ceramic cover cc systems 100 - insind - home · 2594 flat shoals road, ... ceramic cover cc systems...

2594 FLAT SHOALS ROAD, SUITE 2 • CONYERS, GA 30013 • 770-922-4737 • FAX 770-922-4279email [email protected] • web address www.envirotrol-inc.com

CERAMIC COVER CC SYSTEMS 100

Envirotrol, Inc. is the manufacturer’s distributor and technical representative for the productCeramic Cover CC Systems 100. We have traveled throughout North America and abroad,successfully introducing our product, a radiant heat barrier protective coating with insulationproperties. Properties of this product have been viewed with astonishment and the uses deemedunlimited. Ceramic Cover CC Systems 100 provides protection from corrosion, eliminates radiantheat and in comparison testing has out performed 4 inches of R 20 foam with just a 20 milapplication. Ceramic Cover CC Systems 100 also maintains its high tensile strength and elasticitythroughout a very wide temperature range. The product remains durable while providing an effectivethermal energy barrier.

Ceramic Cover CC Systems 100 is state of the art for insulation and environmentalprotection in today’s market place. The product is environmental friendly and contains nocarcinogens or volatile organic compounds. Ceramic Cover CC Systems 100 is a one componentapplication and may be sprayed directly onto hot surfaces without plant shutdown. We haveintroduced the product to industries such as: pulp and paper, refrigeration, cold storagewarehousing, airline industry, oil, tank and pipeline companies with great success. All of theseindustries have expressed their interests and commitment in specifying this product.

Throughout our introduction of Ceramic Cover CC Systems 100 we have expressed theimportance of educating and certifying applicators on the uses and application of this product.Only applicators certified by Envirotrol are qualified to use our product. We will provide a list ofcertified applicators or information regarding Certification for your employees. In addition, Envirotrolprovides educational seminars which we perceive as the best way to answer questions regardingCeramic Cover CC Systems 100 qualities as an insulation and protective coating. Please contactus for information regarding our Seminar dates.

Thank you for your support and interest in our product, Ceramic Cover CC Systems 100.We will be happy to have a representative contact you at your convenience to identify the uses ofour product in your environment.

Envirotrol, Inc.2594 Flat Shoals Rd., Suite 2

Conyers, GA 30013OFF: 770-922-4737FAX: 770-922-4279

email [email protected] address www.envirotrol-inc.com


PRODUCT PROPERTIES AND RESULTS

Our goal in marketing Ceramic Cover CC Systems 100 is to identify the need and benefit ofCeramic Cover CC Systems 100 as opposed to conventional methods, compile data to determinestandards of specifications for similar markets throughout the industry, and then directly approachsources responsible for determining specifications relayed to costs, capital improvements andmaintenance.

Identifying the need and benefits of Ceramic Cover CC Systems 100 is simply understandingthe properties and advantages of the product. Properties such as:

A) Insulation

Applied Technical Services, Inc. in Marietta, GA performed a comparison test with CeramicCover CC Systems 100 material versus a sample of R-20 (R-5/in) Styrofoam for TemperatureResistivity/Heat Reflection. The procedure was to construct two identical galvanized steel boxesin the form of miniature houses. House A was filled with four inches of the identified styrofoaminsulation and House B’s exterior was coated with Ceramic Cover CC Systems 100 to a thicknessof 0.016 of an inch. Each house was insulated in the same areas to simulate identical uninsulatedvolume.

Note: Maximum Air Temperature Achieved Adjacent to House: 170º F.

For this particular test, the temperatures in the house coated with the Ceramic Cover CCSystems 100 were on the average 7.8ºF cooler than the temperatures in the house filled with theR-20 Styrofoam.


OCM Test Laboratories in Anaheim, CA factored R values for Ceramic Cover CC Systems 100based on thinnest measured thickness on a 12 x 12 test square. Test results are below.

Due to the differentiating measurements of density from sprayed application, it is difficult to geta consistent R Value. Therefore, R values must be equated by averaging the combined test results.According to OCM Laboratories, Ceramic Cover CC Systems 100 has an R Value of 14.4 per inchremarkably out performing all insulation’s charted below from the National Bureau of Standards andthe ASHARE 1977 Fundamentals Handbook. However Ceramic Cover CC Systems 100 has neverbeen needed in a thickness over 1/4 of and inch.

ThinnestMeasured Thermal ResistivityThickness R Factor R Factor/Inch

0.058 1.280 22.2 0.058 0.786 13.5 0.075 0.560 7.5

Average 0.064 0.875 14.4


Recommended coating thickness based on surface temperature.

Test results have proven that one coat or 20 mil of Ceramic Cover CC Systems 100eliminates radiant heat and reduces temperature greatly (60ºF to 80ºF degrees) on hot surfaces.Additional coats contribute a reduction in temperature between 40ºF to 45ºF. See Delta T Chartbelow for more information regarding mil thickness based on temperatures. (Temperatures are inFahrenheit located on the left-hand side of the chart).

Degrees F Coats Mil Thickness DFT/per in100 to 120 1 16 to 20 1/64120 to 160 2 32 to 40 1/32160 to 200 3 48 to 60 3/64220 to 260 4 64 to 80 5/64260 to 300 5 80 to 100 3/32300 to 340 6 96 to 120 7/64

*340 to 400 8+ 140 to 200 9/64

* Call Envirotrol, Inc. For Technical Assistance Before Application.


B) Protection from UV Rays

Ceramic Cover CC Systems 100 can be applied directly over composites with 100% adhesionand no chemical adverse effect (i.e. tar roofing, asphalt shingles, paint, etc.) providing protectionagainst UV Rays as well as insulating. Action Testing, Inc., a certified testing laboratory in Tucker,GA reported “coating material found to be extremely durable and high quality, ‘heat barrier’ andreflected 95% to 98% of all radiant heat. The high percentage of radiant heat reflected would becomparable to a rating of R-20 at a 13 mil thickness.” Additional testing by Action Testing, Inc. wasperformed on 1 inch of foam coated with 16 mils of Ceramic Cover CC Systems 100. Foam has atendency to crumble and split when exposed to ultra violent rays. However, when the foam wascovered with a thin coat of Ceramic Cover CC Systems 100 and tested; the conclusion reported:“The Envirotrol coating offers protection against the normal problems of foam, therefore, it preservesthe effectiveness of such insulating materials. The coating was also found to remain flexible attemperatures as low as -30º F, also this additional coating on 1.00 pcf density foam provides thedimensional stability and compressive strength normally found in higher cost 3.0 pcf densities withoutpaying the higher price”.

C) Adhesion

Ceramic Cover CC Systems 100 has been tested for adhesion by tests corresponding toASTM D-3359, a cross hatch adhesion test, resulting in a score of 100% (the highest on a scaleof 1 to 100). Furthermore, Dunkin & Bush, Inc. an industrial paint contractor in Seattle, WA,performed a Elcometer Adhesion Test. Coating was spray applied using air assisted airlessequipment. The coating thickness ranges from 75 mils DFT to 45 mils DFT across the testedcoupon on tightly adhered mil scale. The initial test was performed 20 days after application. Theresult was a pull strength of 210 psi at 74 mils DFT. The coating was disbonded leaving 3-6 milson the substrate. The final pull test was performed about 30 days after final cure. The result wasa pull strength of 210 psi at 45 mils DFT. The coating again disbonded leaving 3-4 mils on thesubstrate. Ceramic Cover CC Systems 100 has been tested under ASTM D4541 Test Methodfor pull of strength of Coating using portable adhesion testers.

The conclusions are that Ceramic Cover CC Systems 100 reaches full adhesive strengthprior to final cure. Further conclusion based on disbondment within the coating shows an actualstronger bond to the substrate surface.

D) Flame Resistance

Ceramic Cover CC Systems 100 flame spread is rated 5 out of 100 according to SouthwestResearch Institute, Department of Fire Technology in San Antonio, TX and MSDS sheet reportsflash point noncombustible. Therefore, Ceramic Cover CC Systems 100 can be applied directly tohot surfaces in a wide temperature ranging from 34ºF to 400ºF without shut down. In addition, theUniversity of Mississippi Medical Center of Jackson, MS tested Ceramic Cover CC Systems 100for toxic smoke. “All exposed animals survived without sickness or irritation” concluding that CeramicCover CC Systems 100 has no effects from smoke inhalation. Ceramic Cover CC Systems100 was tested under IMOA.653(16). Recommendations on improved fire test procedures forsurface flammability of Bulkhead, Ceiling and Deck Finishing Materials.


E) Corrosion Protection

Insulating properties of fiberglass, wools, etc. are largely a result of the air entrapped betweenfibers but are reduced markedly when the material becomes wet. Moisture reduces the performanceof air-filled insulators because the heat conduction of water at atmospheric temperature is morethan 20 times that of air. Because Ceramic Cover CC Systems 100 has no air pockets, itimpedes condensation, stops corrosion and has no loss of insulation properties when wet. ActionTesting Lab rated Ceramic Cover CC Systems 100 .0755 (Superior) by ASTM D-1653 standardsas a moisture vapor barrier and Garneau Inc., a pipe coating company in Calgary, Canadacompleted a hot water soak at 95c=203f for 48 hrs. with excellent results against penetration andno breakdown.

Condensation

A 40 mil application of Ceramic Cover CC Systems 100 on a 38ºF cold water line eliminatingthe condensation caused by the ambient temperature of 74ºF. Also, a pulp and paper plant in themidsouth applied 40 mils of Ceramic Cover CC Systems 100 to a 48ºF CLO2 tank (40 ft. dia. by50 ft. ht.) top coated with polyurethane mastic to eliminate condensation and maintain a consistenttemperature.

In addition, Ceramic Cover CC Systems 100 has properties that are impervious to theenvironment such as a fungal-pesticide resistance - rating of 10 on a scale of 1 to 10 (10 being thehighest). Additional tests have been administered: wind driven rain, hot/cold cycling, and chemicalresistance. In each test and/or analysis, Ceramic Cover CC Systems 100 “tested in the highestpercentiles” of available products.

F) Chemical Resistance

Ceramic Cover CC Systems 100 is an 84% solid latex high density material low in viscositycoating with high insulating properties and chemical resistance. Envirotrol has worked with industryby testing chemical resistivity according to requests. A Sterilization Division uses Ethylene Glycol,Sulfuric Acids and Ethylene Oxide (gaseous) for sterilization of hospital equipment and supplies.Areas designated for applications of Ceramic Cover CC Systems 100 are the metal roof area(repel gases being expelled causing corrosion), pre-conditioning cell duct systems (stopcondensate and hold in heat ), and post-cell duct systems (to seal duct system by retarding gasexpulsion).


Ceramic Cover CC Systems 100 tested for reaction against the following chemicals:

Two tanks at a pulp and paper plant in the midsouth, 1) a hot water tank, approximately 40’dia. x 30’ ht. with a measured temperature of 140ºF, 2) a chemical storage tank, approximately40’dia. x 40’ ht. with a measured temperature of 195ºF. Each had the fiberglass insulation removedand pressure washed. Ceramic Cover CC Systems 100 was then applied, two (2) coats atapproximately forty (.40) mils dft. from ground level to approximately ten feet around eachcircumference, reducing the hot water temperature to ambient, and the chemical storage tank to107ºF.

Property Test Description Results

Sodium Hydroxide immersion 300 hrs excellent, product not(NaOH) affected, no softening or

discoloration coatedaluminum strip showed nosign of corrosion

An environmental lab in Alpharetta, GA, uses sodium hydroxide for removal of contaminatesin water. Sodium hydroxide violently attacks the aluminum mixing paddles accelerating corrosion.Test of Ceramic Cover CC Systems 100TM reaction to sodium hydroxide are as follows:

Ceramic Cover Test Data Property CC Systems 100 Chemical Resistivity Results

Test Description

Ethylene Glycol immersion 300 hrs excellent, product not affected,(HOCH2 CH2OH) no softening or discoloration

Ethylene Glycol + .03 immersion 300 hrs excellent, metal stripSulfuric Acid corrosion, but product(HOCH2 CH2OH) (H2 SO4) stability in-tact. Metal under

coating shows no corrosion

Sulfuric Acid (93%) immersion 300 hrs excellent, metal strip(H2 SO4) corrosion, but product

stability in-tact. Metal undercoat shows no corrosion

Hydrochloric Acid (53%) immersion 300 hrs acid softens the material no(HCI) adverse affect or break down

Methanol (98%) immersion 300 hrs softens the material(CH40) no adverse affects on break down

Acidic Acid (50%) immersion 300hrs acid softens the material(NaHCO) no adverse affects or break down


After only one hour of completing application of Ceramic Cover CC Systems 100 the product fromthe chemical process splashed on the hot water tank. During clean-up the chemical was easily washed offthe Ceramic Cover CC Systems 100 with no adverse reactions, disbondment or staining.

G) Chemical Content

Harland Associates Research Lab in San Francisco, CA, reports Ceramic Cover CC Systems 100as having 0 (zero) grams of volatile organic compounds, (VOC’s) less water per liter, and “is a compliantcoating with regard to VOC content requirement of the Bay Area, Air Quality Management District,” one of thestrictly controlled air quality management districts in the United States. Ceramic Cover CC Systems 100contains no solvents or hazardous chemical elements such as fluorides, chlorines or iodine. An analyticaltesting laboratory, tested the chemical compound of Ceramic Cover CC Systems 100 for chlorides andhalogens with excellent results.

A large number of test at independent research institutes and laboratories have beencarried out and reports are available from Envirotrol, Inc. More details are available [email protected].

PHYSICAL PROPERTIES RESULTS TEST METHODAccelerated Aging: PASSED

200 HOURS ASTM G-531347 HOURS ASTM D-5894

Moisture vapor barrier (Action Testing) PASSED ASTM D-1653Water vapor transmission ( Corrosion Probe) PASSED ASTM E-96 D4708Thermal Conductivity (OCM Test Lab) ASTM C-158Thermal Resistance (Action Testing) ASTM C-177-85Pull-Off Strength (Corrosion Probe) PASSED 250psi ASTM D-4541Radiant Heat Barrier REFLECTS 99.61% UV Rays GA TECHSurface Flammability of Bulkhead PASSED UL IMO A 653(A)Density (g/cm3) at 24C Dried Film 0.41 ASTM D-792Weight Per Gallon 5.94Weight Non-Volatiles 43%Brookfield Viscosity #3 Spindle @ 30 RPM,Centipoise 3564USDA COMPLIANTFDA COMPLIANTGeneric Type: Emulsion Filled with amorphous silicaColors: White (Can be tinted) w/universal tintFinish: FlatVolume Solids: 87% (wet to dry ration 1:1)V.O.C. o g / litre - 0 lbs / US gallonTypical specifications: Depends on required temperature reduction. Normally 1 - 6 coats each 500 microns / 20 mils.

See delta T chart in manual or web site

MECHANICAL PROPERTIES RESULTS TEST METHODCross Hatch Adhesion 100% ASTM D-03359Tensile Strength (LB/IN2) 66.7% ASTM D-882Elongation 65%

Chloride less than 25ppmsWater Soluble Chloride C1 Total Halogen TX

Analytical mg/kg (ppm) mg/kg (ppm)Lab Code As-Rec’d Basis As-Rec’d Basis

6379 22.5 580063749D 19.1 8800


Manufacturer’s Recommendations

The best range of application for Ceramic Cover CC Systems 100 is 40 to 80 mils intemperatures ranging from 150ºF degrees to 300ºF. The product serves all needs regardingcorrosion protection, energy conservation and safety. It is the most cost effective product on themarket regarding tanks and pipelines. Ceramic Cover CC Systems 100 is a one componentapplication. One product provides insulation, protection from corrosion, safety and is imperviousto environmental conditions; therefore eliminating the cost of several steps of application, (forexample, it eliminates the need for sand blasting, primer, top coating and fiberglass wrap).

Ceramic Cover CC Systems 100 is applied directly to the substrate with good adhesionand no air pockets, thus, eliminating the problem of sagging or wicking insulation which leads tocorrosion. In tank design, Ceramic Cover CC Systems 100 would eliminate the need for metalstuds that support insulation. The cost of material and labor for welding the metal supports wouldpay for the cost of the coating. In addition, Ceramic Cover CC Systems 100 eliminates theproblems of animals destroying the insulation or instances of insect or rodent infestation, a commonproblem with fiberglass wrapped pipelines.

When specifying Ceramic Cover CC Systems 100 in temperatures over 300ºF there is apoint of diminishing return regarding cost and safety. According to the Delta T Chart after 100mils application of Ceramic Cover CC Systems 100 the temperature reduction begins to diminish.Therefore, you have eliminated radiant heat, but reached the maximum benefit in accordancewith cost versus performance. Although 100 mils of Ceramic Cover CC Systems 100 wouldreduce surface temperature over 200ºF, in high temperature ranges the surface temperaturemay remain above OSHA standards. In regards to safety, at this point it would be more beneficialto specify Ceramic Cover CC Systems 100 wrapped with one inch of standard insulation orfiberglass instead of additional coats. Ceramic Cover CC Systems 100 with fiberglass is themost cost effective rather than either product specified alone. Ceramic Cover CC Systems 100provides energy conservation and corrosion protection while the small amount of fiberglassprovides the additional safety at a less expensive cost in a much smaller space. Areas in excessof eight feet high where safety is not an issue would not need the additional fiberglass wrap.

Product Limitations

• Ceramic Cover CC Systems 100 should not be applied to surface temperatures lessthan 34ºF or not to exceed 350ºF without consulting Envirotrol Inc.

• Application should not be installed in ambient temperatures below 32ºF unless surfacetemperature of substrate exceeds 100ºF.

• Ceramic Cover CC Systems 100 should not be mixed with solvents or applied nearwhere solvents may come in contact with the product prior to curing. Prior to application insure allsubstrates are free of rust, oil, grease, mil-scale, moisture or any foreign substances which mighteffect adhesion.


APPLICATION AND USES

A) Roofs and Metal Buildings etc.

One of the excellent uses for Ceramic Cover CC Systems 100 is a roof coating. Theproduct forms a radiant heat barrier providing insulation qualities and protection from ultra violentrays. In addition, the ceramic insulating properties keep heat expansion and cold contraction ofmetal roofs to a minimum, thus, eliminating many causes of water damage, uncomfortable winddrafts or costly maintenance problems. Ceramic Cover CC Systems 100 may be applied directlyover composites (i.e. tar roofing, asphalt, shingles, paint, etc.) with 100% adhesion and no chemicaladverse effect. Ceramic Cover CC Systems 100 maintains its durability, tensile strength (ASTMD-882 TENSILE STRENGTH (LB/IN2) 66.7) and elasticity year round passing ASTM G-53accelerated aging test over 200 hours.

Ceramic Cover CC Systems 100 was applied to the dome of a famous restaurant on theharbor in New York, to impede further corrosion, stop water leaks, and provide energy savinginsulation. As noted, Ceramic Cover CC Systems 100, may be tinted to color desired, while stillmaintaining its properties.

Domed roof beforesurface preparation,coating and tinting.

Domed Roof after Ceramic Cover CC Systems 100.


At Camp Casey in South Korea, Ceramic Cover CC Systems 100 was applied to QuansetHuts to stop expansion and contraction thus eliminating corrosion, providing insulating propertiesand saving energy. Ceramic Cover CC Systems 100 was applied in lieu of polyurethane foam,which is now considered hazardous waste when removed.

Quanset before application ofCeramic Cover CC-Systems 100.

Quanset Hut after 16 milapplication of Ceramic CoverCC-Systems 100 and tinting.


Ceramic Cover CC Systems 100 was applied to public transportation buses resulting incooler units. According to Georgia Tech testing, Ceramic Cover CC Systems 100 maintains a99.61 reflectively with only a .039% transmission against radiant heat.

Ceramic Cover CC-Systems 100 duringapplication of 20 mils. Application wasdone to reduce usage of polyurethanefoam.

Ceramic Cover CC-Systems100 reduced under rooftemperature by 50o F.


Applied different millages in various areas to reduce ambient temperature for personal protection, energysavings and condensate control.

B) Rail Industry

Applied 60 mils dft to eliminate radiant heatgain in plastic pellet hopper cars, thuseliminating plastic fusion.

C) Marine Industry

Object #2 - Area 1 illustrated with red arrows.Area 2 is the rest of the door.

Ceramic Cover–Application on Object #2:Door to incinerator facility. Pre applicationsurface temperature: Area 1 - 347ºC Area2 - 203ºFPost application surface temperature:Area 1 - 180ºF Area 2 - 118ºF


20 to 30 mils of Ceramic Cover CC Systems 100 was sprayed to the hot evaporator ductlines entering tanks located at a pulp and paper mill in the southeast. The evaporatorduct line temperatures were reduced from 184ºF to 118ºF.

D) Steam Lines, Tanks, Boilers and Valves

According to the Delta T Chart in this manual, 1 coat or a 20 mil application of Ceramic CoverCC Systems 100 greatly reduces temperature (60ºF to 80ºF) on hot surfaces. Additional coatscontribute a reduction of temperature between 40ºF & 45ºF. Therefore, Ceramic Cover CC Systems100 conserves energy by containing the heat while reducing the surface temperature providingsafety and reducing risk of burns. In addition, Ceramic Cover CC Systems 100 serves as a protectivecoating against corrosion eliminating problems from saturation and sagging which are typicalcharacteristics of fiberglass. Replacing fiberglass with Ceramic Cover CC Systems 100 reducespipe sizes and increases usable space.

Ceramic Cover CC Systems 100 can be applied directly to hot surfaces with minimal surfacepreparation and without plant shutdown. Basic maintenance of Ceramic Cover CC Systems 100is simply washing it clean with a fire hose. In the event that the product needs to be removed, itcan be cut and scrapped or sanded. The dust created from sanding the product is considerednuisance dust and contains no harmful material (See MSDS).


Heat Exchangers

Ceramic Cover CCSystems 100, reducedsurface temperatureswhere a conventionalcoating system wasapplied for colorcoating, and aesthetics.

Ceramic Cover CCSystems 100 wasapplied to heatexchangers at aplywood, pressboardplant, reducing boilerwork load, providingpersonnel protection,and easy clean up(hose down).


TANK APPLICATION

Minimal surface preparation. Ceramic Cover CC Systems 100 may be used as a primer aswell as a finish.

Ceramic Cover CC Systems 100 increased operation efficiency while providingpersonnel protection and insulating properties, with only 60 mils dft. A savings direct to the owner.

Sugar Clarifier Before Sugar Clarifier After

60 mil application was applied to a sugar silo to maintain 90°F winter and summer.


Insulating valves is simplified with CeramicCover CC Systems 100 and is positivelymaintenance friendly. Envirotrol, Inc. and theirCertified Applicators work hand in hand with theend-user’s maintenance teams.

VALVES

Costly maintenance repair exits wheninsulation is removed and an outage takes place.Costs of up to $140,000.00 per hr. exist to theend user when systems are not operating. Mostvalves are uninsulated due to these loss incurred.

Ceramic Cover CC Systems 100 beingapplied at 80 mils dft to reduce existingtemperature of 280ºF to 120ºF. If maintenance isneeded, insulation will not be breached.


20 mil Ceramic Cover CC Systems 100 230ºF60 mil Ceramic Cover CC Systems 100 190ºF75 to 80 mil Ceramic Cover CC Systems 100 137ºF

After 75 to 80 mils of Ceramic Cover CC Systems 100 the follow-up temperature measurementswere taken:

Below are some temperature results from a 150 pound steam line 16 inches in diametercoated with Ceramic Cover CC Systems 100. The surface temperature was measured at 340ºFbefore the coating was applied. Temperature reduction during application is charted below:

Average temperature difference is 174.5ºF which equates to 43.63ºF per coat (each coat 20 mils).

Coated Section Bare Section Temperature Difference

June 6, 1996 170ºF 345ºF 175ºFJune 11, 1996 175ºF 340ºF 170ºFJune 13, 1996 170ºF 350ºF 180ºFJune 19, 1996 180ºF 350ºF 170ºFJune 26, 1996 208ºF 390ºF 182ºFJune 27, 1996 185ºF 355ºF 170ºF

The following results for coating an endothermic gas generator and backup tank. The maingenerator oven surface temperature was 202ºF.

Ceramic Cover CC Systems 100 Coated Section Temperature Difference13 mil 143ºF 59ºF27 mil 130ºF 73ºF50-60 mil 102ºF 100.6ºF

The Back-Up Tank had a surface temperature of 180ºF. A coating of 35 mils of CeramicCover CC Systems 100 was applied to the surface and decreased the temperature to 98ºF.Each coat of Ceramic Cover CC Systems 100 reduced the temperature by 41ºF.


Ceramic Cover CC Systems 100 wasapplied to a stainless steel, hot air ductapproximately 200ºF in a far north pulp andpaper plant. Two coats or 40 mil applicationwas applied to reduce the temperature to105ºF and eliminated radiant heat.

A 40 mil application of Ceramic Cover CCSystems 100 on a 45ºF air conditioning ducteliminating condensation and reducedtemperature by 8ºF in duct work.

E) HVAC Ductwork and Hot Air Duct

Ceramic Cover CC Systems 100 is an excellent application for insulation on HVAC Ductworkand Hot Air Duct. The product eliminates radiant heat on hot duct and impedes condensation oncold air duct. In addition, Ceramic Cover CC Systems 100 contains the temperature inside bycontrolling BTU losses. Furthermore, the elimination of fiberglass reduces the size of spaceneeded for installation and totally eliminating hiding and breeding space of insects and rodentparticularly in the food and beverage industry.

Industry will not specify a latex coating on stainless steel ductwork, tanks, or containers. Thechloride content in water based material causes an adverse reaction to stainless steel. AlthoughCeramic Cover CC Systems 100 is a latex based product, the unique property is it containsonly 22 ppm’s of chloride. Thus, Ceramic Cover CC Systems 100 is actually a complimentcoating for stainless steel.

Ceramic Cover CC Systems 100 wasapplied to air conditioning duct. Eliminationof condensation and temperature reductionof 8ºF.


F) Refrigerated Warehouses, Trucks, and Trailers

Ceramic Cover CC Systems 100 differs from competitive insulation products because ithas no air spaces only tiny ceramic particles. These ceramic particles reflect all energy rays hotor cold; therefore, maintaining temperatures as needed in cold storage. Additional benefits ofCeramic Cover CC Systems 100 over standard insulators is its ability to retard condensationand prevent corrosion.

Tests were conducted by Protech Applications Inc. from Miami, FL at Mad Produce in Dania,FL to determine the insulating qualities of Ceramic Cover CC Systems 100 versus standardrefrigeration foam panels. A test room 22’ by 30’ by 12’ in height was constructed from 18 gauge 6inch studs on 16 inch centers. The ceiling was constructed in 18 gauge 8 inch ceiling joists also on16 inch centers. The interior walls were covered with Duro-rock and the seams taped andcompounded per standard construction procedure. Then approximately 60 mils of Ceramic CoverCC Systems 100 was applied to the interior of the room directly on the Duro-rock.

The purpose of constructing this room was to do a comparison testing of temperaturesbetween the test room and the standard cold storage warehouse. Test procedures were prescribedby Mr. Ray Seay of Commercial Industrial Refrigeration, Inc. and were monitored for 96 hours.The temperatures were to be read at the following areas in the test room and adjoining coldstorage area:

1. Main cold storage area2. Test room3. The top of the Duro-rock above the test room4. One (1’) foot above the test room5. Four (4’) feet above the test room6. Inside the panel insulation above the test room

The following are the test results as recorded at the prescribed time intervals:48 hrs. 72 hrs. 96 hrs.

Main cold storage 36.6 36.8 36.4Test room 41.6 42.0 37.8Topside of Duro-rock 66.8 66.6 66.812” above Duro-rock 71.2 70.0 70.0Four feet above Duro-rock 72.4 71.8 71.8Inside of insulation panel 67.0 67.0 67.0Outside ambient temperature 74.3 72.8 73.0

Test results prove that Ceramic Cover CC Systems 100TM insulates as well as the R30refrigeration foam panels with a greater cost savings with respect to material price and installationlabor. There was no condensation or moisture on the inside of the test room or on the top of theDuro-rock.

American Refrigeration & Ice coated the top of a refrigerated ice delivery truck and loweredthe temperature from melting point to steady temperature of 12ºF eliminating condensation andthe loss of several sacks of ice.


CERAMIC COVER CC SYSTEMS 100 VERSUS CONVENTIONAL INSULATION SYSTEMS

ABSTRACT

Hot liquor and other process vessels including piping create an unsafe environment due toemission of radiant heat.1 Insulating the vessel creates a potential corrosion environment underthe insulation. This paper will discuss a unique coating that provides protection from corrosion,virtually eliminates radiant heat and out performs 4 inches of R20 foam with just a 20 milapplication. In addition, case histories will be discussed.

INTRODUCTION

Most industries encounter corrosion under thermal insulation. Most tanks, process vesselsand piping is insulated with fiberglass or foam with an aluminum or 304 stainless steel jacket.Breaches in the jacket allows permeation of liquid process chemicals and moist ambient aircasing potential corrosion to the substrate. This problem is exacerbated by the wicking of theliquid along the insulation. In addition to the corrosion problem, the insulation also loses itsinsulating properties.

Ceramic Cover CC Systems 100 virtually eliminates the corrosion under insulation problemwhile providing the necessary insulating properties for the specific environment. This product isformulated with a unique acrylic polymer binder combined with a blend of pigments, most notably,a calcined amorphous silica that has extremely high absorption properties with a very low specificgravity (0.59). It is environmentally friendly, cost competitive and easy to apply.

WHY CERAMIC COVER CC SYSTEMS 100 SHOULD BE CONSIDERED VERSUSCONVENTIONAL INSULATION.

Corrosion of carbon and stainless steel under conventional insulation on process equipmentrequires maintenance and repair costs: with safety risks to personnel and the environment.Using the insulating coating will reduce the risk of corrosion to the substrate to which it is appliedby resisting movement of moisture and contaminates to the surface which cause the substrateto corrode. This material is a monolithic film having no fasteners or joints thus eliminating thepotential moisture intrusion problem.

The Issues Affecting Corrosion of Carbon Steel Under Conventional Insulation.

The rate carbon steel will corrode under insulation is influenced by first, the wet exposurecycle, the duration and frequency; second, the corrosivity of the moisture and third, the lack of orfailure of the barrier protection between the insulation and the carbon steel. Although, there aremany factors contributing to corrosion under conventional insulation, the seven main factors,along with how Ceramic Cover CC Systems 100 help mitigate the problem, are as follows:

1. Equipment design2. Service temperatures3. Insulation selection4. Protective coatings5. Weather barriers6. Climate control7. Maintenance procedures

1 Based on independent laboratory test refectivity (emmissivity) is 99.61%


Mastering an understanding of these issues will help to reduce the failure of insulationsystems and reduce costs in these areas. When properly used Ceramic Cover CC Systems100 offers some fixes with lower costs and better performance. It only takes mils not inches.

Equipment Design

Care in equipment design and support layout is key to providing space for the insulation systemused. Pipes, pressure vessels and tanks are the main items involved with process equipment.Building structures and roofs require their own special design to cope with higher levels ofweather proofing require due to exposure. Simplifying the surface to be insulated makes thesetasks easier, more cost effective and provides longer life.

The Ceramic Cover CC Systems 100 is more conforming to the surface than conventionalsystems, and it does not require studs and lagging to support and seal the insulation frommoisture.

Service Temperatures

The warmer the insulated equipment the less effect moisture will have on the insulatedsurface. Corrosion rates will be increased with the number of cycles the equipment goes throughand the contaminants in the moisture. The better the weatherproofing the less the corrosionrate will be. Ceramic Cover CC Systems 100 resist the movement of moisture2 more so thanconventional insulation systems.

Insulation Selection

Corrosion under the insulation system is directly related to moisture absorbency, chemicalsand insulation breaches, consequently selection of an insulating material fitting the serviceapplication is key to minimizing the risk of under insulation corrosion. Non-wicking materialsrate the best choice for high exposure areas to wet service areas. Insulation is normally selectedbased on installed cost versus energy cost saved, unfortunately maintenance costs don’t enterthe picture until later. Without the lagging requirement and being a water based system, whichcan be applied to most surfaces while the operation is in progress, makes the insulating coatingproduct an easily maintained system. Polyurethane foam absorbs water readily, where asCeramic Cover CC Systems 100 does not.3 A wet insulation system does not give theenergy savings and is a corrosion liability.

Protective Coatings

Protective coating under insulation provides corrosion protection; however, it must meetimmersion service conditions. The combination of moisture and heat along with chemicalconcentrations requires a coating system with a high resistance to permeability. With no accessto maintain the coating system it needs to perform for 15 to 20 years. With an insulation systemholding moisture to the surface longer than an non-insulated surface the need for the addedprotection of coating reduce the corrosion rate, significantly. Zinc rich primers and/or conventionalcoatings do not perform well in immersion service and/or under insulation. In certain applications

2 Based on ASTM E96 Method E the coatings perm rate is .6480 grams per 100 square Inches per 24 hours

3 Based on ASTM E96 Method E the coatings perm rate is .6480 grams per 100 square Inches per 24 hours


the coating is only done on the last four to six feet of the tank wall at the foundation, this beingthe zone where spills and splashing occur. Welds and insulation rings must be seal welded orcaulked with material compatible with the coating system. Coating under the insulating coatingwould only be required in high risk areas, example a storage tank containing chilled solution.With high humidity a chilled tank will draw moisture to it like a magnet. The insulation coating iswater based, top coating may be done to meet color requirements. The product may be tinted,however, better color results will occur with top coating. The top coating must be tested forcompatibility with the water based system, so it does not impact adhesion or insulation values.Be careful!

Weather Barriers

For conventional insulation the lagging is critical to the success and life of the system. Thebarrier provides both a liquid and a vapor block to protect the insulation system from contaminationand from moisture and chemicals. The barrier allows moisture to flow from the equipment out ofthe insulation system. Trapped moisture increases the corrosion damage. Screws and otherfasteners must not be on the top of the system, this will allow moisture in around the screwholes; they should be located on high spots and on the sides of pipes. This reduces the risk ofleakage. While insulation systems are designed to last 25 to 30 years, the lagging will requiremaintenance to keep the integrity of the system in place. It should be placed on a preventivemaintenance program. The insulation coating does not require a vapor barrier, as it resistsmoisture movement as is. It, like conventional insulation will suffer from mechanical damageand requires maintenance over the life of the system. It being spray (or brush applied) andcoming in a can allows full use of the product and is maintenance friendly.

Climate Control

The climate and the micro climate within buildings and/or processes are factors to be takenin the planning stage of what system to use. In a high humidity process moisture will come atthe insulation system from both sides. Equipment located next to or down wind from coolingtowers or vents will see more moisture than other equipment. This would require more weatherproofing than would normally be used. The insulating coating handles moisture without addedprotection in most applications (it is UV stable). One clear advantage is the insulating coatingdoes not allow moisture or chemicals to migrate to one location to set up a more active corrosioncell at the tank bottom, insulation rings or pipe elbows.

Maintenance Procedures

With the current use of maintenance planning and computer controlled schedules forinspection of process equipment and facility structure; the insulation systems are simply includedin the inspection process. Visual inspection for insulation integrity is 90% of what is required.The area of greatest risk occurs when mechanical maintenance takes place on the processequipment (opening the insulation). Those crews are usually not responsible for re-insulation ofthe equipment. After the mechanical repair is complete, a policy of prompt repair is required sothe insulation system is not compromised. Low points and other natural moisture traps are highon the inspection list. Various codes require inspection of vessels and tankage every five yearsbased on a risk assessment depending on type of service and history. These inspections require


1 Based on laboratory tests the chloride content is less than 23 ppm and less than 198 ppm halogen.

the insulation be removed to measure shell or wall thickness for material loss. The insulationsystem then has to be replaced or plugs fitted to the inspection areas. On some types ofvessels removable blankets or bats are used for ease of replacement. Repair with the spray onor brush applied insulating coating will meet this need in a cost effective manner. One majorarea of concern is in personnel protection. Some tanks are only insulated up 8’ to protectpersonnel from burns; this requires a weatherproof seal where the system terminates on thetank wall, the caulking breaks down and moisture compromises the system. The insulatingcoating will help to eliminate this risk of moisture intrusion and later the corrosion of the processequipment. Planned maintenance is the key to cost effective insulation and reduce corrosion.The insulation coating resists undercutting.

Stress Corrosion Cracking of Austenitic Stainless Under Insulation

External stress corrosion cracking or environmental stress cracking (ESCC) refers to stresscorrosion cracking of austenitic stainless steel (304L, 316L and 317L) in general. The productin the vessel, tank or pipe is only supplying the heat to promote the cracking mechanism. Processspills or leaks would add to the problem, but usually the normal moisture penetrating conventionalinsulation systems containing chlorides will cause cracking. Temperatures from 140°F to 250°·F(60°C to 121°C) seem to be the range where the ESCC normally occurs.

Sources of Chlorides

Insulation material itself will contain chlorides ranging from 10 ppm to close to 1000 ppm;the problems really occur when moisture moves the chlorides from the material to the surface ofthe stainless equipment. The coastal regions have more problems due to atmospheric chloridesand these my be deposited on the surface before the insulation system is ever applied. Thechlorides may be related to the chemical process at the site.

Inhibitors may be used to reduce the leachability of chlorides in the insulation system. ThepH, if under 5.5, will tend to increase the corrosion rate, rapidly with the chlorides present.

Controlling the Cracking

History shows that in austenitic stainless steel, presence of chlorides and time, ESCC willoccur. Concentrations and stresses in the fabricated vessel will dictate the rate at which it willoccur. Gland water, on shaft packing, flowing at 3-5 gal/hr (11.4-19 litter/hr) containing 50 to 70ppm chlorides and penetrating the insulation jacket caused a $500,000 mixing vessel to fail inthree years time. Low chloride insulation was used, but time, temperature, chloride andconcentration with the stresses in the equipment caused the untimely failure. Other cases maytake much longer. The main difference between the stainless and carbon steels is the crackingcannot be effectively repaired without replacing major sections of the vessel or tank. Weldrepair to the cracks does not work or does not work long. Protecting the stainless steel surfacewith coating is the safest approach to use in the 140°F to 250°·F (60°C to 121°C). Immersionservice coatings are the only ones to use. The key is to remove one or more of the elementscausing the corrosion mechanism to develop. Coating does this well The insulating coating haslow chlorides1 and provides the insulations as well as serving the function as a coating.


The Benefits of Envirotrol Ceramic Cover CC Systems 100

Minimal surface preparation. Equivalent to SSPC-SP2 or SP3. Pressure 3000 psi min. toremove dirt, grease, loose rust, mil scale cracked or chipped paint and other foreign materialwhich may have effect on adhesion).

Superior adhesion for an insulation. The Ceramic coating has been tested on several substrates with different type SSP preparation (Corrosion Probe Report). Average adhesionstrength is 250 psi then coating disbonds within coating leaving 3 to 6 mils on substrate.

Another example is the product applied over galvanized with heavy thin film oil four couponswere submitted for pull testing. Sample (#1) surface oil sprayed with International DegreaserProduct then sprayed with the coating. Sample (#2) panel preheated, no surface prep, prod-uct then sprayed over oil and force cured. Sample(#3) No surface prep, product sprayed onambient substrate then let dry at ambient Sample(#5) Surface preparation by a solvent cleanthen sprayed and let dry at ambient Results of adhesion on report dated March 18th. OnMarch 25th all panel were tested in hot/cold cycling for 100 hours, inspected for blisteringthen resubmitted to Corrosion Probe for more pull testing. March 27th report is the result ofadhesion of the product applied over oil under different scenarios.

Space savings and visual inspection (Ceramic Cover CC Systems 100 is applied in mils notinches, therefore reducing pipe rack sizes, etc. and exposing hot spots by discoloration if thevessel is losing it's integrity).

No VOC's and Environmental friendly (minimizes cost of disposal). Passed all safety require-ments tested by the University of Mississippi for toxic smoke inhalation.

Primer (Ceramic Cover CC Systems 100 serves as a corrosion inhibitor by impeding con-densation and disallowing water to migrate behind the product).

Serves as a Top coating or protective coating. Product can be tinted any color.

Chemical resistance. See Chemicals tested; additional tests not in the manual: methanol,Acidic, Citric Acid.

Permeability is equivalent to some epoxies. (Corrosion Probe Report)

Superior Environmental barrier. The product conforms directly to the surface of several typestyle substrates providing a weather barrier and eliminating places that could harbor bugs orrodents, a common problem in fiberglass. Also prevents animals from destroying the insula-tion, a common problem on fiberglass insulated pipelines.

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Ceramic Cover CC Systems 100 is unaffected by UV rays (Ceramic Cover CC Systems100 has Past 1300 Hours of accelerated aging by exposure of 12 hours salt fog and 12 hoursUV rays. (Corrosion Probe Report)

Noncombustible and low flame spread.(Ceramic Cover CC Systems 100 is 5 out of 100 flame spread).In addition, the product passed Marine Fire Safety testing (A-653(16)) fire test procedures forsurface flammability of bulkheads, ceiling and deck materials.

Due to the low thermal conduction and other insulating properties, Ceramic Cover CC Systems100 insulates and reduces surface temperatures enough for the application of inexpensive topcoatings while providing personnel safety from burns by incidental contact.

Ceramic Cover CC Systems 100 can be applied without operation shut down except on cold,wet applications.

The insulation properties of Ceramic Cover CC Systems 100 are not affected by moisture orbreachment. Minor repairs can be done with a brush on application.

Cost savings (Ceramic Cover CC Systems 100 does not require lagging support to avoidsagging or jacketing for a moisture vapor barrier).

Superior radiant heat barrier. The product has less than one-half percent (.39%) transmit-tance, eliminating the majority of radiant heat penetration. (Ga. Tech Report)

Low chloride content. The product has been tested for chlorides (less than 23ppm) and Halo-gens (l9ppm). This makes Ceramic Cover CC Systems 100 a compliment coating to stain-less steel.

Cleans-up with soap and water. Application is dry fall over five feet.

Ceramic Cover CC Systems 100 remains flexible in temperatures of -30 degrees F. (ActionTesting lab Reports on Styrofoam; an increase in the insulation value of the foam, protectivecoating against UV Rays.

Increased strength of foam (tripled from 1.0pcf to 3.0pcf) and remained durable at -30f.

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The Benefits of Envirotrol Ceramic Cover CC Systems 100


CASE HISTORIES

Process Locations Surface SurfaceTemperature Coating TemperatureBefore Coating Thickness After Coating

1. Bottom of a continuous Digestor(approx. 350 sq. ft.) (32 sqm) 200°F (93°C) 80 mils (2mm) 120°F (48°C)

Midway on the same Digestor(approx. 10 sq. ft.) (1 sqm) 350°F (177°C) 250+ mils (6.4mm) 150°F (65°C)

2. Evaporator ductwork, 20-30” approx.(approx. 1,500 sq. ft.) (39 sqm) 200°F+ (93°C) 40-60 mils (1-1.5mm) 130°F (54°C)

C102 storage tank chilled reduced(approx. 5,000 sq. ft.) (465 sqm) 50°F (10°C) 40-50 mils (1-1.3mm) condensation

3. Warm water tank(approx. 8,500 sq. ft.) (790 sqm) 165°F (74°C) 40 mils (1mm) 100°F (38°C)Green liquor tank(approx. 6,500 sq. ft.) (604 sqm) 180°F (82°C) 60 mils (1.5mm) 120°F (49°C)

4. HVAC ventilation duct 170°F (77°C) 40 mils (2mm) 70°F (21°C)

5. EFG (electrified filter bed units) 240°F (116°C) 60 mils (1.5mm) 140°F (60°C)

6. Heavy Black Liquor Storage Cone(approx. 5,000 sq. ft.) (465 sqm) 285°F (140°C) 80 mils (2mm) 145°F (63°C)

7. Black Liquor Storage(approx. 5,000 sq. ft.) (465 sqm) 185°F (85°C) 60 mils (1.5mm) 125°F (52°C)

CONCLUSION

Process vessels, tanks and piping requiring insulation where the corrosion risk from processor the environment is high are good candidates for the insulating coating. If the surface is toohot for paint systems then the insulating coating maybe applied to the equipment, while inoperation. Water or chemical have little effect on the insulating coating, as there is no wicking ormigration of chlorides to the substrate being insulated. If the insulation skin is damaged theinsulating coating only exposes the substrate where the breach occurs.

The history with the product is short thus making the engineering of the systems moreimportant, because the insulation factors between conventional systems and the insulating coatingare not direct. One deals in inches (cm) thickness and the other deals in mils (mm) of thickness.Conventional insulation when wetted promotes energy loss and corrosion; the key advantage ofthe insulating coating is it does neither.


If you have insulated equipment corrosion will occur to some degree. By using propermaterials, specifications, engineering design, inspection and maintenance methods the costcan be kept to a minimum. The problem will most likely never go away; but it can be controlled.The insulating coating offeers answers to some of the challenges faced by the other insulationsystems. Just like all systems it needs proper design and application along with good productknowledge to be successful.

REFERENCES1. Lazar P. III “Factors affecting corrosion of carbon steel under thermal insulation”

2. McIntyre, D. “Factors affecting the stress corrosion cracking of austeniticstainless steels under thermal insulation”

3. Ashbaugh, W. G. “External stress corrosion cracking of stainless steel underthermal insulation—20 years later”

4. “The Control of Corrosion Under Thermal Insulation and Fire Proofing Materials – ASystems Approach.” NACE RPO 198-98, Item No. 21084 NACE International 1998.


MATERIAL SAFETY DATA SHEET(808230P-RR)

Product Name

Ceramic Cover

Section I Manufacturer

Therma-Cote, Inc. Emergency Phone #: 770-458-68773652 North Peachtree Rd Information Phone#: 770-458-6877Chamblee, GA 30341 Date Prepared: February, 1989

Date Reviewed February, 1997

Section II Hazardous Ingredients/Identity Information

The following ingredients are subject to the reporting requirements of Section 313 of Title III of the SuperfundAmendments and Reauthorization Act of 1986 and 40 CFR part 372.

Cas No. Hazardous Ingredients (%) OSHA PEL ACGIH TLVnone

Section III Physical/Chemical Characteristics

Boiling Point: 212ºF Specific Gravity (H20 = 1): 0.59

Vapor Pressure (mm Iig): 17 @ 25°C Melting Point: N/A

Vapor Density (Air =1): >1 Evaporation Rate: <1

Solubility in water: dilutable

Appearance & Odor: This material is a viscous solution of ceramic & acrylic latexwhich has a slight ammonia order

Section IV Fire and Explosion Hazard Data

Flash Point: Non combustible

Flammable Limits: N/A

Extinguished Media: (for dried film) Carbon dioxide, dry chemical or alcohol foam


Special Fire (for dried film) Full protective equipment including self contained breathingProcedures: apparatus should be used. Water spray may be ineffective. If water is used,

fog nozzles are preferable. Water may be used to cool containers to preventpressure build up & possible auto ignition or explosion when exposed toextreme heat.

Unusual Fire and Product will not burn but may spatter if temperature exceeds boiling point.Explosion Hazards: Extreme heat may cause closed containers to burst.

Dried films of product are capable of burning, giving off oxides ofcarbon/nitrogen.

Section V Reactivity Data

Stability: Non-reactive

Incompatible (materials to avoid): Strong oxidants

Hazardous Decomposition or By-products: Oxides of carbon and nitrogen

Hazardous Polymerization: Will not occur

Section VI Health Hazards and First Aid Data

Route(s) of Entry: skin: possible ingestion: possible inhalation: possible

Health Hazards: Acute: in a confined area. Vapors in high concentration are anesthetic.Overexposure may result in light-headedness and staggering gait. Irritantto skin and upper respiratory system. May cause allergic skin reaction.

Carcinogenicity: N/A

Signs/Symptoms Redness and/or irritation of exposed areas. Repeated excessive dermalexposure may cause marked skin irritation and increase potential for allergicreaction.

First Aid Procedures: Eye exposure: flush eyes with clean water.Skin contact: wash area with soap and water.

If redness persists seek medical attention

Section IV Fire and Explosion Hazard Data (Cont)

of exposure:


Section VII Precautions for Safe Handling and Use

Steps to be taken in case Remove all source of ignition. Ventilate and remove withmaterial is released or spilled: inert absorbent.

Waste Disposal Methods: Waste from this material is not hazardous as defined under theResource Conservation & Recovery Act (RCRA) 40 CFR 261.Incinerate in approved facility. Do not incinerate closedcontainer. Dispose of in accordance with Federal, State andlocal regulations regarding pollution.

Precaution to be taken in Use only with adequate ventilation. Avoid breathing vapor andhandling and storage: spray mist. Avoid contact with skin and eyes. Wash hands after

using. Protect against dust which may be generatedby sanding or abrading the dried film.

Other Precautions: Keep container closed when not in use. Transfer only to approvedcontainers with complete and appropriate labeling. Do nottake internally. Keep out of reach of children

Section VIII Control Measures

Respiratory Protection: If personal exposure cannot be controlled by ventilation, wearrespiratory device approved by NIOSH/OSHA.

Ventilation: Local Exhaust: Preferable Mechanical (gen.): Acceptable

Protective Gloves: As recommended by supplier for ethylene glycol.

Eye Protection: Spectacles with unperforated sideshields.

Other Protective Equipment: None needed.

World/Hygienic Practices: See Section VII


EQUIPMENT SPECIFICATIONS AND APPLICATION GUIDELINES

EQUIPMENT LIST TO APPLY CERAMIC COVER

Air CompressorMinimum: 100 CFM

120 p.s.i. constant

Spray Equipment

Air Driven: 33:1 to 56:1Minimum: 33:1 ratio (Graco Bulldog)Maximum: 56:1 ratio (Graco King ) 45:1 ratio (Graco Premier)

Gasoline:Minimum: GM 5,900 manufactured by Graco

GM 7,900 manufactured by GracoMaximum: GM 10,000 manufactured by Graco

Note: All Spray equipment: remove all in-line filter systems!!

Spray Lines: Coming from pump: 3/8 I.D. (interior diameter)Ship Hose to Gun: 1/4 O.D. spray line 6’ (feet max)

Spray Gun:Graco Contractor Gun: (Note) Remove in-line filter from handleSpray Tips: Graco Revers-a-clean

Minimum: 517 Interior finish, walls, ceilings etc. (smooth finish)519, 521, 525, exterior finish, tanks, silos, ducts 319, 321,325, exterior finish; (smaller diameter) pipes small duct systems etc.

Maximum: 535 Exterior finish; roofs, exterior walls etc.

Note: where 1 ct. .016 to .020 mils is specified w/1 coat system.

Mixing: 3/4” Variable speed mixing drill motorSheetrock mud mixing paddle

Note: It is imperative air line fittings from compressor to pump or from shop air to pump bedetermined in advance.


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EQUIPMENT SPECIFICATIONS AND APPLICATION GUIDELINES

Ceramic Cover CC Systems 100 is a single component, high solids insulation coatingdesigned for application by standard high pressure airless coating equipment. Ceramic sphereseparation utilizing ASTM Designation D-185 (no.325 sieve) microscopic examination andphotomicrographs (30x magnification) was done to evaluate possible Ceramic sphere damageafter spraying. The results indicated absolutely NO DAMAGE to the spheres in Ceramic CoverCC Systems 100 when applied by high pressure spray. Ceramic Cover CC Systems 100 canalso be applied by brush or roll; however, inconsistency becomes a problem due to the lightweight of the material.

Airless Coating Pump

The Ceramic Cover CC Systems 100 requires a single component high pressure airless coating pump,capable of maintaining 3500 psi fluid pressure at the gun 30:1 ratio pump is acceptable.

It is imperative to removeall inline filters from thepump and gun.

Fluid Hose

The high pressure fluid hose should be a nylon lined rated for the maximum pump pressure. For hoselengths up to a total of 200 feet, the first 150 feet of hose from the pump should be 3/8 inch I.D. and the last 50 feet,to the gun should be 1/2 inch O.D.. These combinations are necessary to minimize the pressure drop through thehose and maintain a consistent flow. Note Ceramic Cover CC Systems 100 is 85% granular solids.

Spray Gun

The gun should be an airless typed designed for use with viscous materials and pressure rated for themaximum system pressure. A reverse clean style tip with a 418 to 521 orifice and 60 to 80 degree fan angle shouldbe used at time of spraying. For optimum spray atomization and application characteristics, the material in the pailshould be maintained at a minimum of 50 degrees F. Application should not be installed in temperatures below 32degrees F unless surface temperature of substrate exceeds 100 degrees F. Product must be protected from freezing.Should this occur the product will be rendered useless.

3/8 npt(m)Fluid Outlet


Application Guidelines

* Call Envirotrol Inc. for technical assistance when application is in excess if 350 degrees F.

1. Instructions on Pump Preparation

a. Remove any product initially sprayed through the system (i.e. solvents)

b. Remove “all” filters from the pump and contractors gun.

c. Set the ball within the pump in the up position if using pump older than 5 years.

d. Required CFM minimum is 100 psi @ contractor gun. There should always be a minimumof 90 lbs/airless psi @ contractor gun/2200 psi minimum spray.

e. Review O.D. and I.D. of hoses at different lengths.

f. Review tip sizes in Manual.

g. We suggest you experiment with pot gun application (need Graco Spray)(bottom feed pot w/pressure plate).

2. Mixing Instructions

a. Mix product 2 to 3 minutes to accomplish a homogenous liquid combining the solids withthe liquids.

b. Remove solids from the sides of the container w/ paint stick and mix thoroughly again!

c. Discuss cautions of over mixing or the importance of using the helix type paddle to avoiddamaging the Ceramics (i.e. leave product to dry on the paddle for added protection duringmixing).

d. Remix the product if unused after 30 minutes. Discuss separation due to light weight solids.

e. General Rule: To reduce entrapment of moisture and maintain consistency of solids. ApplyCeramic Cover CC Systems 100 as follows:

12-14 wet mils150 degrees F to 250 degrees F *10-14 wet mils 250 degrees F to 350 degrees F

Large surface areas (tanks) (all areas i.e. dryers, etc.)20 to 24 wet mils 160 degrees F to 300 degrees F


f. When applying Ceramic Cover CC Systems 100 @ ambient temperatures referenceacrylic paint standards for drying time. Demonstration was provided of brushing CeramicCover CC Systems 100 or on ambient substrates and hot substrates. Examples ofdifferences in drying time.

g. Apply Ceramic Cover CC Systems 100 by brushing on hot surface temperatures todemonstrate: the separation of solids from liquids; how to reduce surface temperaturein order to apply consistent smooth coats for esthetic purposes; and how to avoid cakingor solids build-up on hot surfaces.

h. Rolling application with Ceramic Cover CC Systems 100 to demonstrate difficulty ofrolling and using thinner additives such as water or (penethol or solax). Remember: additivesmay effect the insulation properties and adding water is adding chlorides!)

i. Adding colorant to tint Ceramic Cover CC Systems 100 to colors of owner’s choice.Reference products for top coating over Ceramic Cover CC Systems 100 that haveexpansion and contraction properties, i.e. mastic epoxies. Type of colorant to use (Glycolbase). Discuss color absorption. Amount to use? General rule: Buy color desired notcolor to mix, (i.e. Do not add red & yellow to make orange. Buy orange).

j. Color can be discontinued until the next day then reapplied without obvious color seamsdue to the percentage of solid content in Ceramic Cover CC Systems 100 .

3. Surface Preparation

a. Surface preparation is a clean, dry surface removing all loose rust, debris, oil, greaseor mil scale.

b. If you do an SSPC-SPI (solvent cleaning) for surface preparation use alcohol basedsolvents due to drying time. Do not use oil based solvents, i.e. mineral spirits, xylenedue to oil residue.

4. Application

a. Surface temperature must be read and milage to be determined by using the Delta“T” Chart in the Manual for estimating the correct amounts of milage required.

b. Apply a coat of Ceramic Cover CC Systems 100 @ 12 wet mils – wet mil gauge every 20– 24 lineal inches. Discuss the problems of checking mils with wet mil gauge in quick dry times.

c. The proper spray technique regarding fan spray (keep wrist and gun straight 12inches from the substrate). The amount of passes versus tip size and pipe size(3.1416 x pipe size diameter then divided by tip fan size) i.e., 5 passes on a substrateor cylinder 360 degrees circumference per 12 mil application.

d. Take surface temperature readings after each 20 mil coat. Remember the saturationeffect may cause high temperature reading. Use the correct type thermal coupling.(i.e. laser heat guns will not provide the correct surface temperature measurements).(Remember coated surface temperatures will increase if heat source is not reduced,i.e. energy savings).


Application for Ambient Temperatures

The C.C.-100 heat conductivity seems is a variable. We notice that for each completed curedcoating the surface layer and the layer contacted the base material are much denser than the rest of C.C.-100. There is a thin film effect between each completed cured coating and between C.C.-100 andbase material. This thin film conductance combined with the conventional heat conductivity provide thesuperior heat insulation property.

The proper installation should always spread only 12 wet mil (0.012 in. /0.3 mm), 10 dry mil (0.0l in./ 0.254 mm). Wait until completely dry, then apply the next coating.

Because the variable temperature and humidity the drying time is also a variable . One can determinewhether the coating is completely dried by using the thumb test.

Thumb Test: Press your thumb on the supposedly dried coating surface firmly. Then turn yourthumb 90 degrees, if the surface wrinkles it is not yet completely dry.


Testing Drying Time at Ambient Temperatures

Situation #1: Empty CansAmbient temp-64 to 68 degrees

Substrate temp-60 to 68 degreesRelative Humidity-54% to 78%

Sample 1: 1st Coat – 15 mils DFT/2.5 hours dry time2nd Coat – 20 mils DFT/25% moisture after 3.5 hours, allowed to dry overnight

Total Dry Film Thickness 35 mils

Sample 2: 1st Coat – 15 mils DFT/2.5 hours dry time2nd Coat – 15 mils DFT/34% moisture after 3.5 hours, allowed to dry overnight3rd Coat – 20 mils DFT/7% moisture after 6 hours, allowed to dry overnight4th Coat – 25 mils DFT/3% moisture after 8 hours, allowed to dry overnight


Sample 3: 1st Coat – 15 mils DFT/2.5 hours dry time2nd Coat – 19 mils DFT/32% moisture after 3.5 hours, allowed to dry overnight3rd Coat – 6 mils DFT/6 hours dry time4th Coat – 18 mils DFT/22% moisture after 8 hours, allowed to dry overnight5th Coat – 22 mils DFT/17% moisture after 5.5 hours, allowed to dry overnight


Situation #2: Empty CansAmbient temp – 85 degrees

Substrate temp – 85 degreesRelative humidity – 42% to 52%

Sample A: 1st Coat – 15 mils DFT/1 hour dry time2nd Coat – 17 mils DFT/3.25 hours dry time3rd Coat – 15 mils DFT/60% moisture after 2.25 hours, allowed to dry overnight


Sample B: 1st Coat – 18 mils DFT/3% moisture after 1 hour, allowed to dry overnight2nd Coat – 20 mils DFT/5 hours dry time3rd Coat – 25 mils DFT/60 moisture after 2.25 hours, allowed to dry overnight


Sample C: 1st Coat – 22 mils DFT/7% moisture after 1 hour, allowed to dry overnight2nd Coat – 23 mils DFT/13/5 moisture after 5 hours, recoated at this time3rd Coat – 25 mils DFT/60% moisture after 2.25 hours, allowed to dry overnight



6. Storage

Ceramic Cover CC Systems 100 should be stored in a cool dry area where ambienttemperatures do not reach below freezing or in direct sunlight.

Situation #3: Cans Filled w/Water, Temp Elevated & MaintainedUsing Electric Immersion Heat Element

Ambient temp – 64 degreesLiquid temp – 182 to 185 degrees

Relative humidity – 50 to 52 degrees

Sample 4: 1st Coat – 22 mils DFT/1 hour dry time/surface temp – 1602nd Coat – 20 mils DFT/1.5% hours dry time/surface temp – 1473rd Coat – 18 mils DFT/1 hour dry time/surface temp ≠ 108


Sample 5: 1st Coat – 15 mils DFT/1 hour dry time/surface temp – 1322nd Coat – 20 mils DFT/1.5 hours dry time/surface temp – 1223rd Coat – 15 mils DFT/1 hour dry time/surface temp – 112

5. Clean Up

a. Solvent (Xylol, Xylene, MEK) are used to remove Ceramic Cover CC Systems 100from tools or substrates where overspray is undesirable.

b. To remove Ceramic Cover CC Systems 100, use soap and water or type ofsolvent.

c. Dry fall over 7 feet can be swept up with a broom.

d. Use water to thoroughly clean pump. Product left in pump must be under pressureto be reused. Mix the remaining product in the container. When using thinner:

Clean pump-make sure all thinner is removed before using Ceramic Cover CCSystems 100. Solvents are our enemy.

ceramic cover cc systems 100 - insind - home · 2594 flat shoals road, ... ceramic cover cc systems...

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