pa-4000.pdf

7/27/2019 PA-4000.pdf

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1. SCOPE 1 . 1 The procedures outlined in this specification

are to be used in applying PLASGUARD 4100,4300, 4 1 1 0 and 4310 to steel and concretesurfaces in immersion service.

1.2 The coating system is to be applied in two tothree multi-pass spray coats to a nominal filmthickness of 40 mils. The acceptable minimumis 35 and the maximum is 45.

1.3 A current PLASGUARD 4100 or 4300 datasheet is to be used in conjunction with and

become part of this specification.

2. SURFACE PREPARATION - STEEL 2.1 All sharp edges shall be ground to produce a

radius and all imperfections, such as skipwelds, delaminations, scabs, slivers and slagshall be corrected prior to abrasive blasting.Skip welds shall be welded solid.

2.2 The coating material manufacturer’s currentproduct data sheets are to be used in conjunction with and become a part of thisspecification. The applicator should adhere to

all accommodations of product shelf life,mixing ratios and acceptable thinners.

2.3 The degree of profile shall be a minimum of 4mils as determined by comparing withPLASSITE’S blasted panel, using adequatelight and magnification if desired. Panel isavailable to inspectors on a job basis.

2.4 In preparing the surface, compressed air shallbe used, maintaining a minimum of 100 psig atthe blasting nozzle. The size of nozzle usedshall be dictated by the scfm/psi available. Theair supply shall be free of oil, water and othercontaminants.

2.5 An abrasive for surface preparation of carbonsteel shall be selected that is free ofcontaminants, dry, hard and of proper size toobtain the specified profile. Suggestedabrasives are bagged BLACK BEAUTYfi BB-1040, steel grit HG-25, or Flint Abrasive #S7(6-30 mesh).

2.6 The freshly blasted surface shall be cleanedof all abrasives by blowing down with cleanair, brushing and/or vacuum cleanerequipped with stiff brush. Brushing andblow down are not as satisfactory as vacu-um cleaning.

2.7 The surface temperature shall be main-tained at a minimum of 5 above the dewpoint to prevent oxidation of the surface.The coating shall be applied within thesame day that the surface has been pre-pared. Visible oxidation or condensation is

not allowed.

3. APPLICATION - 4000 SERIES 3.1 Coating is supplied in 5-gallon and 1-gallon

kits. A kit consists of 3 containers identifiedas Part I, Part II and Part III. In a 1-gallonkit, Part I and Part II are supplied in galloncans with a small container of Part III, cata-lyst. A 5-gallon kit is supplied in two 5-gal-lon containers with a small container of cat-alyst.

3.2 Airless or conventional atomizing spray

shall be used for applying PLASGUARD4100 and 4300. For applying PLASGUARD4110 and 4310, only atomizing air sprayshall be used because of the high wear rateof the tips and pumps on an airless spray.For airless spraying, use GRACO Bulldogor equivalent having a capacity of 3 gallonsper minute and a tip size with .025 orifice orlarger with a 12" minimum spray pattern. All screens should be removed from thegun. Screens no smaller than 60 meshshould be used at the pump. A 3/8" diame-ter fluid line is recommended with a liquid

pressure of 1600 to 1800 psig. For conven-tional spray, use a Binks No. 2001 gun with aNo. 251 air cap and No. 59ASS fluid tip orequivalent. An alternate Binks nozzle setupwould be a No. 261 air cap and No. 59BSSfluid tip. A heavy-duty trigger spring isrequired with gun. The atomization pressureshould be adjusted to 60 Ibs. with a potpressure of 50 Ibs.

PA-4000

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3.3 Do not allow substrate or air temperature tobe below 69 F for more than 16 hours or a

minimum temperature of 60 F for 12hours.If the foregoing conditions occur, it is

required that the substrate and air tempera-tures be raised to a minimum of 70 F before

the time limits shown. The temperatures of70T and above shall be held until coating

surface is tack-free. The time required to

obtain this "non-tacky" condition will bedecreased as surface temperatureincreases. When surface temperatures are

over 100T, consult the Plasite TechnicalService Department for application instruc-

tions. 3.4 PLASGUARD 20 Thinner shall be used to

adjust coating for various application condi-tions. First coat application does not nec-essarily require thinning. Succeeding coatswill require thinning a minimum of 5% byvolume. Additional thinning will be needed

to adjust coating for higher temperature andvarious other application conditions, includ-ing the topcoat of previous coating films withlong term cure.

3.5 Parts I and II shall be mixed with a motorizedagitator driven by air or an explosion-proofmotor. The gray-colored powder (Part II)shall be slowly added so that it does notleave lumps in the resin (Part I). Part I andPart II will require approximately 15 to 30minutes of thorough mixing to be properlyblended. Part III shall then be added with

power agitation.

Mixing can be expedited by the blending ofPart I and Part II 16 to 24 hours in advanceof application. The mixture of Part I and PartII must be used within 72 hours. Part III (thecatalyst) can then be added and thoroughlymixed into the solution just prior toapplication. The pot life, after mixing, variesfrom 1 to 2 hours depending upon materialtemperature. Do not divide parts or add newmixtures to old. Continuous mixing duringuse is required.

3.6 The coating, thinned 30% by volume withPLASGUARD 20 Thinner, shall be brushapplied to all welds and seams. The tech-nique for brushing shall be to brush out andnot to flow on the coating.

3.7 The mixed coating shall be applied utilizing amulti-pass spray system. Apply horizontaland vertical passes with 50% overlap. Thetotal wet mils per coat shall be approxi-mately 24 mils, resulting in a dry film thick-ness of 18 to 22 mils. Special precautionsare required at overlaps and welds to elimi-

nate excessive film build. Spray gun shouldbe perpendicular to surface at all times,approximately 14" from surface.

3.8 Coating may be overcoated after initial "set,"which will occur normally in 3 to 6 hours at70 F with proper ventilation. Initial "set" timewill decrease as surface temperatureincreases. When physical contact (foottraffic, scaffolding, etc.) with the previously

applied coating is required, a minimum of 10hours at 70 F substrate and air temperaturewith ventilation is normally required beforeproceeding. Previously applied coats musthave reached a "non-tacky" state beforebeing exposed to physical contact. Thiscondition will occur in less t ime as surfacetemperature increases.

Note:Previously applied coating exposed todirect sunlight or surface temperature inexcess of 130 F may result in intercoatdisbondment. Coating film exposed to anaccumulation of over 24 hours of UV

exposure before topcoat-ing will result inintercoat disbondment. Special procedures(such as shading with tarps) should be usedto prevent an accumulation of 24 hours of UVexposure. Overcoating shall be performed assoon as possible to prevent contamination. Any moisture from condensation or anysource will kill the cure on freshly appliedcoating before it reaches a "non-tacky" stage.

4. CURING 4.1 The minimum air dry time at 70 F surface

temperature is 10 days. If force curing isincorporated, an air dry time with airmove-ment of a minimum 2 hours shallbe allowed. Temperatures should thenbe raised approximately SOT inincrements of 30 minutes to final surfacetemperature. Curing schedule asoutlined in PLASGUARD data sheet4100 or 4300 can be incorporated.

Note:The final cure requirement can beaccumulative. Final cure requirementsmust be met within 14 days of applica-tion.

5. CURING CHECK 5.1 Compare hardness with cured test

panels with knife point or any physical

test. 6. METAL TEMPERATURE - AIR

TEMPERATURE -DEW POINT 6.1 Metal temperature shall be recorded at

least every 4 hours and beforeapplication of coating.

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6.2 Humidity or wet bulb reading shall be taken atsame time as metal temperature reading toensure that metal temperature is at least 5 Fhigher than the dew point. Dry bulbtemperatures shall be recorded at the sametime to ensure curing. Metal temperature isthe governing factor.

7. INSPECTION 7.1 Dry film thickness shall be determined utilizing

a non-destructive magnetic type high rangegauge. The anticipated film thickness shall bein the middle range of the gauge. The total dryfilm thickness shall be a minimum of 35 mils,with a maximum of 45 mils, and acceptablespot readings at 50 mils. A suspect area, thatbeing in excess of 45 mils, shall then beacceptable if an average of 35 to 45 mils isobtained when four additional readings areobserved, taken approximately one foot fromthe suspect area at top, bottom and bothsides.

7.2 For immersion service, a pinhole-free film is

essential and testing with Tinker & RasorModel AP-W or equivalent is required on finalfilm. Use 4000 to 4500 volts for PLAS-GUARD4100or4300. Use 3000 to 3500volts for PLASGUARD 4110 or 4310. Allow aminimum cure of 48 hours at 70 F or 36 hoursat 90 F before holiday testing.

8. REPAIR 8.1 Clean damaged area, removing all contami-

nants and loose coating. 8.2 Abrasive blast substrate to original specifi-

cation where coating has been exposed toenvironment and where oxidation is evident.Feather the original coating not less than 2inches from damaged area.

8.3 If new coating is physically damaged andhas not been in service, repair as shownabove. For repairing holidays, sand surfaceand brush apply proper thickness of

coating. 8.4 Apply coating by brush or spray. Do not apply

by brush on areas larger than 1 square foot. WARNING!Contamination of previouslyexposed coating film may be detrimental toadhesion of the repair and may affect servicelife expectancy.

8.5 Refer to Section 4 for curing information.

9. SURFACE PREPARATION - CONCRETE 9.1 Inspect for structural failures, cracks, pro-

trusions and fins. Grind surface flush andgrind cracks to "V" configuration. Chip outall loose concrete to width of 1/4" minimum.

9.2 Repair all large holes, cracks, voids and other

imperfections with PLASGUARD 9029 filler-sealer, with addition of specified sand as

required to provide proper stiffness used asthe grout. Mixtures of specified sand up toequal parts of sand to resin may be used.Refer to PLASGUARD data sheet 9029. ,

9.3 Concrete surface must have 30 days cure, beclean, hard, dense and free of laitance, formoil and release agents. Blow holes, pits andcavities must be opened in order that they maybe properly filled and sealed. To provide theforegoing requirements, it is necessary toprepare the surface using one or moremethods listed in order of preference.

9.3.1 Whip blast with sand that is 90% 50 or 60mesh with nozzle pressure of approximately70 psi. Pressure and distance of nozzle fromsurface depends on characteristics ofconcrete.

CAUTION! Do not overblast as it will result in

high consumption of material and labor. 9.3.2 Water blasting at pressure of approximately

3000 psi may be used to produce similarresults required in 9.3 and 9.3.1.

10. FILLING AND SEALING CONCRETE 10.1 Concrete surface must be filled and sealed

with PLASGUARD 9029 filler-sealer. Refer toPLASGUARD data sheet 9029 for mixing andapplication instructions.

10.2 Apply first coat by spray or hand method,

thoroughly work into surface with squeegee orflexible plastic to provide a flush uniformsurface.

10.3 Apply second coat in same manner as 10.2.This will normally fill all small voids and leave10 to 15 mils on the flush surface. Coverage

rates for 10.2 and 10.3 are approximately 80to 120 square feet per gallon depending onthe roughness of concrete surface. This coatmay be applied immediately after first coat orwhenever first coat is hard.

10.4 Damp concrete surface may be filled andsealed with PLASGUARD 9029.

10.5 Visually inspect all surfaces and repair anyvoids.

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1 1 . TOPCOAT APPLICATION 1 1 . 1 Filled and sealed surface must be clean, dry,

uncontaminated and hard before top-coating. Thefiller-sealer will reach the foregoing condition attemperatures of 50 to 60T with low humidity within16 hours. At 70T with relative humidity of 40 to60%, it may be suitable for coating within 8 to 10hours.

11.2 Apply topcoats of PLASGUARD 4000 series inaccordance with PLASGUARD data sheets 4100,4300 and the foregoing Sections 1, 3, 4 & 6.

11.3 Inspect final topcoat for imperfections and repair.

We guarantee our product to be f ree of defects in material and workmanship and to be in accordance with our company quali ty control standards. Al l data, statements and recommendations made

herein are based upon i nformation we bel ieve to be reli able, but are made without any representation or guarantee or warranty of accuracy and are made with reservation of all patent rights. Our

products are sold on the conditi on that the user himself will evaluate them, as well as our recommendations, to determine their suitabi li ty for his own purpose before adopti on. Also, statements

regarding the use of our products or processes are not to be construed as recommendations for their use in violation of any patent rights or in violation o f any appli cable laws or regulati ons. Liabil ity

under any condition shall be limited to replacement of material only. No liability is assumed or implied, for injury to personnel, labor costs, product loss or any other expenses incidental to the structureor operation of the pl ant and equipment where this coating is applied. Rev. 8/00 8/00

StonCor Middle East L.L.C.

P.O. Box 3034, Dubai, U.A.E.

T e l : 9 7 1 4 3 4 7 0 4 6 0F a x : 9 7 1 4 3 4 7 0 2 4 2

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