater and electrical installation should be carried out by a qualified electrician to meet prevailing regulatory requirements. Heaters should be protected by guards to prevent accidental damage and also to prevent Chartek drums being placed directly against the heaters. Alternatively heaters may be installed under a grated floor allowing the heat to rise through stacked drums of Chartek. Figure D4: Example fin tube heaters (heater type dependent on local regulations) The number of heaters used and their power rating will depend on the size of container used, local climate conditions and amount of insulation fitted. Heater manufacturer should be consulted for advice. For smaller projects, or where greater portability is required, custom made hot boxes can be used, these should be of adequate size and number to allow sufficient material to be held at the correct temperature for the work to progress smoothly. QA/QC measurement of storage conditions should be maintained. It should also be noted in tropical or desert climates it may be required to fit refrigeration equipment to ensure the material does not become too hot. D4.7 Mixing Equipment There are two critical aspects to mixing Chartek, firstly to ensure that the two components are thoroughly mixed and secondly to undertake the mixing operation as quickly as possible to ensure maximum working pot life is maintained.





Proprietary Chartek mixing equipment is available from a number of manufacturers. D4.8 Use of Solvent If a single leg airless spray pump application is utilised, the Chartek must be premixed and generally will require the use of solvent to reduce viscosity for mixing and spraying and to extend the working pot life of the material. Propylene Methoxyacetate (PMA) solvent is the approved solvent type for use with Chartek. It is essential that the solvent is of high quality, clean and not contaminated with water or other contaminants. It must be of “Virgin”, “Technical”, “Laboratory” or “A1” grade and with certified water content less than 100ppm. It should be stored in drums/containers that are airtight and re-sealable. Under no circumstances should recycled or reclaimed solvents be used or old, used containers refilled. International Protective Coatings’ product GTA123 is recommended.

Figure D5: Suitable Chartek mixing equipment




The solvent is added to Part A (resin) of the Chartek kit. The amount of PMA solvent required varies with initial material temperature but typically will be 0.5 litres (1 pint) per full 20kg (44.1 lb) kit of Chartek. At most, a maximum of 1.0 litre (0.25 US gallons) may be used per full 20kg (44.1 lb) kit of Chartek. The solvent used for mixing should also be at room temperature (typically 20°C (68°F)) to prevent it cooling down the Chartek when added. D4.9 Mixing Procedure Kits should not be mixed until they are ready to be used. Once mixed the kit should be sprayed as soon as possible, ideally it should be loaded into the machine within a few minutes of mixing. After addition of PMA solvent into part A it should be mixed to incorporate the solvent fully within the resin. The mixing should begin slowly and speed built up gradually. When Part A has reached a smooth consistency, Part B is then poured into the Part A container, scraping the sides of the Part B container to empty it completely, ensuring correct ratio of material is mixed. Only full kits should be mixed to ensure the material is mixed in the correct ratio. Again, the mixing should begin slowly and speed built up gradually, mixing carefully until a smooth texture and uniform colour are achieved. The shearing action of mixing the material will cause the material to heat up so temperature should be checked after mixing. In addition, once the material is in a mixed state and left in the drum, the exothermic nature of the reaction will cause the material to continue to increase in temperature, greatly reducing the available pot life. If spray operations are held up for any reason then extended pot life can be achieved by emptying out mixed Chartek on to flat surfaces, spreading it out to reduce exothermic reaction and using it for trowel application. D4.10 Single Leg Airless Spray Equipment Only airless single leg spray equipment qualified by International Protective Coatings should be used. Typical equipment specification would be as follows: Pump Compression Ratio


Figure D6: Modified Airless Spray Unit










Figure D7: High Pressure Spray Gun





During stoppages in the day’s production (lunch breaks, etc.) the machine must be circulated with solvent (GTA007) and the spray gun and tip must also be removed and immersed in solvent. D4.11 Single Leg Spray Application Method In order to ensure trouble free operation of this type of pump the material must be maintained at the correct temperature. It is therefore necessary to provide controlled heated storage for the Chartek and advisable to place the machine in a modified insulated container for work at low air temperatures. There should be sufficient area available to spray and enough manpower to keep up with the gun. Frequently shutting down spray machines causes wasted time and material spent cleaning and causes pressure build up in the material lines and spray gun, which may represent a safety hazard. The first coat of Chartek is sprayed and quickly trowelled into the surface to ensure good wetting and even thickness. Trowelling also helps to thoroughly encapsulate any pre-installed mesh and reduces the formation of air pockets. With airless spray applications using qualified equipment and where HK-1TM or no mesh is being used, trowelling the first coat may be eliminated. In these instances it is essential that there is thorough atomisation achieving consistent even spray fan (no fingering) and 100% wetting of the surface. If trowelled, trowel marks and high points are knocked down with a short nap roller dampened with PMA solvent. The real purpose of this rolling is to achieve a uniform thickness of the coat, which allows uniform build up of subsequent coats and ultimately the correct final thickness. Rolling also serves to produce a smooth surface finish, when required. Two precautions to take with rolling are:






Beyond 24 hours, surfaces must be suitably washed with one of the approved methods described in Section A2. It is imperative that surfaces are clean and thoroughly dry before additional coats of Chartek are applied. When using HK-1 mesh and more than 24 hours is expected before overcoating, it is a requirement that a sprayed holding coat is applied over the HK-1 mesh to prevent contamination entrapment. The final coat, when applied to a ‘wet’ surface, should be sufficiently thick to allow good ‘flowing out’ and to minimise surface roughness and to achieve the specified final thickness. In applying a final coat to a hardened surface the thickness should be no less than 3mm (1/8”) to ensure adequate adhesion to the hardened surface. When spraying in cold conditions, the pump should be located in a heated area, ideally the same area that is used to store the Chartek at a sprayable temperature. Hoses may be insulated and ambient temperature parameters must be frequently checked and maintained. In hot conditions, the spray unit and Chartek must be located in an air-conditioned environment. Hoses should be insulated and wrapped with heat reflecting tape. It may also be necessary to raise hoses above the ground in extremely hot environments. High substrate temperatures should be avoided by providing suitable shade cover and air-conditioning of the area immediately surrounding the workface may also be necessary. D4.12 Water Contamination CAUTION: If rain or condensation occurs during application or shortly thereafter, moisture may be absorbed into the uncured material. In addition, an amine bloom may form on the Chartek surface. These conditions will affect intercoat adhesion. Take the following action if water contamination occurs: Contamination Action Cured Chartek (fresh water): Dry and solvent wipe Cured Chartek (salt water): Warm water wash - maximum 60°C (140°F)



D4.13 Surface Finish Discontinuities, pinholes, voids or isolated deposits of excess thickness in the coating are not acceptable. Where there is the risk of water ponding on horizontal surfaces, the Chartek should be sloped sufficiently to avoid ponding.




Samples of the surface finish acceptable to the client, a reference area, must be prepared by the applicator prior to project start-up. See the Quality Control Manual for Chartek Fireproofing Systems Application for further details. D4.14 Terminations Caulking or sealing of free edges and terminations is not required for Chartek fireproofing.




D5.0 CHARTEK APPLICATION WITH PLURAL SPRAY EQUIPMENT D5.1 Ambient Conditions Suitable application conditions are of critical importance for the successful application of Chartek. Consequently, Chartek should only be applied when the ambient conditions are within the following parameters:


However, Chartek may be applied at an air temperature minimum 5°C (41°F) using plural spray equipment only, recognising that the time to cure will in such applications be extended. Additionally, there may also be a higher propensity for amine bloom formation which would affect overcoating with further layers of Chartek, where required, and may affect overcoating with topcoats. For such low air temperature applications, plural equipment is the only recommended dispensing method. D5.2 Surface Cleanliness To ensure proper adhesion of Chartek to the primed substrate, the surfaces to be coated must be dry and free from oil, grease, dirt or any other contaminants that have been deposited since surface preparations were completed. It is the applicator’s responsibility to inspect all surfaces to be coated and clean them if necessary (see the notes on degreasing in Section A2.2). Ambient conditions are of critical importance for a successful application. If they cannot be kept within the above parameters, Chartek application may only proceed if adequate environmental protection is provided. D5.3 Primer and Surface Preparation It is the applicator’s responsibility to verify that the correct primer type (included in the list of qualified primers), thickness (as specified in Section A2.0, Table A1: Chartek Surface Preparation Requirements) requirements are complied with. It is also the applicator’s responsibility to ensure that the preparation of the surface which is to be overcoated with Chartek is in accordance with the requirements of this Application Manual and other documents that may be applicable. For acceptance of the primed surface, checks shall include, but not be limited to, the following: (a) The surface profile is in accordance with this Application Manual and other documents that









It is the applicator’s responsibility to ensure that the primed surface and the primer itself are in an acceptable condition for overcoating with Chartek. Such factors as ageing of the primer (degradation and surface chalking), contamination, rust bloom, etc. shall be considered when determining a surface’s suitability before overcoating with Chartek. Where there is any doubt as to a primer’s acceptance, the primer manufacturer should be consulted and International Protective Coatings advised. NB: Overcoating a primer system with a 100% solids epoxy material such as Chartek is different to overcoating with further layers of material, especially solvented materials. Consequently, it is important that the primer manufacturer should be fully informed of the overcoating system and purpose of that system when directing any questions to the manufacturer concerning overcoating. International should be consulted where any doubt exists. D5.4 Material Preparation for Plural Component Spray Application Prior to spraying Chartek with plural component spray equipment, the material should be preheated to the following requirement: • 30 to 34°C (86 to 93°F) for 24 hours (maximum 48 hours) prior to use WARNING: Accelerated methods of heating the Chartek containers, such as electrical heaters in direct contact with the containers or hot water baths, are not permitted. Such methods can cause overheating of the outer layers of Chartek in the container, which may produce undesirable changes to its properties (including shorter pot life). D5.5 Plural Component Spray Equipment As Chartek is a thixotropic material, it is most efficiently applied with purpose built hot spray plural component pumps, which have the advantage of not requiring any premixing of the two parts. Parts A and B of Chartek are pumped into separate pressurised heated tanks, equipped with high torque paddle mixers, where they are brought up to temperature. From here, the separate parts are drawn into a fixed ratio displacement pump that establishes the correct ratio in volume. The two parts, still separate, are then pumped through electric in-line heaters and on through heated insulated hoses to an in-line static mixer (“worm”). As the two parts are pushed through the worm they are intimately mixed, then fed through a short whip line, typically 4.5 metres (15ft) long, to the high pressure (minimum 500 bar (7250 psi)) airless spray gun. Too cool a gun exit temperature may result in fingering of the spray pattern due to insufficient atomisation, while too hot a temperature will produce too rapid a cure and make trowelling difficult.




In order to ensure trouble free operation of this type of pump the material must be maintained at the correct temperature. It is therefore necessary to provide controlled heated storage for the Chartek and advisable to place the machine in a modified insulated container for work at low air temperatures. The importance of keeping all spray equipment clean and efficient cannot be overstated, as down time is very costly. For this reason a skilled and experienced machine operator is a vital component of the team. Machines built to spray Chartek are supplied by a number of companies. Each supplier provides instructions on machine operation and maintenance. International Protective Coatings should always be consulted regarding the suitability of spray equipment. Because of the larger volume of material delivered by these machines, crew sizes are larger to keep up with the gun. The material is delivered hot and therefore must be worked more quickly than conventional spray Table D2: Operating Parameters for Plural Component Spray Machines Operating Parameters Storage tank temperatures Part A: max. 60°C (140°F)

Part B: max. 50°C (122°F) In-line heater temperatures Part A: 55 to 65°C (131 to 149°F)

Part B: 45 to 55°C (113 to 131°F) Hose heater temperature 55 to 65°C (131 to 149oF)

Gun exit temperature 50 to 55°C (122 to 131°F) Storage tank pressures Part A: 5.5 bar (80 psi)

Part B: 2.72 bar (40 psi) Tank stirrer speed Part A: 10rpm minimum






D5.6 Ratio Checks It is important that the delivery ratio of plural spray pumps is regularly checked. As a minimum, a ratio check by weight should be performed at the start up of each day’s production and again if the machine is shut down and restarted for any reason. Use the following procedure for ratio checks by weight:

1. Weigh clean empty Parts A and B containers and note the respective weights. 2. Place the containers under the ratio check valves located on the mixing block and open the





Part B full container weight 4.05kg (8.91lb







D5.7 Plural Spray Application Method In order to ensure trouble free operation of this type of pump the material must be maintained at the correct temperature. It is therefore necessary to provide controlled heated storage for the Chartek and spray pump. When spraying in cold conditions, the spray pump should be located in a heated area, ideally the same area that is used to store the Chartek at a sprayable temperature. Hoses should be insulated and heated and ambient temperature parameters must be frequently checked and maintained.




In hot conditions, the spray pump and Chartek must be located in an air-conditioned environment. Hoses should be insulated and wrapped with heat reflecting tape. It may also be necessary to raise hoses above the ground in extremely hot environments. High substrate temperatures should be avoided by providing suitable shade cover and air-conditioning of the area immediately surrounding the workface may also be necessary. There should be sufficient area available to spray and enough manpower to keep up with the gun. Frequently shutting down spray machines causes wasted time and material spent cleaning and causes pressure build up in the material lines and spray gun, which may represent a safety hazard. The first coat of Chartek is sprayed and quickly trowelled into the surface to ensure good wetting and even thickness. With plural spray equipment applications and where HK-1TM or no mesh is being used, trowelling the first coat may be eliminated provided there is thorough atomisation achieving consistent even spray fan (no fingering) and 100% wetting of the surface. Trowelling also helps to thoroughly encapsulate any pre-installed mesh and reduces the formation of air pockets. If trowelled, trowel marks and high points are knocked down with a short nap roller dampened with PMA solvent. Rolling achieves a uniform thickness of the coat, which allows uniform build up of subsequent coats and ultimately the correct final thickness. Rolling also serves to produce a smoother surface finish, reducing high spots and stippled finish. Two precautions to be taken with rolling are:


For subsequent coats, sufficient time must pass for the applied Chartek to gel (“set up” or partially cure) in order to support the weight of the additional material. Preferably, subsequent coats should be applied when the previous coat is still tacky. Where practicalities prevent “wet on wet” application, overcoating time should be reduced to a minimum and a sprayed holding coat should be applied to leave the Chartek with a good key to improve the adhesion of the next coat. In addition, a sprayed holding coat is applied over HK-1TM mesh to prevent contamination entrapment when extended overcoating intervals are expected. The holding coat is produced by boosting the Chartek temperature (in the plural component spray equipment) and/or raising the pump output pressure to give a wide fan and increased atomisation. The spray pass is much faster than normal and the result is a coarse finish that promotes good bonding with subsequent coats. Before spraying subsequent coats onto cured surfaces, they should be checked for cleanliness and, if required, suitably cleaned with one of the approved methods described in Section A2.0 “Surface Preparation”. It is imperative that surfaces are clean and thoroughly dry before additional coats of Chartek are applied.




The final coat, when applied to a ‘wet’ surface, should be sufficiently thick to allow good ‘flowing out’ and to minimise surface roughness and to achieve the specified final thickness. In applying a final coat to a hardened surface the thickness should be no less than 3mm (1/8”) to ensure adequate adhesion to the hardened surface. D5.8 Water Contamination CAUTION: If rain or condensation occurs during application or shortly thereafter, moisture may be absorbed into the uncured material. In addition, an amine bloom may form on the Chartek surface. These conditions will affect intercoat adhesion. Take the following action if water contamination occurs: Contamination Action Cured Chartek (fresh water): Dry and solvent wipe Cured Chartek (salt water): Warm water wash - maximum 60°C (140°F)



D5.9 Surface Finish Discontinuities, pinholes, voids or isolated deposits of excess thickness in the coating are not acceptable. Where there is the risk of water ponding on horizontal surfaces, the Chartek should be sloped sufficiently to avoid ponding. Samples of the surface finish acceptable to the client, a reference area, must be prepared by the applicator prior to project start-up. See the Quality Control Manual for Chartek Fireproofing Systems Application for further details. D5.10 Terminations Caulking or sealing of free edges and terminations is not required for Chartek fireproofing.




D6.0 HAND TROWEL APPLICATION D6.1 Ambient Conditions Suitable application conditions are of critical importance for the successful application of Chartek. Consequently, Chartek should only be applied when the ambient conditions are within the following parameters:


However, Chartek may be applied at an air temperature minimum 5°C (41°F) using plural spray equipment only, recognising that the time to cure will in such applications be extended. Additionally, there may also be a higher propensity for amine bloom formation which would affect overcoating with further layers of Chartek, where required, and may affect overcoating with topcoats. For such low air temperature applications, plural equipment is the only recommended dispensing method. D6.2 Surface Cleanliness To ensure proper adhesion of Chartek to the primed substrate, the surfaces to be coated must be dry and free from oil, grease, dirt or any other contaminants that have been deposited since surface preparations were completed. It is the applicator’s responsibility to inspect all surfaces to be coated and clean them if necessary (see the notes on degreasing in Section A2.2). Ambient conditions are of critical importance for a successful application. If they cannot be kept within the above parameters, Chartek application may only proceed if adequate environmental protection is provided. D6.3 Primer and Surface Preparation It is the applicator’s responsibility to verify that the correct primer type (included in the list of qualified primers), thickness (as specified in Section A3.0) requirements are complied with. It is also the applicator’s responsibility to ensure that the preparation of the surface which is to be overcoated with Chartek is in accordance with the requirements of this Application Manual and other documents that may be applicable. For acceptance of the primed surface, checks shall include, but not be limited to, the following: (a) The surface profile is in accordance with this Application Manual and other documents that









It is the applicator’s responsibility to ensure that the primed surface and the primer itself are in an acceptable condition for overcoating with Chartek. Such factors as ageing of the primer (degradation and surface chalking), contamination, rust bloom, etc. shall be considered when determining a surface’s suitability before overcoating with Chartek. Where there is any doubt as to a primer’s acceptance, the primer manufacturer should be consulted and International Protective Coatings advised. NB: Overcoating a primer system with a 100% solids epoxy material such as Chartek is different to overcoating with further layers of material, especially solvented materials. Consequently, it is important that the primer manufacturer should be fully informed of the overcoating system and purpose of that system when directing any questions to the manufacturer concerning overcoating. International should be consulted where any doubt exists. D6.4 Material Preparation for Hand Trowel Application Prior to applying Chartek by hand trowel, the material should be preheated to the following requirement: • Warm enough to mix, typically 20 to 25°C (68 to 77°F) Note: The higher the temperature the shorter the working pot life. Pot life durations are published on the product data sheets Accelerated methods of heating the Chartek containers, such as electrical heaters in direct contact with the containers or hot water baths, are not permitted. Such methods can cause overheating of the outer layers of Chartek in the container, which may produce undesirable changes to its properties (including shorter pot life). D6.5 Mixing For hand application Chartek must be premixed. A small amount of PMA (propylene methoxyacetate) thinner is added to Part A to reduce viscosity for mixing and application International’s thinner GTA123 is recommended for this purpose. The amount required varies with initial material temperature but up to 0.5 litres (0.13 US gallons) may be used per full kit of Chartek. When Part A has reached a smooth consistency, the Part B is then poured into the Part A container, scraping the sides of the Part B container to empty it completely. The two parts are thoroughly mixed together with a high torque variable speed paddle mixer, minimum 5 HP air motors (or 1000W/110V electric motor minimum) equipped with 250mm (10”) paddles. Mixing should continue until a uniform colour is achieved




For best results, the mixer should be mounted on a power ram base to ease the effort required and to allow vertical movement of the paddle blade. The mixing should begin slowly and speed built up gradually. Mix carefully until a smooth texture and uniform colour are achieved. For a full kit this is approximately 4 minutes. Kits should not be mixed until they are ready to be used. D6.6 Hand Trowel Application Method Chartek may be applied using plasterer’s trowels, which has the advantage of very little waste and virtually eliminates the need for masking. After a kit has been mixed, it may be spread out on flat clean boards or surfaces for each applicator to work with. This prevents the material from curing too quickly and allows sufficient working time. Alternatively the material may be applied directly from the pail. Trowel marks and high points are knocked down with a short nap roller dampened with PMA solvent. Rolling achieves a uniform thickness of the coat, which allows uniform build up of subsequent coats and ultimately the correct final thickness. Rolling also serves to produce a smoother surface finish, reducing high spots and stippled finish. Two precautions to be taken with rolling are: 1. If the Chartek has not gelled (started to cure) sufficiently, it can sag or slump. 2. Too much solvent on the roller can reduce the cure rate if it is forced into the wet Chartek. For subsequent coats, sufficient time must pass for the applied Chartek to gel (“set up” or partially cure) in order to support the weight of the additional material. Preferably, subsequent coats should be applied when the previous coat is still tacky. Where practicalities prevent “wet on wet” application, overcoating time should be reduced to a minimum. In addition, an encapsulating coat is applied over HK-1TM mesh to prevent contamination entrapment when extended overcoating intervals are expected D6.7 Mixing of Partial Kits Often trowel application will require less than a full kit of Chartek. In these cases, the required amounts of Parts A and B should be accurately weighed out into a clean container and thoroughly mixed. The correct ratio by weight for Chartek is as follows: When complete kits are to be split down the following method of calculation may be used:





2.50:1



Required Weight of Part B calculated as follows: Measured Weight of Part A ÷ 2.50 (the Chartek 1709 weight

ratio) e.g. 8kg of Part A ÷ 2.50 = 3.20kg of Part B Therefore the required amount of Part B to be weighed out and added to the 8kg of Part A is 3.20kg.

D6.8 Water Contamination CAUTION: If rain or condensation occurs during application or shortly thereafter, moisture may be absorbed into the uncured material. In addition, an amine bloom may form on the Chartek surface. These conditions will affect intercoat adhesion. Take the following action if water contamination occurs: Contamination Action Cured Chartek (fresh water): Dry and solvent wipe Cured Chartek (salt water): Warm water wash - maximum 60°C (140°F)



D6.9 Surface Finish For trowel application a smooth, even and rolled finish should be achieved. Discontinuities, pinholes, voids or isolated deposits of excess thickness in the coating are not acceptable. Where there is the risk of water ponding on horizontal surfaces, the Chartek should be sloped sufficiently to avoid ponding. Samples of the surface finish acceptable to the client, a reference area, must be prepared by the applicator prior to project start-up. See the Quality Control Manual for Chartek Fireproofing Systems Application for further details. D6.10 Terminations Caulking or sealing of free edges and terminations is not required for Chartek fireproofing.




APPENDICES




APPENDIX A – HK-1TM Meshing Details

Underw riters Laboratories Inc. ANSI/UL 1709 Fire Resistance Ratings

Chartek 1709 - Design No.XR625 Rating (hours)

Chartek 1709 Thickness (m m )

Chartek 1709 Thickness (m ils)

M esh Reinforcem ent

½ 2.74 108 ¾ 4.55 179 1 5.78 228

No m esh reinforcem ent required.

1½ 8.24 324 2 10.70 421

2½ 13.16 518 3 15.62 615

3½ 18.08 712

HK-1 carbon fibre com posite m esh applied

in m id film over the flange and around tips.




APPENDIX B – Not Applicable THIS PAGE HAS DELIBERATELY BEEN LEFT BLANK.




APPENDIX C – Not Applicable THIS PAGE HAS DELIBERATELY BEEN LEFT BLANK.








edge terminations





Mesh Overlaps



ID Rev. Date

APP MAN UK 0 01/05/07 Chartek® Application Manual Page 37 of 53



1. Clean surface

Clean and degrease to SSPC-SP1, blast surface

to SSPC-SP10 or ISO 8501-1 Sa 2½, profile 50-

75 microns (2-3 mils)

2. Prime surface*

Apply 50-75 microns (2-3 mils)of qualified primer*

3. Inspect

4. Wetting coat of Chartek 1709

Apply typically 2-3mm (75-115 mils). Ensure surface is fully wetted,

trowel if required.

5. Build up to mesh depth

Chartek 1709 Basic Installation Checklist

6. Inspect for thickness and uniformity 7. Install HK-1 mesh into wet Chartek

Wet gauge Ensure correct mesh overlaps, minimum 50mm (2”)




12. Finish with Interthane 990 topcoat*, 50 microns (2 mils).

Record QA details

For full details refer to the current Chartek 1709 Application Manual.

Record QA details. i.e. weather, blast profile,

type of primer, etc.

1 October 2005 – Rev.1

Where mesh reinforcement is required,

install HK-1 at mid film.

Where mesh reinforcement is

required.

©International Paint Limited, 2005This document and its contents are the copyright of International Paint Limited and may not be reproduced in whole or in part without the express permission of International Paint Limited

Wet gauge or drill

Where mesh reinforcement is required, mesh applied across flanges and around flange tips.

* For qualified primers and alternative topcoats, please contact International Paint







1


(PITR)











2




• The primer system is of known origin and qualified by International Paint for use under Chartek fireproofing. The primer system must be a recognised primer in accordance with the current acceptable primers list for use with Chartek fireproofing, obtainable from International Paint.








(2–3 mils) 100


(3–4.4 mils)



breakthrough, contamination, or other defective condition which would indicate that the primer may not be suitable for overcoating with Chartek fireproofing in accordance with the Chartek Application Manual.






3


















4





3.5 Chartek fireproofing must be installed in strict accordance with the Chartek

Application Manual. Particular attention should be paid to the environmental conditions during application of material.




overcoating of the prepared surface has been given as in 2.9 above. Where required this will include acceptance by the Chartek fireproofing Technical Service Engineer as part of the fire protection installation audit procedure conducted by International Paint.




4.2 Topcoating should be applied in accordance with the Chartek Application Manual

in a timely fashion.





Technical Note

TN/F/083_Rev.1_040205


1







Technical Note

TN/F/083_Rev.1_040205


2


Technical Note

TN/F/083_Rev.1_040205


3








1








TO L E R A N C E S

GL O S S LE V E L


DRY I N G TI M E















Minimum


OV E R C O AT I N G

IN T E RVA L








Maximum


Extended










FL A S H PO I N T

















SH E L F LI F E


CO N T E N T (VOC)



Documents

Chartek 7 8+1709 Application Manual Rev0 010507