Technical Service For Chartek Fire Proofing Intoduction

Chartek Fire Proofing Introduction / Training Chartek Introduction To show differences between PC paint products, applications, equipment, against Chartek fireproofing applications, equipment. Chartek Training To be carried out by International Chartek Technical Service Chartek applications with dedicated PC Technical Service Personnel, competent to carry out an Chartek Field Audit Report in compliance with the Chartek Audit programme.

CHARTEK Agenda For Training

Introduction Chartek Materials Application of Chartek 7:
Surface Preparation Priming Masking Application ( 1st coat , 2nd coat )

Final Inspection Top coating

Introduction and Product Background

Over 30 years of oil, gas, petrochemical and power generation experience Chartek 59, the worlds first epoxy intumescent material developed out of the NASA Research Programme Chartek Materials 59, 3, 4, 7. Over 30 years track record and experience, backed up by International Paint Ltd CHARTEK 1709: Advanced Chartek technology, qualified by Underwriters Laboratories (UL) ANSI/UL 1709 Exterior Listing

Chartek Definition: Definition Chartek is a reinforced intumescent epoxy system, supplied in a two component kit

Base : Epoxy Curing Agent : Polyamine

Method of Protection : Intumescent

Reinforcement : Generally : Patented hybrid carbon glass fibre mesh named HK-1

Base/Cure Packaging
Chartek 7 50 Kg Kit Standard Plural Kit Part A: 35.48kg Part B: 14.52kg Chartek 1709 Part A: 35.7 kg Part B: 14.3 kg Part A: 14.3 kg Part B 5.7 kg Chartek 8 Part A: 35.7 kg Part B: 14.3 kg Part A: 14.3 kg Part B 5.7 kg

20 Kg Kit Part A: 14.20kg Single leg / Premix Kit Part B: 5.80kg 50 Kg Kit:

20 Kg Kit:

Chartek Ratio Range

Chartek 7 Chartek 1709 Chartek 8

Part A:B as a ratio by volume Part A:B as a ratio by weight Maximum acceptable ratio Minimum acceptable ratio

2.33:1 2.45:1 2.56:1 2.32:1

2.33:1 2.5:1 2.61:1 2.37:1

2.33:1 2.5:1 2.61:1 2.37:1

INTUMESCENCE

Chartek will react, intumesce and is dependent on a heat source The swelling mechanism is known as Intumescence The intumescent reacts in strata, inner layers progressively reacting as the heat penetrates the outside layer

INTUMESCENCE

Stage 1: Initial fire Exposure

Fire

Unreacted Material

Substrate

INTUMESCENCE

Stage 2: Short term fire exposure

Fire

Char Reaction Zone Unreacted Material Substrate

INTUMESCENCE

STAGE 3: Mid term fire exposure

Fire

Char

Reaction Zone Unreacted Material Substrate

INTUMESCENCE

STAGE 4: End of fire term

Fire

Char fully reacted

Substrate

INTUMESCENCE CHAR FORMATION

General Application Procedure Surface Preparation Priming Masking 1st coat + Mesh installation 2nd coat Final Inspection Top Coat

Surface Preparation

Make certain good bond between primer and substrate Make certain good bond between primer and Chartek Make certain clean surface to ensure optimum bond between Chartek /primer/substrate

Surface Preparation
Dry Blast Cleaning (Main) - Surface shall be free of all
visible oil , grease , dust , dirt millscale , rust , oxides

- Sa 2,SSPC SP10,NACE No.2 - Blast Profile ( Carbon Steel ) must be

50 to 75 microns ( 2 to 3 mils ) profile < Note > - Stainless Steel Non-metallic abrasive should be used and a profile of 35 to 50 microns is required - Aluminium Non-metallic abrasive should be used and a profile of 75 to 100 microns is required

Surface Preparation

Power Tool Cleaning

- 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 1 , for example welds and local repair areas ) - SSPC SP3

Priming Purpose of Primer

- Holding primer : To prevent corrosion formation prior to overcoating with Chartek - Correct primer type and thickness are required to achieve strong bonding of Chartek to the substrate

Applied epoxy primer ( Intergard 269 )

Applied epoxy zinc primer ( Interzinc 52 )

PRIMER QUALIFICATION PRIMERS TYPES AND THICKNESS

PRIMER TYPE a) Epoxy Polyamide b) Zinc Silicate c) Zinc Rich Epoxy

ALLOWABLE THICKNESS Up to 75 microns with 100 microns allowed in small overlap areas Up to 75 microns maximum Up to 75 microns maximum

PRIMER QUALIFICATION PRIMERS TYPES AND THICKNESS

b) or c)

with epoxy tie coat 110 microns dft total system maximum up to 75 microns tie coat not to exceed 40 microns 125 microns total system allowed in small overlap areas

b) or c)

PRIMER QUALIFICATION PRIMERS TYPES AND THICKNESS

Epoxy polyamide Zinc silicate Zinc rich epoxy Zinc silicate and tie coat

Zinc rich and tie coat Aluminium epoxy (surface tolerant) Moisture tolerant

MANUFACTURERS DATA SHEETS AND RECOMMENDATIONS APPLY PRIMED SYSTEM MUST BE FULLY CURED PRIOR TO OVERCOATING WITH CHARTEK

Masking
Sheeting for weather protection/environment maintenance Masking for termination of Chartek Instruments, gauges, Electrical conduits etc

Application ( Plural spray equipment ) Check points prior to application

a. Ambient Conditions - Air temperature : minimum 5 - Relative humidity : 85% - Surface temperature : at least 3 above dew point temperature b.Material Preheating - In order to make a good spray pattern and work efficiency, the material should be preheated ( 100% volume solid ) * 30 to 34 for 24 hours ( maximum 48 hours ) prior to use - Accelated overheating may undesirable changes to its properties ( including shorter pot life )

Application ( Plural Spray Equipment )

c. Plural Spray Equipment preparation - Machine must be placed at clean and warm area - Prior to use , machine should be fully pre warmed - All pressure,gauge,valve,coupling,hose,gun should be checked during warming

Operating parameters for plural component spray machines

Application ( Plural Spray Equipment )

d. Ratio Check - When all preparation are finished , Ratio Check should be performed before spray work - As a minimum , Ratio Check by weight should be performed at the start up of each days production and again if the machine is shut down and restarted for any reason - Constant checking of the displacement pump pressure gauges and the color of the mixed Chartek should be carried out by the machine operator and sprayer respectively

Application ( Plural Spray Equipment )

< Ratio Check Procedure > A. Weigh clean empty Part A and B containers and note the respective weights B. Place the containers under the ratio check drain valves and open the valves at exactly the same time C. Close the valves when the containers are at least half full at exactly same time D. Find the net weight of each part by subtracting the weight of the containers E. Calculate the ratio of Part A to Part B as a percentage of the total weight Example. - Part A empty container weight : 1.3kg , Part B empty container weight : 1.3kg - Part A full container weight : 15.3kg , Part B full container weight : 7kg - Part A net weight : 15.3kg-1.3kg = 14kg , Part B net weight : 7kg-1.3kg = 5.7kg - Part A / Part B : 14kg / 5.7kg = 2.45 , Ratio by weight = 2.45 : 1

Application ( Plural Spray Equipment )

Ratio Check Progress

Prepare empty containers

Weigh and note the weight

Drain materials at least half

Calculate the net weight

Application ( Plural spray equipment ) 1st coat + Mesh installation

a. Spray

- In order to make a good fan , enough pressure and temperature

proper spray tip should be needed * Recommended Tip Size : 0.035 ~ 0.041 - Sprayer have to check wet film thickness frequently for specified thickness and even surface b. Trowelling - Trowelling helps to ensure good wetting to substrate and even thickness - To make sagging,slumping surface evenly

Application ( Plural spray equipment )

c. Mesh Installation

- Cut mesh to reqired sizes before starting application

- Apply mesh to wet Chartek at approximately - Roll the mesh thoroughly into the wet Chartek with short nap rollers dampened with solvent - Overlap adjacent pieces of mesh by at least 50mm(2). For jet fire application, overlap by at least 150mm (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 coat - For jet fire application the minimum overlap shall be 150mm and the HK-1 shall cover all surfaces ( 100% coverage )

Application ( Plural spray equipment )

Subsequent coat ( Overcoating )

Optimum
Wet on wet Within 12 hours Holding coat (spray surface) to be applied if unable to complete specified thickness within working shift

Acceptable
12-24 hours, checking that the surface is not contaminated/amine bloomed

With Care
24 hours upwards - thoroughly check surface for contamination/amine bloom. If necessary, solvent wipe/sweepblast

Application ( Plural spray equipment )

Progress ( 1st coat + mesh installation ) a. Spray

A good fan makes the even surface and thickness

b. Trowelling
Makes the even surface and good wettability to the substrate

Application ( Plural spray equipment )

C. Mesh Installation

After trowelling,Mesh install with a proper mesh overlap ( 50 mm , 150 mm )

b. Stipple Holding Coat

- Make the rough surface and prevent contamination of mesh - Extend overcoating interval

Application ( Plural spray equipment ) 2nd coat

a. Spray - In order to make a good fan , enough pressure and temperature proper spray tip should be needed * Recommended Tip Size : 0.035 ~ 0.041 When the spray fan is poor , air pockets on the rolled surface will be occurred due to roughened surface - Sprayer have to check wet film thickness frequently for specified thickness and even surface b. Trowelling - Trowelling helps to ensure good wetting to substrate and even thickness - To make sagging,slumping surface evenly - To reduce the formation of air pockets

Application ( Plural spray equipment )

c. Rolling - To achieve a uniform thickness - To produce smoother surface preventing trowel marks and high points d. Stippled finish

Application ( Plural spray equipment )

Progress ( 2nd coat , Stipple finish ) DFT Check before Next Coat

In order to make a specified DFT , DFT check should performed before next coat

a. Spray ( 1st coated area )

Application ( Plural spray equipment )

b. Trowelling

Make the even surface and good wettability to substrate

c . Rolling

Make the flat surface with a big roller at the big area

Make the flat surface with a small roller at corner,edge

Application

Final Inspection

Check Point
- Coated area should be followed to design needed - DFT should be followed to a specified DFT - Discontinuities,pinholes,voids,mesh showing are acceptable - Debonding,gap at termination are not allowed - Surface should be regular shape and smooth

Final Inspection < Thickness Measurement >

a. Method of measuring DFT - Drilling Check with pin gauge - Using an electromagnetic gauge b. Measurement Criteria Location - Thickness measurements should be taken randomly over coated area - It is recommended that no thickness measurements are taken within 25mm of the edge of structural sections and divisions or within 25mm of the join of flange to web Frequency * " I " sections , tee sections , channels - Webs : 2 readings per meter length on each face - Outer flanges : 2 readings per meter length on each face - Inner flanges : 1 reading per meter length on each face

Final Inspection
* Square or rectangular angles and hollow sections - 2 readings per meter length on each face * Circular hollow sections - 8 readings per meter length spread evenly around the section * Division and large flat plates - 2 readings per 1 Acceptance Criteria - In all cases , the average thickness must be the specified design or certified thickness - Unless specifically stated in the project documentation , the minimum acceptable thickness at any point shall not be less than 85% or the design or certified thickness up to a maximum 0f 1.5mm less than the 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.That area shall be brought up to the required thickness

Top Coat Chartek will be topcoated to meet owners colour schemes and finish requirements
There are specific situations where the use of a topcoat is considered mandatory - Off shore environment installation - Area of high UV exposure : chalking, color change - Areas of high moisture exposure : splash zone - Coarse sprayed finish : a stippled finish may collect airborne contaminants

It is recommended that Chartek is tipcoated when it is sufficiently cured and the surfaces are clean and dry

Final Condition

Final Condition