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PITT-CHAR XP
Consolidated File
SUPPORT MANUAL
Version 29.10.2010
PASSIVE FIRE PROTECTION
INFORMATION
PROTECTION OF STEEL FROM HYDROCARBON FIRES
PITT-CHAR XP CONTENTS
a one page issue
1200
December 2008
sheets nrs
GENERAL
Contents
Introduction
1200
1201
PRODUCT DATA SHEETS
Pitt-Char XP
7589
APPLICATION GUIDELINES
Pitt-Char XP Application Guidelines
1202
GENERAL INFORMATION SHEETS
Conversion tables
Explanation to product data sheets
Safety indications
Safety in confined spaces and health safety
explosion hazard - toxic hazard
Directives for ventilation practice
Cleaning of steel and removal of rust
Specification for mineral abrasives
Relative humidity - substrate temperature - air temperature
Pitt-Char XP - Fire Protection Certificates
Pitt-Char XP - Requirements for Applicator Training Courses
Pitt-Char XP - Qualified Primers - PPG
Pitt-Char XP - Primer Qualification Form
Pitt-Char XP - Project Information sheet
1410
1411
1430
1431
1434
1490
1491
1650
1897 A
1203
1204
1205
1207
Limitation of Liability - The information in this data sheet is based upon laboratory tests we believe to be accurate and is
intended for guidance only. All recommendations or suggestions relating to the use of the Sigma Coatings products made by PPG
Protective & Marine Coatings, whether in technical documentation, or in response to a specific enquiry, or otherwise, are based
on data which to the best of our knowledge are reliable. The products and information are designed for users having the requisite
knowledge and industrial skills and it is the end-user's responsibility to determine the suitability of the product for its intended
use.
PPG Protective & Marine Coatings has no control over either the quality or condition of the substrate, or the many factors
affecting the use and application of the product. PPG Protective & Marine Coatings does therefore not accept any liability arising
from loss, injury or damage resulting from such use or the contents of this data sheet (unless there are written agreements
stating otherwise).
The data contained herein are liable to modification as a result of practical experience and continuous product development.
This data sheet replaces and annuls all previous issues and it is therefore the user’s responsibility to ensure that this sheet is
current prior to using the product.
page 1/1
PASSIVE FIRE PROTECTION
INFORMATION
PROTECTION OF STEEL FROM HYDROCARBON FIRES
PITT-CHAR XP INTRODUCTION
a four page issue
1201
January 2009
Any structure has a built in amount of 'passive' fire protection due to the inherent strength of the materials
used and their resistance to fire. These basic strengths can be enhanced by the addition of insulating
materials of one sort or another. Pitt-Char XP is an intumescent coating which may be applied principally to
steel surfaces which, under fire conditions will extend the period during which the steel concerned is
capable of withstanding the affects of heat.
In practice passive fire protection is used in the following areas:
− To insulate structural steel elements against damage or collapse in various fire scenarios, thus
maintaining the integrity of the structure and allowing evacuation and fire fighting measures to become
more effective.
− On compartmentation within a structure, such as used in living quarters, temporary safe refuges,
production, storage and utility areas, to help provide the maximum opportunity for safe egress in the
event of fire.
Fire Classifications - Divisions
These come in three main areas being designated 'A', 'H' and 'B'. The first two may be load bearing but the
B classification is always non load bearing. Living quarters and other areas in the A- and B-class sections
are likely to be panel systems or steel sheet and these are often made as proprietary units. In utility and
production areas the partitions are usually steel sheets which are often profiled and will be insulated. The
classification of these fire walls is as follows:
− A-Class divisions are those formed by bulkheads and decks, and are constructed to prevent the passage
of heat, smoke and flame to defined standards during a standard fire test. They can be rated as A-O
which has no limiting temperature on the back face of the bulk head, or A-60 which has a limiting
temperature of a rise of a 140°C above ambient measured as an average of the number of
thermocouples used in the test, with a maximum rise of 180°C in any one point in the test.
− B-Class divisions will be constructed from non-combustible materials which themselves have defined
periods of fire resistance expressed in minutes from a minimum of 15.
− H-Class divisions will also be manufactured from non-combustible materials and be capable of
maintaining their structural integrity during a defined fire test based upon the DEn/NPD interim
hydrocarbon fire curve (or BS476 Part 20/21 - Appendix D). As with the A-60 division, the temperature
rise on the back face is limited to 140°C above ambient and the period is stipulated by the use of the
numeric indication of minutes from 30 up to 240. When specifying the period for both A- and H-Class
protection the time period, allied to a required failure temperature, will be specified. This would normally
start at 400°C, but could be either lower or higher (maybe up to 600°C) in certain circumstances. e.g.
H-60 400 indicates: Hydrocarbon Fire situation - steel must not reach a temperature of 400°C in less
than 60 minutes.
page 1/4
PASSIVE FIRE PROTECTION
INFORMATION
PROTECTION OF STEEL FROM HYDROCARBON FIRES
PITT-CHAR XP INTRODUCTION
1201
January 2009
Fire Types
Hydrocarbon Fires
Reference has been made above to the standard hydrocarbon fire curve which
is used in testing, but fires may be of three basic types.
Formally designated as a pool fire, the use of the DEn/NPD interim hydrocarbon
fire curve in testing has meant that materials are tested to a standard curve as
opposed to the open pool fire previously used. This gives a more reliable
comparison of results.
Cellulosic Fires
These are defined by the ISO Standard No 834, or as the BS476 part 20
cellulosic curve. It differs from the hydrocarbon curve by rising at a
considerably slower rate to a maximum temperature of just over 900°C,
compared with a maximum temperature of almost 1100°C for the hydrocarbon
curve over a 60 minute duration.
Jet Fire
A jet fire demonstration is an attempt to simulate the effects of a fracture in
ariser or product line which will give rise to a fire of particularly fierce intensity,
with greater heat flux and higher levels of turbulence of the flame, and with a
danger of erosion of insulating material.
Classification of protection may include the appendix 'J' to indicate the period
of jet fire which is required and this period may be determined by the speed at
which emergency shut down valves (ESDV) and other measures can decrease
the flow and shut down the line concerned. Where both jet and hydrocarbon
fire parameters are laid down, an assessment of the results of test under both
sets of conditions must be carried out to determine the levels of protection
required by a particular insulating material.
1400
Jet Fire
Hydrocarbon Fire
1200
1000
TEMP.
0
800
[ C]
Cellulosic Fire
600
400
200
0
0
10
20
30
40
50
60
70
TIME [min]
page 2/4
80
90 100 110 120
PASSIVE FIRE PROTECTION
INFORMATION
PROTECTION OF STEEL FROM HYDROCARBON FIRES
PITT-CHAR XP INTRODUCTION
1201
January 2009
Risk Analysis
Because oil and gas structures, either on-shore or off-shore, handle large quantities of various hydrocarbon
products at high pressures and/or elevated temperatures, and are often operating under adverse weather
conditions, they present logistical problems of escape which require the provision of safe havens for
emergency use. In many cases the basic materials used to construct such plants will have built in strength
in a fire situation, and in order to determine the additional protection which is required from passive fire
protection materials, an engineer must decide on the following points:
•
Exactly what needs additional protection ?
•
What limiting temperatures need to be applied ?
•
What type of fire is likely to be involved ?
•
What compartmentation needs are involved ?
•
What period needs to be specified for the fire protection ?
•
If there is a risk of jet fire how long will it take for ESDV to operate and are there other considerations to
extend the period ?
In specifying the thicknesses of epoxy PFP in particular, consideration must be given to:
•
The type and function of the structure.
•
The Hp/A factor of the steel involved.
•
The type of fire.
•
The period for which protection is required.
•
The limiting temperature required.
In protecting steel surfaces from weakening under fire conditions, consideration must also be given to the
fact that for the normal operating life of the structure, the steel will need to be protected from atmospheric
conditions and corrosion. The use of epoxy PFP provides a thick layer of high quality epoxy material which
may be applied over a compatible anti-corrosive primer, and should be sealed by a good weathering coat
which will maintain the general condition of the PFP material itself, and provide a good aesthetic
appearance in operation. Under a PFP, the design must stipulate an approved primer and a suitable
finishing/sealer coat to give the required cosmetic appearance.
A further consideration in the design of the system is that at higher film thicknesses (film weights), and on
bulkheads and decks, some form of mechanical reinforcement is often required. This may take the form of
welded steel pins and galvanised mesh, or specially designed hydrocarbon or jet fire meshes. Under
extreme conditions both may occasionally be used. The reinforcement assists not only in the integrity of the
whole film during normal operating conditions, but also helps to ensure the adhesion of the carbon char
formed by the intumescent reaction of the coating itself. Reinforcement is particularly valuable under jet fire
scenarios as it limits the erosion of char during the jet fire period.
The final decision on what type of system reinforcement is required, and whether or not pins should be
used, must involve the specifiers, designers and engineers on a particular project.
page 3/4
PASSIVE FIRE PROTECTION
INFORMATION
PROTECTION OF STEEL FROM HYDROCARBON FIRES
PITT-CHAR XP INTRODUCTION
1201
January 2009
Product Quality Assurance
PPG manufacturing sites are certified according to EN-ISO 9001
All raw materials are subjected to quality testing before being released for manufacture.
Random batches of Pitt-Char XP are routinely selected from production and subjected to hydrocarbon fire
testing
Test Certification
Testing and certification of Pitt-Char XP is ongoing. If any circumstance arises which is not covered by the
certification in this manual, consult PPG Protective & Marine Coatings.
Limitation of Liability - The information in this data sheet is based upon laboratory tests we believe to be accurate and is
intended for guidance only. All recommendations or suggestions relating to the use of the Sigma Coatings products made by PPG
Protective & Marine Coatings, whether in technical documentation, or in response to a specific enquiry, or otherwise, are based
on data which to the best of our knowledge are reliable. The products and information are designed for users having the requisite
knowledge and industrial skills and it is the end-user's responsibility to determine the suitability of the product for its intended
use.
PPG Protective & Marine Coatings has no control over either the quality or condition of the substrate, or the many factors
affecting the use and application of the product. PPG Protective & Marine Coatings does therefore not accept any liability arising
from loss, injury or damage resulting from such use or the contents of this data sheet (unless there are written agreements
stating otherwise).
The data contained herein are liable to modification as a result of practical experience and continuous product development.
This data sheet replaces and annuls all previous issues and it is therefore the user’s responsibility to ensure that this sheet is
current prior to using the product.
page 4/4
PITT-CHAR XP
3 pages
DESCRIPTION
July 2010
Revision of January 2009
solvent free thick film intumescent epoxy coating for hydrocarbon pool and
jet fires
PRINCIPAL CHARACTERISTICS – highly durable intumescent coating for protection of steel against
hydrocarbon pool and jet fires; typical applications include:
Offshore - structural steel members, bulkheads and decks
Onshore - pipework, storage tanks and vessels
– unique flexibility offers enhanced performance on vibrating structures and in
conditions of explosion overpressure
– suitable for use in cryogenic conditions
– good resistance to splash and spillage of chemicals
– excellent abrasion resistance
– suitable for corrosivity categories up to C5-I and C5-M
– meets the requirements for Norsok M501 rev 5 accelerated aging and
hydrocarbon fire testing
– approved by DNV, Lloyds, BV, UL and GASAFE
COLOURS AND GLOSS
grey - matt
BASIC DATA AT 20°C
(1 g/cm³ = 8.25 lb/US gal; 1 m²/l = 40.7 ft²/US gal)
(data for mixed product)
1.10 g/cm³
note:the applied density is dependent upon many variables such as
temperature, test method and application method
100%
max. 0 g/kg (Directive 1999/13/EC, SED)
max. 0 g/l (0 lb/gal)
see information sheet 1411
normally 1000 - 7000 μm applied in one coat
note:the required dry film thickness must be in accordance with the
approval certification
1.10 kg/m² for 1000 μm *
10 hours *
min. 4 hours
max. 1 month
Mass density
Volume solids
VOC (supplied)
Recommended dry film thickness
Theoretical spreading rate
Touch dry after
Overcoating interval
(data for components)
Shelf life (cool and dry place)
base: at least 18 months
hardener: at least 24 months
* see additional data
page 1/3
PITT-CHAR XP
July 2010
RECOMMENDED
SUBSTRATE CONDITIONS
AND TEMPERATURES
– approved primer, dry, sound and free from contamination
– where mesh reinforcement of Pitt-Char XP is necessary, this should be
carried out in accordance with the Pitt-Char XP Application Guidelines
– substrate temperature should be at least 5°C and at least 3°C above dew
point during application and curing
– curing will be retarded at temperatures below 10°C and will cease below 5°C
– relative humidity during application must be lower than 85%
INSTRUCTIONS FOR USE
mixing ratio by volume: base to hardener
mixing ratio by weight: base to hardener
for details see the Pitt-Char XP Application Guidelines
Induction time
none
Pot life
45 minutes at 25°C *
AIRLESS SPRAY
twin feed application
– twin feed spray equipment utilising a minimum 10 inch King air motor is
recommended
– base and hardener need to be pre-heated to a minimum of 60°C while
circulating through the unit
– suitable insulated and heated hoses should be used
no thinner should be added
40° (for large flat surfaces)
approx. 0.89 - 1.09 mm (= 0.035 - 0.043 in)
24 MPa (= approx. 240 bar; 3500 p.s.i.)
Recommended thinner
Nozzle angle
Nozzle orifice
Nozzle pressure
2.33 : 1
3.25 : 1
Nozzle angle
Nozzle orifice
Nozzle pressure
single feed application
5% - 7% of Thinner 60-30 may be necessary, but the quantity shall never
exceed 10%.
The addition of thinner will affect sag resistance and overcoating intervals.
60° (for large flat surfaces)
approx. 0.84 - 0.89 mm (= 0.033 - 0.035 in)
35 MPa (= approx. 350 bar; 5000 p.s.i.)
use of spray equipment with a ratio of 74 : 1 is recommended
material temperature (mixed): 23 - 35°C
the maximum length of the hoses should not exceed 30 m
TROWEL
Recommended thinner
(recommended for small areas and touch up only)
no thinner should be added
CLEANING SOLVENT
Thinner 90-53
SAFETY PRECAUTIONS
for paint and recommended thinners see safety sheets 1430, 1431 and relevant
material safety data sheets
Recommended thinner
although this is a solvent free paint, care should be taken to avoid inhalation of
spray mist as well as contact between the wet paint and exposed skin or eyes
page 2/3
PITT-CHAR XP
July 2010
ADDITIONAL DATA
Curing table (for solvent free aplication)
substrate temperature
dry to handle (Shore D = 25)
10°C
15°C
25°C
40°C
52 hours
40 hours
13 hours
7 hours
– curing times may vary depending on substrate, ambient and material
temperature
– adequate ventilation must be maintained during application and curing
(please refer to sheets 1433 and 1434)
REFERENCES
Explanation to product data sheets
Safety indications
Safety in confined spaces and health safety
Explosion hazard - toxic hazard
see information sheet 1411
see information sheet 1430
see information sheet 1431
LIMITATION OF LIABILITY
The information in this data sheet is based upon laboratory tests we believe to be accurate and is intended for
guidance only. All recommendations or suggestions relating to the use of the coatings products made by PPG
Protective & Marine Coatings, whether in technical documentation, or in response to a specific enquiry, or otherwise,
are based on data which to the best of our knowledge are reliable. The products and information are designed for
users having the requisite knowledge and industrial skills and it is the end-user's responsibility to determine the
suitability of the product for its intended use.
PPG Protective & Marine Coatings has no control over either the quality or condition of the substrate, or the many
factors affecting the use and application of the product. PPG Protective & Marine Coatings does therefore not accept
any liability arising from loss, injury or damage resulting from such use or the contents of this data sheet (unless there
are written agreements stating otherwise).
The data contained herein are liable to modification as a result of practical experience and continuous product
development.
This data sheet replaces and annuls all previous issues and it is therefore the user's responsibility to ensure that this
sheet is current prior to using the product.
The English text of this document shall prevail over any translation thereof.
281999
PDS
grey
7589
3000002504
page 3/3
PASSIVE FIRE PROTECTION
INFORMATION
PROTECTION OF STEEL FROM HYDROCARBON FIRES
PITT-CHAR XP APPLICATION GUIDELINES
a 49 pages issue
1202
August 2010
revision of April 2009
Content.........................................................................................................................................................1
1.0 Introduction ............................................................................................................................................4
1.1 What is Pitt-Char XP and where is it used?....................................................................................4
1.2 Product Quality Assurance.............................................................................................................5
1.3 Technical Support .........................................................................................................................5
2.0 Surface Preparation and Priming.............................................................................................................6
2.1 Surface Defect Repair & general painting conditions .....................................................................6
2.2 Blast Cleaning – steel substrates ..................................................................................................6
2.3 Repair / Touch Up .........................................................................................................................6
2.3.1 UHP Water Jetting (Hydroblasting) ....................................................................................7
2.3.2 Low pressure ‘precision’ wet blasting...............................................................................7
2.4 Retention ......................................................................................................................................7
2.5 Priming .........................................................................................................................................7
2.5.1 Primer Qualification..........................................................................................................8
2.5.2 Zinc Silicate Primer Systems ............................................................................................8
2.5.3 Over-coating of approved primers with Pitt-Char XP .........................................................9
2.5.4 Application of Pitt-Char XP to Bare Steel...........................................................................9
3.0 Reinforcement and mechanical retention ..............................................................................................10
3.1 Pins, Fixing and Layout ...............................................................................................................10
3.1.1 Pinning prior to blasting .................................................................................................11
3.1.2 Pinning after Blasting and prior to Priming......................................................................11
3.1.3 Pinning after Priming......................................................................................................11
3.1.4 Pin Weld Strength...........................................................................................................11
3.1.5 Pin layout .......................................................................................................................12
3.1.5.1 I-sections ..........................................................................................................12
3.1.5.2 Hollow Sections (Square or Rectangular) ...........................................................12
3.1.5.3 Hollow Sections (Circular)..................................................................................13
3.1.5.4 Bulkheads .........................................................................................................13
3.1.5.5 Decks................................................................................................................13
3.1.5.6 Other Shapes or Items .......................................................................................13
3.2 Reinforcement systems...............................................................................................................14
3.2.1 Reinforcement System Descriptions ...............................................................................14
3.2.2. Reinforcement Systems Conforming LR (Lloyd’s Register) for Hydrocarbon Fires ...........15
3.2.3. Reinforcement Systems Conforming LR (Lloyd’s Register) for Cellulosic Fires ...............17
3.2.4. Reinforcement Systems Conforming DNV (Det Norske Veritas) for Hydrocarbon Fires ...18
3.2.5. Reinforcement Systems Conforming DNV (Det Norske Veritas) for Cellulosic Fires ........20
3.2.6. Reinforcement Systems Conforming UL (Underwriters Laboratories) .............................21
3.2.7 Wire Mesh, Fibre Glass or FM Fabric Mesh Incorporation................................................22
3.2.7.1 Wire Mesh, Fibre Glass Mesh or FM Fabric Mesh not Required ..........................22
3.2.7.2 Fibre Glass and FM Fabric Mesh........................................................................22
3.2.7.3 Square Galvanized Steel Mesh...........................................................................22
3.2.7.4 Hexagonal Wire Mesh........................................................................................22
3.2.8 Terminations ..................................................................................................................22
page 1/49
PASSIVE FIRE PROTECTION
INFORMATION
PROTECTION OF STEEL FROM HYDROCARBON FIRES
PITT-CHAR XP APPLICATION GUIDELINES
1202
August 2010
3.3 Reinforcement Systems for Tanks, Vessels and Spheres .............................................................23
3.3.1 Bullet Tanks ...................................................................................................................23
3.3.2 Spheres..........................................................................................................................23
3.3.3 All Tank Shapes - Use of Fibre glass or FM fabric Mesh..................................................23
4.0 Application............................................................................................................................................24
4.1 Storage .......................................................................................................................................24
4.2 Twin Component Application Procedure ......................................................................................24
4.2.1 Weight Ratio Checks ......................................................................................................25
4.2.2 Spray Tips and Operating Pressure.................................................................................25
4.2.3 Spraying.........................................................................................................................25
4.2.4 Flushing of Equipment....................................................................................................26
4.3 Single Component Airless Spray..................................................................................................26
4.3.1 Spray Tips and Operating Pressure.................................................................................27
4.4 Finishing after Spray Application .................................................................................................27
4.5 Hand Application .........................................................................................................................28
4.6 Warm Climate Application ...........................................................................................................29
4.6.1 Twin Component Application ..........................................................................................29
4.6.2 Single Component Application ........................................................................................29
4.6.3 Hand Application ............................................................................................................29
4.6.4 Final Appearance ...........................................................................................................29
4.7 Removal and Repair Procedure ...................................................................................................30
4.8 Welding.......................................................................................................................................30
4.9 Overcoating.................................................................................................................................30
4.10 Exposed Top Flanges ................................................................................................................31
4.11 Preformed Castings...................................................................................................................31
5.0 Coatback ..............................................................................................................................................32
6.0 Thickness Control and Measurement ....................................................................................................33
6.1 Methods of Measurement............................................................................................................33
6.1.1 Destructive Method ........................................................................................................33
6.1.2 Non-destructive Method .................................................................................................33
6.2 Calibration of Electromagnetic gauge ..........................................................................................33
6.3 Frequency of Measurements .......................................................................................................34
6.3.1 Structural Steelwork.......................................................................................................34
6.3.2 Flat Plate, Decks and Bulkheads.....................................................................................34
6.4 Acceptance Criteria .....................................................................................................................34
7.0 Topcoat Selection .................................................................................................................................36
Appendix 1 Recommended Topcoats for Pitt-Char XP..................................................................................37
Appendix 2 Pitt-Char XP Repair Sketch .......................................................................................................38
page 2/49
PASSIVE FIRE PROTECTION
INFORMATION
PROTECTION OF STEEL FROM HYDROCARBON FIRES
PITT-CHAR XP APPLICATION GUIDELINES
1202
August 2010
Appendix 3 Reinforcement and Retention Details ........................................................................................39
Appendix 3.1 I-Sections Details Conforming LR and DNV – FM Fabric Mesh......................................39
Appendix 3.2 I-Sections Details Conforming LR and DNV – Metal Mesh.............................................40
Appendix 3.3 I-Sections Details Conforming LR and DNV – 60 and 120 Minutes................................41
Appendix 3.4 I-Sections Details Conforming UL – Fibre Glass and Metal Mesh ..................................42
Appendix 3.5 I-Sections and Other Open Profiles – General Reinforcement Requirements.................43
Appendix 3.6 Underdecks and Bulkhead Details Conforming LR and DNV..........................................44
Appendix 3.7 PG-Box Details.............................................................................................................45
Appendix 3.8 Spheres .......................................................................................................................46
Appendix 4 Typical Coatback Details...........................................................................................................47
Appendix 4.1 I-Section To I-Section ..................................................................................................47
Appendix 4.2 Circular Hollow Section To Circular Hollow Section.......................................................48
page 3/49
PASSIVE FIRE PROTECTION
INFORMATION
PROTECTION OF STEEL FROM HYDROCARBON FIRES
PITT-CHAR XP APPLICATION GUIDELINES
1202
August 2010
1.0 Introduction
The purpose of this manual is to ensure consistent and correct installation (application) of Pitt-Char XP and
associated materials such as fibre glass mesh. For the safe handling and use of Pitt-Char XP reference must
also be made to both the Product Data and Material Safety Data Sheets.
Pitt-Char XP is fully tested and certified and whilst this manual is not intended as a source for the
determination of Pitt-Char XP loadings or other specification criteria, such information is available to design
architects and engineers on request.
The information contained in this manual is based upon independent test data, comprehensive research and
field experience, and is considered to be accurate at the time of publication. However, the contents will be
subject to revision from time to time due to our policy of continuously improving our products, processes
and service.
1.1 What is Pitt-Char XP and where is it used?
Pitt-Char XP is a solvent free, thick film epoxy intumescent coating, providing an uncompromising solution
for the fire protection of many different types of structure in the most demanding environments.
Successfully used on over 100 major projects worldwide, Pitt-Char XP has an enviable track record.
Epoxy intumescent coatings have major advantages in durability, weight, ease of application and aesthetics.
As a result they have become the fire protection method of choice offshore and offer design architects and
engineers a highly adaptable PFP solution, which is both practical and functional.
Pitt-Char XP is used to enhance the fire resistance of structural materials by providing a layer of insulation,
which is formed as a result of a chemical reaction initiated by fire. This insulation reduces the rate of heat
transfer and extends the time period for which the structural material can resist the weakening effects of
the heat.
Passive fire protection is predominantly used:

To insulate structural steel elements against damage or collapse in various fire scenarios,
maintaining the load bearing properties of a structure thus allowing evacuation and fire fighting
measures to be effected.

To insulate walls and decks so reducing the rate at which these structures weaken or transfer heat.
Such divisions are used to isolate accommodation areas and safe havens from production, storage
and utility areas, providing the maximum opportunity for escape in the event of fire.
Pitt-Char XP is designed to protect against the very severe conditions that are associated with the
combustion of hydrocarbon fuels (oil, methane, LNG, LPG, etc.). Typically these fires can involve explosions,
‘jet fires’ (fuel under pressure) and ‘pool fires’ (fuel not under pressure). Additionally, the aggressive
production environments normally associated with these industries require Pitt-Char XP to be extremely
durable. The unique binder technology used in Pitt-Char XP also provides remarkable flexibility, which not
only enables the coating to resist stresses usually incurred during thermal cycling but also to withstand
inherent movement and vibration of a structure, while offering high impact resistance. Pitt-Char XP has
improved resistance to cracking caused by deflection of a structure in an explosion or during lifting of
fabricated sections during construction.
page 4/49
PASSIVE FIRE PROTECTION
INFORMATION
PROTECTION OF STEEL FROM HYDROCARBON FIRES
PITT-CHAR XP APPLICATION GUIDELINES
1202
August 2010
Although Pitt-Char XP has excellent durability, it is normally specified with a suitable anti-corrosive primer
and a good quality topcoat.
Mechanical reinforcement may also be required in the form of welded steel pins, galvanized mesh or
specially designed fire resistant fibre glass mesh. Reinforcement is particularly valuable under jet fire
scenarios as it limits the erosion of char during the jet fire period. Full details are contained in Section 3.
The aim of these guidelines are to provide relevant technical information to the applicator of Pitt-Char XP,
helping to ensure that the completed application is fit for purpose.
Since product failure could threaten life in an emergency fire situation, applicators must not deviate from
these guidelines without written agreement from PPG.
1.2 Product Quality Assurance
PPG operates quality systems to ISO 9001. All raw materials are subjected to quality testing before being
released for manufacture. Representative batches of Pitt-Char XP are routinely selected from production and
subjected to hydrocarbon fire testing.
1.3 Technical Support
PPG has a technical support network second to none in the industry. Our Protective and Marine Coatings
Business Unit, staffed by engineers, chemists, former applicators and other industry professionals,
coordinates the front line technical and sales focus for Pitt-Char XP. To support our customers in the field
we have experienced Field Technical Service personnel working in conjunction with a dedicated Fire
Research Department.
page 5/49
PASSIVE FIRE PROTECTION
INFORMATION
PROTECTION OF STEEL FROM HYDROCARBON FIRES
PITT-CHAR XP APPLICATION GUIDELINES
1202
August 2010
2.0 Surface Preparation and Priming
All surfaces to be protected by Pitt-Char XP must be correctly prepared and primed, including the fixing of
support pins where appropriate. It is anticipated that most substrates will be steel and hence the majority of
the detail in this manual refers to this substrate. Surface preparation and painting should be carried out in
line with ‘best industry practice’ as indicated in many publications by organisations such as NACE, SSPC,
ICORR, ISO, etc. The standards of surface preparation contained herein are to be considered minimum
requirements. Where other client company specifications or product technical data sheets demand a higher
level then the higher level should be adopted.
Whilst some information is provided for use over aluminium, it is recommended that confirmation for this
and other non-ferrous substrates be sought from PPG.
Details of reinforcement methods are given in Section 3.
2.1 Surface Defect Repair & general painting conditions
All surface defects, including weld spatter, cracks, surface delaminations and deep pitting likely to be
detrimental to the fire proofing system must be removed. All fins at saw cuts; burrs and sharp edges shall
be removed by grinding to a minimum radius of 2 mm. Welds must be inspected for condition, as these are
often a source of corrosion. Undercut welds, blow holes, discontinuous seams and other defects must be
rectified. As uneven welds are likely to be the source of corrosion they will need to be ground smooth. It is
not necessary to grind flush.
In addition to other specified environmental parameters, painting must not take place outside the following
conditions:
Minimum substrate temperature
5°C and at least 3°C above dew point during
application and curing
Maximum relative humidity
85%
For full water and chemical resistance the temperature during application and curing should be above 10°C.
Curing time will be significantly extended below 10°C and will effectively cease below 5°C. Conversely
curing time will be reduced at temperatures above 10°C. Refer to the product data sheet for details.
2.2 Blast Cleaning – steel substrates
All surfaces must be clean, dry and free from surface contamination prior to abrasive blast cleaning to a
minimum standard Sa 2.5 ISO 8501-1: 1988. Blast profile should generally be in the range of 30 - 75 µm.
All used grit blast material must be removed from the steel work by vacuum cleaner, oil free airline or brush.
2.3 Repair / Touch Up
For small areas of repair/touch up where blast cleaning is not possible, the coating system comprising
primer and Pitt-Char XP can be applied to surfaces prepared to a minimum standard of St 3 ISO 8501-1:
1998 at the time of coating.
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Suitable power tools should be used but wire brushes are not recommended as they can cause surface
polishing.
Alternative methods of surface preparation used in maintenance painting are UHP and Wet Abrasive
Blasting. These methods are discussed below:
2.3.1 UHP Water Jetting (Hydroblasting)
This method of surface preparation uses water at pressures in excess of 2400 bar (35,000 p.s.i.). As it
cannot provide a blast profile it is not suitable for new, previously un-blasted steel. It is, however, a very
effective process for maintenance where a previously blasted substrate is available, whether previously
painted or not. Where the existing profile is exposed, the surface roughness must be measured to ensure
that it meets the requirements stated in section 2.2 of these guidelines.
There is currently no internationally recognised standard for UHP water blasting, however, NACE/SSPC have
produced standard NACE No. 5/SSPC-SP 12 and visual standard NACE VIS 7/SSPC-VIS 4. Prior to priming
our minimum standard of surface cleanliness in line with this specification is VIS WJ-2 (very thorough
cleaning). In practice there is likely to be some flash rusting occurring after UHP preparation has been
completed. The maximum degree of flash rusting allowed is that described as ‘Light Flash Rusting (L)’ in the
above NACE/SSPC standard. Any loose, powdery flash rust must be removed with a ‘stiff bristle’ brush.
2.3.2 Low pressure ‘precision’ wet blasting
This is a technique of wet abrasive blasting using a relatively low volume of water, grit and air pressure. The
technique is very controllable with little interference to ‘other trades’ and provides a blast profile similar to
that obtained with dry grit blasting. Whilst theoretically suitable for new steel it is more often used as a
maintenance tool for the removal of old coatings.
There is currently no internationally recognised standard published and so our requirements for surface
preparation are a mix of ISO 8501-1 and NACE No. 5/SSPC-SP 12. The degree of cleanliness required is
equivalent to Sa 2.5 as described in ISO 8501-1 and allowable flash rusting should be no more than ‘Light
Flash Rusting (L) as described in NACE No. 5/SSPC-SP 12. Any loose, powdery flash rust must be removed
with a ‘stiff bristle’ brush.
2.4 Retention
In instances where it is necessary to have mechanical retention of metal or fibre glass mesh, copper coated
steel pins usually need to be fixed to the steel. This can be carried out either prior to blasting, after blasting
and prior to priming, or after priming. Full details are given in Section 3.
2.5 Priming
In a fire situation it is essential that Pitt-Char XP remains adhered to the substrate for the duration of the
expected protection period. In most cases the substrate will be primed and hence the compatibility of
Pitt-Char XP with the primer must be verified.
For this reason only primers and coating systems satisfactorily tested and qualified by PPG shall be used
under Pitt-Char XP.
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The method of primer qualification is the same whether the primer is manufactured by PPG or by another
coating company. Coating manufacturers are encouraged to seek qualification of their primers for use
under Pitt-Char XP. An overview of the qualification process is given below. Further information is available
from PPG.
2.5.1 Primer Qualification
The qualification process consists essentially of impact and lap shear testing under various climatic
conditions designed to establish any potential weaknesses in the total system composition. A pass/failure
criterion is established based on PPG’s extensive knowledge of coatings and PFP, and against benchmarks
set by our own products.
For certain types of product additional fire testing is carried out.
The qualification process is free of charge, requiring the primer manufacturer to provide either a ‘wet
sample’ of the relevant product for us to apply, or a minimum of four plates prepared and coated with the
primer as per the relevant site conditions.
In all cases the application form (see Information Sheet 1205) shall be completed and sent to PPG along
with either the wet samples or the test plates. A copy of the form may be sent in advance by fax, e-mail or
post.
Where wet samples are supplied then both the MSDS and Product Data Sheet for each product MUST be
supplied to ensure correct application and safe handling. If the project specified primer DFT is different from
that quoted on the Product Data Sheet, then it is this thickness that should be identified on the application
form.
Where test plates are provided, these should be approximately 200 mm x 150 mm with a minimum
thickness of 3 mm but preferably 5 mm thick. Plates thinner than 3 mm are likely to give a ‘false fail’ result
when impact tested. The actual dry film thickness of each coat applied to the plates should be identified,
since in a multi-coat system we would only be able to confirm the total DFT.
If panels are supplied rather than wet paint, then it is strongly recommended that an additional set of four
plates be provided with the primer applied at the maximum thickness expected on the project. Otherwise
qualification will be restricted to the nominal specified DFT and there will be no scope to accommodate
over-application on site.
The primer qualification has a validity of maximum 5 years. The qualification expires also in case of
formulation changes. After 5 years or a formulation change re-testing is required.
An application form for primer qualification can be found on Information Sheet 1205.
2.5.2 Zinc Silicate Primer Systems
The use of zinc silicate primers under epoxy PFP should be treated with extreme caution because of their
inherent mechanical weakness. Zinc silicates are prone to ‘splitting’ within the film when subjected to
impact damage, especially when overcoated with high build, high strength films. This tendency is more
prevalent when primer DFT is high and/or when temperatures are low. Consequently very high levels of site
control over both application and dry film thickness are essential, as is knowledge of the lowest conceivable
operating temperature in service.
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It is for this reason that zinc silicate coatings are normally not recommended under Pitt-Char XP, although a
view can be taken on a project specific basis and after testing as noted above.
2.5.3 Over-coating of approved primers with Pitt-Char XP
Before application of Pitt-Char XP, the primed substrate must be dry and free from all traces of surface
contaminants, especially grease and soluble salts. Ensure that dry film thickness, overcoating time /
temperature intervals are in line with the primer’s Product Data Sheet and the Pitt-Char XP approval.
2.5.4 Application of Pitt-Char XP to Bare Steel
It is also possible to apply Pitt-Char XP directly to blast cleaned steel. In such instances it is essential that
Pitt-Char XP is applied within 4 hours of blasting, in a controlled environment (RH <60%; substrate
temperature >15°C and at least 3°C above dew point) and before contamination of the substrate takes
place.
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3.0 Reinforcement and mechanical retention
The reinforcement of passive fire protection products has its roots in the protection of steel by concrete and
lightweight cementitious systems. In such systems galvanised steel mesh was used to ensure that the fire
protection material did not crack and ‘fall off’ the steel during normal ‘in-service’ conditions. It was also
necessary to fix the steel mesh to the substrate by some form of mechanical retention, often by the use of
welded steel pins.
Pitt-Char XP has high levels of flexibility, durability and excellent bonding to the steel substrate and does not
need to be reinforced in the ‘normal’ (un-reacted) state. Reinforcement is used only to strengthen the
insulation char that is formed when Pitt-Char XP reacts in a fire. Either galvanised steel mesh, fibre glass or
FM fabric mesh or pins with speed washers may be used to achieve this reinforcement of the char.
In most cases fibre glass or FM fabric mesh is used without the need for retention pins. Metal mesh, on the
other hand, will not easily follow the contours of the steel section profile. It also tends not to lie flat on large
surface areas. In such cases the metal mesh may not remain within the Pitt-Char XP and hence would be
less effective at reinforcing the char in a fire. It is therefore necessary to use pins or an equivalent method
for retention in conjunction with metal mesh.
There is a lot of debate about where pins should be located with considerations relating to both practical
installation and certification requirements. Essentially most classification societies take the view that pins,
where used, should be located at 300 mm centres. This is based partly on the historical case for concrete
and cementitious systems and partly on the test data for the specific epoxy intumescent product. Practically
one often finds that pins need to be placed at no more than 300 mm centres to ensure that it lies close to
the steel. If such spacing is used in the preparation of the test specimen then it also becomes a requirement
of the certification.
The reinforcement types allowed and the need to pin or not, will depend on many factors such as fire type
and duration, section or plate size, project requirements, certification, etc.
Applicators should be aware that dependent on the thickness of Pitt-Char XP specified, it might be possible
to see the ‘shape’ of the mesh and pins. Whilst this may not be aesthetically pleasing it is not detrimental to
the fire resistance, provided the specified dry film thickness of Pitt-Char XP has been achieved and the
mesh is not standing ‘proud’ of the Pitt-Char XP surface.
Whilst pinning is the most popular method of retention, other methods may be more appropriate under
certain circumstances.
3.1 Pins, Fixing and Layout
Pins are normally copper coated steel and welded to the substrate by capacitance discharge. Typical pins
are nominally 35 mm in length and 2-3 mm in diameter, but other lengths and diameters may be more
appropriate. This will depend on the structure to be coated and the dry film thickness of Pitt-Char XP
required. Other pin types and fixing methods may also be used. Contact PPG where a variation is required.
Pinning can be carried out prior to blasting, after blasting and prior to priming, or after priming, using the
following methods.
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3.1.1 Pinning prior to blasting
This is the most practical and preferred method. Before pinning all pin areas must have mill scale, rust or
other surface contamination removed using a grinder. These areas need only be large enough to
accommodate the pin. Pins shall be attached as soon as possible after the grinding operation and a check
made on the weld bond strength (see section 3.1.4)
3.1.2 Pinning after Blasting and prior to Priming
This is the least likely situation and is not recommended, as it will lead to surface contamination and some
delay prior to application of primer. It is appropriate for small areas only where it is impractical to pin prior to
blasting. Where carried out pinning should occur immediately after blasting, and priming occur immediately
after pinning.
3.1.3 Pinning after Priming
In this case, it is necessary to grind off primer, to a white metal finish. This only requires an area large
enough to take the pin. Pins should be attached as soon as possible after the grinding operation and a
check made on the strength of the weld bond. (see section 3.1.4)
After pinning, the ground area around each pin must be repaired with the specified primer.
3.1.4 Pin Weld Strength
All pins must be tested to ensure that they are firmly welded to the substrate. This is a very basic test and
simply involves bending the pin to approximately 45 degrees from the vertical, and then straightening up
again.
If the pin detaches from the steel, the area must be reground and another pin attached.
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3.1.5 Pin layout
3.1.5.1 I-sections
Pins shall be located 25 mm from outer edges or inner corners. Thereafter pins to be spaced at maximum
300 mm centres on each face along the length. A diamond pattern may be used if more economical in pin
usage.
Typical pin location on 'standard' I-section
25 mm
300 mm
300 mm
Stud welded pins
25 mm
3.1.5.2 Hollow Sections (Square or Rectangular)
Pins shall be located 25 mm away from the outer corners. Thereafter pins to be spaced at maximum 300
mm centres on each face along the length.
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3.1.5.3 Hollow Sections (Circular)
Pins are to be located at maximum 300 mm centres along the length. The distance over the curved surface
between any two adjacent lines of pins is maximum 300 mm.
Typical pin location on CHS
Stud welded pins
300 mm
3.1.5.4 Bulkheads
Pins must be located at maximum 300 mm centres along the length and width but be at least 25 mm away
from stiffeners.
3.1.5.5 Decks
Pins must be located at maximum 300 mm centres along the length and width but be at least 25 mm away
from stiffeners.
On the stiffeners themselves pins must be located at maximum 300 mm centres down the length of the
stiffener and be placed centrally on the bottom of the stiffener, and centrally on the outside of the angle.
3.1.5.6 Other Shapes or Items
For reinforcement and retention requirements on other shapes of steel, please consult PPG.
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3.2 Reinforcement systems
Due to different views and interpretation of test results, the types of reinforcement system required are
different for Lloyds and DNV.
3.2.1 Reinforcement System Descriptions
Reference
Details
pins and speed
washers
pin: typically copper clad steel pin, diameter 2 mm, length 25 – 37 mm
fibre glass mesh
238-2/66:
1/8” x 1/8” holes,
152.6 g/m2, 1.22 x 45.7 m (55.7 m2)
4.5 oz/yd2, 4 x 150 ft. (600 ft2)
238-4/66:
1/4" x 1/4" holes,
152.6 g/m2, 1.22 x 45.7 m (55.7 m2)
4.5 oz/yd2, 4 x 150 ft. (600 ft2)
FM fabric mesh
238-5/66:
203.4 g/m2,
2
6.0 oz/yd ,
1 x 50 m (50 m2)
40’ x 164 ft (538 ft2)
square wire mesh
13 mm square welded mesh, from 1 mm diameter (19 gauge) galvanised
steel wire
hexagonal wire
mesh (chicken
wire)
12 - 25 mm hexagonal mesh, made from 0.75 - 0.90 mm diameter
(20 - 22 gauge) galvanised steel wire.
washer: diameter 30 mm
238-2/66 fibre glass mesh
238-4/66 fibre glass mesh
square wire mesh
238-5/66 FM fabric mesh
hexagonal wire mesh
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3.2.2. Reinforcement Systems Conforming LR (Lloyd’s Register) for Hydrocarbon Fires1)
steel / section – type
I – sections
hydrocarbon pool fire
hydrocarbon jet fire
a) steel mesh (square, hexagonal);
butt joined, gaps maximum 25 mm;
pins at maximum 300 mm centres;
a) steel mesh (square, hexagonal);
butt joined, gaps maximum 25 mm;
pins at maximum 300 mm centres;
b) 238-5/66 FM fabric mesh;
overlap minimum 50 mm;
b) 238-5/66 FM fabric mesh;
for ≤ 60 minutes;
overlap minimum 150 mm;
≤ 60 minutes: reinforcement on the
2)
pinning on boundaries and
flange tips only ;
terminations at maximum
> 60 minutes: reinforcement on the
300 mm centres;
outer flange face, edges
and half the distance to
the web;
Structural Hollow
Sections
H-60 / H-120
Underdecks
a) steel mesh (square, hexagonal);
butt joined, gaps maximum 25 mm;
pins at maximum 300 mm centres;
a) steel mesh (square, hexagonal);
butt joined, gaps maximum 25 mm;
pins at maximum 300 mm centres;
b) 238-5/66 FM fabric mesh;
overlap minimum 50 mm;
b) 238-5/66 FM fabric mesh;
for ≤ 60 minutes;
overlap minimum 150 mm;
pinning on boundaries and
terminations at maximum
300 mm centres;
a) pins and washers;
flat surfaces;
pins at maximum 305 mm centres;
a) steel mesh (square, hexagonal);
butt joined, gaps maximum 25 mm;
pins at maximum 300 mm centres;
b) steel mesh (square, hexagonal);
flat surfaces, stiffeners, boundaries,
corners and protrusions;
butt joined, gaps maximum 25 mm;
pins at maximum 300 mm centres;
b) 238-5/66 FM fabric mesh;
for ≤ 60 minutes;
overlap minimum 150 mm;
pinning on boundaries and
terminations at maximum
300 mm centres;
c) 238-5/66 FM fabric mesh;
flat surfaces, stiffeners, boundaries,
corners and protrusions;
overlap minimum 50 mm;
notes:
1)
2)
see also drawing in Annex 3
if the distance between the mesh on the flange tips exceeds 500 mm, reinforcement is
required for the whole outer flange face
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3.2.2. Reinforcement Systems Conforming LR (Lloyd’s Register) for Hydrocarbon Fires (continued) 1)
steel / section – type
H-0 Bulkheads
hydrocarbon pool fire
a) pins and washers;
flat surfaces;
pins at maximum 305 mm centres;
a) steel mesh (square, hexagonal);
butt joined, gaps maximum 25 mm;
pins at maximum 300 mm centres;
b) steel mesh (square, hexagonal);
flat surfaces, stiffeners, boundaries,
corners and protrusions;
butt joined, gaps maximum 25 mm;
pins at maximum 300 mm centres;
b) 238-5/66 FM fabric mesh;
for ≤ 60 minutes;
overlap minimum 150 mm;
pinning on boundaries and
terminations at maximum
300 mm centres;
c) 238-5/66 FM fabric mesh;
flat surfaces, stiffeners, boundaries,
corners and protrusions;
overlap minimum 50 mm;
H-60 / H-120
Bulkheads
hydrocarbon jet fire
a) steel mesh (square, hexagonal);
flat surfaces, stiffeners, boundaries,
corners and protrusions;
butt joined, gaps maximum 25 mm;
pins at maximum 300 mm centres;
b) 238-5/66 FM fabric mesh;
flat surfaces, stiffeners, boundaries,
corners and protrusions;
overlap minimum 50 mm;
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a) steel mesh (square, hexagonal);
butt joined, gaps maximum 25 mm;
pins at maximum 300 mm centres;
b) 238-5/66 FM fabric mesh;
for ≤ 60 minutes;
overlap minimum 150 mm;
pinning on boundaries and
terminations at maximum
300 mm centres;
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3.2.3. Reinforcement Systems Conforming LR (Lloyd’s Register) for Cellulosic Fires 1)
steel / section - type
A-60 Bulkhead
cellulosic fire –scenario 1
a) pins and washers;
flat surfaces;
pins at maximum 305 mm centres;
b) steel mesh (square, hexagonal);
flat surfaces, stiffeners, boundaries,
corners and protrusions;
butt joined, gaps maximum 25 mm;
pins at maximum 300 mm centres;
c) 238-5/66 FM fabric mesh;
flat surfaces, stiffeners, boundaries,
corners and protrusions;
overlap minimum 50 mm;
notes:
1)
see also drawing in Annex 3
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cellulosic fire – scenario 2
a) no reinforcement;
flat surfaces, dft + 1 mm;
b) steel mesh (square, hexagonal);
stiffeners, boundaries, corners and
protrusions;
butt joined, gaps maximum 25 mm;
pins at maximum 300 mm centres;
c) 238-5/66 FM fabric mesh;
stiffeners, boundaries, corners and
protrusions;
overlap minimum 50 mm;
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3.2.4. Reinforcement Systems Conforming DNV (Det Norske Veritas) for Hydrocarbon Fires 1)
steel / section – type
I – sections
hydrocarbon pool fire
a) steel mesh (square, hexagonal);
butt joined, gaps maximum 25 mm;
pins at maximum 300 mm centres
b) 238-5/66 FM fabric mesh;
overlap minimum 50 mm;
≤ 60 minutes: reinforcement on the
2)
flange tips only ;
> 60 minutes: reinforcement on the
outer flange face, edges
and half the distance to
the web;
Structural Hollow
Sections
a) steel mesh (square, hexagonal);
butt joined, gaps maximum 25 mm;
pins at maximum 300 mm centres;
b) 238-5/66 FM fabric mesh;
overlap minimum 50 mm;
H-60 / H-120
Underdecks
hydrocarbon jet fire
for scenarios ≤ 60 minutes
a) steel mesh (square, hexagonal);
butt joined, gaps maximum 25 mm;
pins at maximum 300 mm centres;
b) 238-5/66 FM fabric mesh;
overlap minimum 150 mm;
reinforcement on the outer flange face,
edges and half the distance to the web;
for scenarios ≤ 60 minutes
a) steel mesh (square, hexagonal);
butt joined, gaps maximum 25 mm;
pins at maximum 300 mm centres;
b) 238-5/66 FM fabric mesh;
overlap minimum 150 mm;
a) pins and washers;
flat surfaces;
pins at maximum 300 mm centres;
a) pins and washers;
flat surfaces;
pins at maximum 300 mm centres;
b) steel mesh (square, hexagonal);
flat surfaces, stiffeners;
butt joined, gaps maximum 25 mm;
pins at maximum 300 mm centres;
b) steel mesh (square, hexagonal);
flat surfaces, stiffeners;
butt joined, gaps maximum 25 mm;
pins at maximum 300 mm centres;
c) 238-5/66 FM fabric mesh;
flat surfaces, stiffeners;
overlap minimum 50 mm;
c) 238-5/66 FM fabric mesh;
flat surfaces, stiffeners;
overlap minimum 50 mm;
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3.2.4. Reinforcement Systems Conforming DNV (Det Norske Veritas) for Hydrocarbon Fires
(continued) 1)
steel / section – type
H-0 Bulkheads
hydrocarbon pool fire
a) pins and washers;
flat surfaces;
pins at maximum 300 mm centres;
b) steel mesh (square, hexagonal);
flat surfaces, stiffeners;
butt joined, gaps maximum 25 mm;
pins at maximum 300 mm centres;
hydrocarbon jet fire
a) steel mesh (square, hexagonal);
flat surfaces, stiffeners;
butt joined, gaps maximum 25 mm;
pins at maximum 300 mm centres;
b) 238-5/66 FM fabric mesh;
flat surfaces, stiffeners;
overlap minimum 50 mm;
c) 238-5/66 FM fabric mesh;
flat surfaces, stiffeners;
overlap minimum 50 mm;
H-60 / H-120
Bulkheads
a) no reinforcement;
flat surfaces;
b) steel mesh (square, hexagonal);
stiffeners;
butt joined, gaps maximum 25 mm;
pins at maximum 300 mm centres;
c) 238-5/66 FM fabric mesh;
stiffeners;
overlap minimum 50 mm;
notes:
1)
2)
a) steel mesh (square, hexagonal);
stiffeners;
butt joined, gaps maximum 25 mm;
pins at maximum 300 mm centres;
b) 238-5/66 FM fabric mesh;
stiffeners;
overlap minimum 150 mm;
see also drawing in Annex 3
if the distance between the mesh on the flange tips exceeds 500 mm, reinforcement is
required for the whole outer flange face
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3.2.5. Reinforcement Systems Conforming DNV (Det Norske Veritas) for Cellulosic Fires 1)
steel / section – type
A-60 Bulkhead
no reinforcement;
A-60 Underdecks
a) pins and washers;
flat surfaces;
pins at maximum 300 mm centres;
b) 238-2/66, 238-4/66 fibre glass mesh;
stiffeners;
overlap minimum 50 mm;
notes:
1)
see also drawing in Annex 3
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3.2.6. Reinforcement Systems Conforming UL (Underwriters Laboratories) 1)
steel / section – type
I-Sections
UL 1709 (hydrocarbon pool fire)
columns: reinforcement on flange tips
beams:
reinforcement on the whole
flange
a) square steel mesh, 1/2 by 1/2 in.;
butt ended mesh bent to fit tightly
over the flange edges along the
column length;
flange edge clips shall be used,
when the required coating thickness
exceeds 0.50 in., placed at ends of
mesh and shall be spaced a max
24 in. OC;
the mesh shall be fastened together
across the flange faces with wire;
UL 263 (cellulosic fire)
a) no reinforcement;
for scenarios ≤ 60 minutes;
b) 238-2/66, 238-4/66 fibre glass
mesh;
mesh on the flange tips;
b) square steel mesh, 1-1/2 by 1-1/2 in.;
secured to the column with 5/16 in.
wide by 3/16 in. deep steel staples;
c) hexagonal steel mesh;
wrapped around the column flanges
and secured in position by means of
Type C furring clips spaced
approximately 12 in. apart;
d) 238-2/66, 238-4/66 fibre glass mesh;
for scenarios ≤ 60 minutes;
Structural Hollow
Sections
notes:
1)
a) 238-2/66, 238-4/66 fibre glass
mesh;
overlap minimum 50 mm;
see also drawing in Annex 3
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3.2.7 Wire Mesh, Fibre Glass or FM Fabric Mesh Incorporation
The following details describe the method of incorporation of each of the reinforcement products detailed in
Section 3. In all instances the substrate must have been prepared in accordance with Section 2.
3.2.7.1 Wire Mesh, Fibre Glass Mesh or FM Fabric Mesh not Required
Simply apply Pitt-Char XP to the required thickness.
3.2.7.2 Fibre Glass and FM Fabric Mesh
When installing fibre glass or FM fabric mesh with overlaps it is essential to ensure that good bonding is
achieved between each layer of mesh. Pitt-Char XP should be applied between each layer and the mesh
shall be fully ‘wetted out’. The fibre glass or FM fabric mesh shall be installed in the mid third of the total
film thickness required and as close to the centre (mid film) as possible. Within the same application shift
apply a coat of approximately 1 mm of Pitt-Char XP such the mesh or fabric is sealed.
3.2.7.3 Square Galvanized Steel Mesh
Galvanized wire mesh should be pre-cut to the correct size and placed over the retaining pins ensuring it is
kept as flat as possible. It may prove necessary to tension the mesh by twisting it at various points.
It is not necessary to overlap the mesh and gaps between pieces may be allowed. The requirement is
dependent on the fire case and certifying authority and details are given in tables 3.2.2 - 3.2.6.
Where the total Pitt-Char XP thickness is 10 mm or less the mesh should be fitted at the substrate. It is
normal practice to use stand-off wire to hold the mesh a little distance from the substrate thus allowing the
Pitt-Char XP to coat behind the wire strands. The pins are bent over prior to application of Pitt-Char XP.
Where the total DFT of Pitt-Char XP is greater than 10 mm, it is applied to a thickness approximately onethird of the total specified and allowed to cure such that installation of the mesh and ‘knocking over’ of the
pins causes no more than minimal damage to the coating. The remaining Pitt-Char XP should then be
applied.
3.2.7.4 Hexagonal Wire Mesh
All details are as for Section 3.2.7.3
3.2.8 Terminations
Where the PFP terminates abruptly at the end of an I-section, channel- or T-section, the reinforcing mesh
should be folded around the edges. This measure is essential to ensure that the ends of fire protected
sections do not suffer erosion damage in the event of jet fire.
Similarly, where Pitt-Char XP is extended onto secondary steelwork (coatback), the reinforcing mesh should
be terminated 50 mm from the edge of the PFP. This overlap of Pitt-Char XP onto the steelwork ensures that
there are no edges of reinforcement visible that could suffer from undercutting in the event of jet fire. See
also Section 5 on coatback.
Lloyd’s Register certification requires that the periphery of epoxy PFP terminations reinforced with FM fabric
mesh, be retained to the substrate by welded pins or an equivalent method.
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3.3 Reinforcement Systems for Tanks, Vessels and Spheres
It is often the case that the use of welded pins is not allowed on process and storage equipment. For such
equipment a different procedure is used for installing metal mesh. The procedure is also dependent on the
shape of the tank i.e. a bullet tank, or a sphere.
N.B. Generally it is easier to use square galvanized mesh on cylindrical surfaces and chicken wire mesh on
spherical surfaces.
3.3.1 Bullet Tanks
For all PFP systems with a DFT of 10 mm or above apply Pitt-Char XP to half total thickness and allow
curing. Then wrap around square galvanized or chicken wire mesh on the body of the tank (see also Section
3.2.1) Tie the ends together with 1.0 mm - 1.5 mm galvanised steel wire so that the mesh is tight.
This tie should be on the bottom quarter of the tank for horizontal tanks, with adjoining pieces of mesh
attached as above. Ties should be offset from each other.
For vertical tanks, ties can be made at any point, but adjoining pieces of mesh should have the ties offset by
at least 90°.
For PFP systems with a DFT of less than 10 mm the metal mesh should be applied direct to the substrate.
3.3.2 Spheres
Apply Pitt-Char XP to half the total DFT and allow curing. Then mesh using chicken wire. Adjoining pieces
should be tied together using 1.0 mm - 1.5 mm galvanized steel wire. Gaps between the mesh sections
shall not exceed 25 mm. It may be helpful to first attach anchor wires to the sphere. The wire shall be of
high tensile stainless steel with 2 mm diameter. Typically one is placed at the tank’s equator and one half
way to the top and the bottom. Temporary glue pins with galvanised self locking speed washers may be
used to hold the mesh in place until tie wire or lacing is accomplished. Pitt-Char XP may be used as
adhesive to attach the glue pins. For details see also Appendix 3.8.
3.3.3 All Tank Shapes - Use of Fibre glass or FM fabric Mesh
Where specified, fibre glass or FM fabric mesh may be used as an alternative to either square galvanized or
chicken wire mesh. In such cases, apply Pitt-Char XP to half total thickness and then apply the mesh in
accordance with Section 3.2.7 noting that adjoining pieces of fibre glass or FM fabric mesh must overlap by
at least 50 mm in the case of hydrocarbon pool fire and 150 mm for jet fires.
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4.0 Application
The Pitt-Char XP product data sheet also contains important information regarding application parameters
and must be read in conjunction with these guidelines. A copy of the product data sheet can be obtained
from PPG.
Pitt-Char XP can be applied through a twin component airless spray unit that utilises a minimum 10” air
motor (contact PPG for a list of suitable equipment). Pitt-Char XP is supplied in 70 kg sets for this purpose.
For areas where application using twin component spray equipment is not possible, Pitt-Char XP can be
sprayed through an suitably modified airless spray pump utilising a recommended ratio of 75:1. Thinning
may be required depending on temperature and pump used. Pitt-Char XP is supplied in 26.4 kg sets for
this purpose.
It is also possible to hand apply Pitt-Char XP by trowel or float. The contractor must determine if this is
practical for larger areas.
The mixing ratio is 2.33 parts base to 1 part hardener by volume (3.25 : 1 - by weight), irrespective of
pack size.
The practical density of Pitt-Char XP is 1.10 g/cm3 determined after application by plural component
airless spray.
The base component is coloured white and the hardener is coloured black. When correctly mixed a
homogeneous grey colour should be achieved, free from streaks of either white or black.
Regular wet film thickness checks should be made during the application process.
4.1 Storage
For twin component spray application using equipment having holding tanks it is strongly recommended
that both base and hardener are stored at 30 - 35°C for at least 24 hours prior to use. Base and hardener
may be stored for up to 3 months in closed containers under these conditions. Storage at these
temperatures will reduce the inherent viscosity of the product facilitating airless spray application.
For single component spray it is strongly recommended that both base and hardener are stored at 25 - 35°C
for at least 24 hours prior to use. Storage above this temperature will reduce the pot life when mixed. Base
and hardener may be stored at these temperatures for the duration of the shelf life quoted on the product
data sheet.
4.2 Twin Component Application Procedure
Dispense components from the 70 kg twin component sets into the
holding tanks, ideally using ram assisted shovel feed pumps.
Typical temperature settings (varies with ambient temperature):
Base
60 – 70°C
Hardener
60 – 65°C
Line heaters
60 – 70°C
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The components should be circulated through the metering cylinders (and line heaters) until the base has
reached 65°C and hardener has reached 60°C.
Switch on main pump for approximately 10 minutes at an input pressure of 1.4 bar (20 p.s.i.).
Empty a minimum of 20 litres of base and 10 litres of additive through the sampling valves. If the equipment
does not have sampling valves then the hoses before the mixing block should be disconnected. Material
should be kept clean and unmixed so that it can be re-used.
Carry out weight ratio check with input pressure on main pump at 2.1 bar (30 p.s.i.) (see 4.2.1). If the
weight ratio check is satisfactory commence spraying.
Note: The above temperatures and are for guidance and will vary for different spray equipment. Whatever
equipment is used, the minimum temperature for mixed Pitt-Char XP to achieve good atomisation
using a 10-inch motor is 57°C.
4.2.1 Weight Ratio Checks
Weight ratio checks should be carried out at the start of each day, and whenever there has been a break in
spraying of more than one hour. Pitt-Char XP should have a weight ratio in the range 2.93 : 1 and 3.58 : 1 /
base : hardener. Spray application should not be started until the correct weight ratio has been achieved.
Procedure
Weigh two clean and empty containers.
If spray equipment does not have sampling valves, disconnect hoses before mixer block.
Discharge a minimum of 20 litres base and 10 litres hardener into the pre-weighed containers for the
ratio check, ensuring the materials are kept clean and unmixed so that they can be re-used.
Re-weigh containers, subtract weight of original empty container and calculate ratio of base to additive.
4.2.2 Spray Tips and Operating Pressure
nozzle size:
0.89 - 1.09 mm (35 - 43 thou)
fan angle:
50 deg.
operating pressure:
240 bar (3500 psi)
The above is given as a guide only.
4.2.3 Spraying
It is possible to apply Pitt-Char XP in one coat to a minimum thickness of 1 mm and a maximum thickness
of 7 mm. Pitt-Char XP can be applied with a normal spray pattern, but It may still be necessary to roller to
obtain a smooth finish.
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4.2.4 Flushing of Equipment
Hot water can be used very effectively for flushing out lines and equipment, but care should be taken, as
water will not dissolve epoxy resin based materials. If a true solvent is required for equipment maintenance,
the use of Sigma Thinner 90-53 is recommended.
4.3 Single Component Airless Spray
For areas where application using twin component spray equipment is not possible or desirable,
Pitt-Char XP can be spray applied using an airless spray pump of a recommended ratio of 75:1, fitted with a
ram feed plate and wiper to fit the size of drum.
Thinning may be required normally in the range from 5% to 7% using 97-733 or Sigma Thinner 60-30. The
addition of thinner must not exceed 10%.
Exact level of thinning required will depend on air temperature, temperature of Pitt-Char XP and the
equipment used. However, experience has shown 6% addition of 97-733 or Sigma Thinner 60-30 to give
good results with Pitt-Char XP at temperatures of about 25°C after mixing.
For any given dry film thickness, the required wet film thickness of Pitt-Char XP will vary depending on the
level of thinner added. In the region of 1% to 10% thinning a reduction in volume solids as per the following
table can be assumed:
solvent
addition
resulting volume solids
Pitt-Char XP
[%]
[%]
Calculation of wet film thickness (WFT)
from known dry film thickness (DFT) and
known volume solids (% VS)
0
100
100
1
99
%VS
2
98
3
97
4
96
5
95
6
94
7
93
8
92
9
91
10
90
x DFT [mm] = WFT [mm]
e.g. 6% thinned; required DFT = 5 mm
100
x 5 mm = 5.32 mm (WFT required)
94
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Half the required volume of 97-733 or Sigma Thinner 60-30 shall be added to Pitt-Char XP base white and
mix until homogeneous. To facilitate removal of Pitt-Char XP hardener black from the container half of the
required thinner may be added. Work the thinner around the walls of the container with a long spatula.
DO NOT MIX! Add the entire contents of the hardener pail to the base component and mix until a uniform
grey colour is obtained. Only full kits of Pitt-Char XP should be thinned, as this ensures the correct ratio of
base to hardener, and hence correct curing of the mixed product.
It is recommended that a heavy-duty mixer specifically designed for high viscosity epoxy PFP is used, or
alternatively a heavy-duty air or electric powered mixer with suitable paddle. The base of the mixer should
have a clamp suitable for retaining the pail during mixing.
Maximum wet film thickness achievable will depend on many factors such as air and steel temperature,
spray tip size and complexity of the steelwork as well as the level of thinning. Typically 3 mm – 5 mm
should be achievable.
The maximum length of fluid line recommended for this type of application is 25 m, and if external
temperatures are low, the line should be insulated. Fluid line diameters should be at least ¾” ID although a
short whip end of ½” may be used to facilitate use of the gun.
Application by this method can be as quick as for twin component application, but delays will occur
on changing over pails of Pitt-Char XP, and it may be necessary to flush the unit with 97-733 or
Sigma Thinner 60-30 after every two to four pails, to prevent build up of Pitt-Char XP within the pump.
Trowel and roller finishing should be carried out, as would be normal practice with plural pump application
of Pitt-Char XP. If reinforcement is required this should be incorporated as per these guidelines.
4.3.1 Spray Tips and Operating Pressure
nozzle size:
0.84-0.89 mm (33-35 thou)
fan angle:
50 deg.
operating pressure: 350 bar (5000 psi)
The above temperatures, pressures and sizes are given as a guide only and may be adjusted to provide
optimum application characteristics.
4.4 Finishing after Spray Application
Following spray application of Pitt-Char XP the surface should be trowelled to eliminate any voids and then
rollered to attain a smooth uniform finish, unless a ‘stipple finish’ is required. The optimum time for finishing
will be temperature dependent, but for most projects it has been found to be approximately 20 to 30
minutes after spraying. A medium pile simulated sheepskin roller has been found to give good results, but
other short or medium nap synthetic rollers may be suitable. It is recommended that suitability of roller be
established on a small area prior to use.
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If preferred, solvent can be used to dampen the roller as per normal site practice for application of epoxy
PFP, but one must ensure that the roller is suitable for use with strong solvents. The quantity of 97-733 or
Sigma Thinner 60-30 used should be kept to a minimum. If health and safety considerations allow a spray
mist bottle, it is a useful tool in this respect. Care should be taken to ensure that all residual solvent has
evaporated from the film before applying subsequent layer of Pitt-Char XP or a topcoat. Failure to do so
could lead to solvent entrapment within the film and subsequent coating failure.
All horizontal flat surfaces must be finished to provide a slight incline designed to shed water and prevent
pooling.
4.5 Hand Application
It is also possible to apply Pitt-Char XP by trowel, plaster trowel or other similar tool, and then smoothed off
using a roller as detailed in section 4.4. To improve the application at low temperatures up to 5% 97-733 or
Sigma Thinner 60-30 may be added.
Care should be taken to avoid air entrapment in Pitt-Char XP. As this is a relatively slow method of
application, do not mix more product than can be easily applied within the pot life of Pitt-Char XP.
If this method is used for large areas, the applicator must be confident that he can manage this within the
pot life.
As with all epoxy products, high temperature will significantly reduce the pot life.
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4.6 Warm Climate Application
4.6.1 Twin Component Application
In general terms, application will be in accordance with the guidelines given in Section 4.2 above, but
additional consideration should be given to the following:
a) Heat loss along the fluid line will be less and hence it may be possible or necessary to reduce the
temperature of the base and hardener holding tanks.
b) The warmer the air temperature, the shorter will be the working life after application for trowel and
rolling finishing.
c) For application onto steelwork above 50°C contact PPG for guidance. Under no circumstances
should the steel substrate be above 75°C.
d) Relative humidity should be below 85% and substrate temperature at least 3°C above the dew point
and free from other surface contamination. Above 85% relative humidity, consult PPG.
4.6.2 Single Component Application
This would have to be carried out at the applicators own discretion, as at higher ambient temperatures there
is a significant risk that the material will cure within the spray unit.
Method of application will be in accordance with the guidelines given in Section 4.3 above, but additional
consideration should be given to the points raised above in Section 4.6.1 b), c) and d) above as these will
also apply.
4.6.3 Hand Application
Application by this method will still be in accordance with Section 4.5, but additional consideration should
be given to the points raised above in Section 4.6.1 b), c) and d) as these will also apply.
4.6.4 Final Appearance
The spray applied finish of Pitt-Char XP has a matted or orange peel appearance. A smoother finish can be
achieved by roller or trowel. The desired final texture should be agreed upon between the applicator and the
client prior to the job start-up. This can either be done by using a representative sample beam or plate kept
on site for comparison or a reference area will be designated. This sample will be documented and signed
off by both parties prior to the job start-up.
sprayed finish
rolled finish
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4.7 Removal and Repair Procedure
(See drawing Appendix 2)
Where it is possible, areas to be removed should be cut and sliced using angle grinders and then
mechanically chopped and scraped using hand held pneumatic chisels.
Where dust from the use of angle grinders is not acceptable, removal can be achieved by cutting vertically
into the surface using an appliance such as a circular saw. This has a depth setting so that it can be set to
cut without going into the steel. The use of the circular saw blade with this tool produces shavings rather
than dust. The area for removal should be marked and cut out around the boundary.
Horizontal and vertical cuts should be made within the area to give a cross-hatch pattern. A hand held
pneumatic chisel with a slightly blunt blade can then be used to remove the Pitt-Char XP without damaging
the steel surface.
An alternative and very effective method is the use of Ultra High Pressure Water Jetting (UHPWJ).
After removal of Pitt-Char XP prepare the surface to a minimum standard of St.3 (ISO 8501-1), as detailed in
Section 2.3, immediately prior to coating.
The edges of the repair should be feathered down to the reinforcement (if present), so that the mesh within
the repair patch can be overlapped with the existing mesh for a minimum of 50 mm.
Fix pins if required then apply primer and fire protection system as per the specification.
4.8 Welding
Welding cannot be carried out in areas previously coated with Pitt-Char XP until it has been removed. Using
one of the methods discussed above, remove Pitt-Char XP to a distance of at least 200 mm in all directions
from the point of welding and on both sides of the steel if applicable.
In certain instances, it may be necessary to remove more than 200 mm. This can be determined at the time
of welding by observing any discolouration, blistering or lifting, or excessive softening of Pitt-Char XP. If
such defects occur Pitt-Char XP should be cut away to the point where the defect no longer occurs. It may
also be possible to remove less than 200 mm, on occasions where only small items are being welded onto a
main section. Again this can be best determined at the time of welding.
If in doubt, the temperature of the steel immediately adjacent to the Pitt-Char XP termination line should not
exceed 80°C.
4.9 Overcoating
Solvent must not be used to clean or soften the surface of Pitt-Char XP prior to overcoating with itself or
with a topcoat. Cleaning of contaminated surfaces between coats will be achieved by thorough washing
with detergent, followed by rinsing with clean fresh water and drying. If contamination cannot be removed
by this method, consult PPG.
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4.10 Exposed Top Flanges
Some designs may not allow for the coating of top flanges. This decision would form part of the fire and
safety case analysis and is determined by the client’s engineer. It is not a decision that can be made
by PPG.
Where the design allows for the omission of fire proofing to the top flange, appropriate procedures must be
taken to ensure correct termination of Pitt-Char XP. Details are given in Section 3.2.8 and in Section 5.
4.11 Preformed Castings
Pitt-Char XP can be pre-formed into cast assemblies for subsequent dry fit. This allows for removable fire
protection around valves and flanges and on process vessels where desired. Given the wide variation in
requirements each project would have to be considered on its own merits. For advice please consult PPG.
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5.0 Coatback
Secondary steelwork and non protected under deck areas need to be protected to an extent with
Pitt-Char XP to prevent heat transfer into the primary structure. There is no agreed standard for the
determination of coatback required. However a commonly adopted industry ‘norm’ is to coatback along
secondary steelwork for a distance of 450 mm. It is normally considered that the distance should be
measured from the point at which the secondary member connects to the primary. Typical drawings are
given in Appendix 4: Typical Coatback Details.
Please note, however, that PPG has data on other coatback distances and alternative recommendations may
be given. These will be project specific and dependent on the view of both the client and the verification
society. If distances other than 450 mm are considered appropriate then please contact PPG.
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6.0 Thickness Control and Measurement
One of the most important aspects of quality control in the use of Pitt-Char XP is the attainment of correct
dry film thickness. It is imperative that Pitt-Char XP is applied to the dry film thickness stated in the project
specification documentation and certification issued by the independent classification societies such as
Lloyd’s Register and DNV.
The proposals given below are those considered appropriate by PPG
6.1 Methods of Measurement
For high film thickness epoxy PFP two types of method for dry film thickness measurement are typically
employed:

destructive

non-destructive - the electromagnetic gauge
- the ‘drill depth gauge’
6.1.1 Destructive Method
Drilling holes and the use of a calibrated depth gauge is acceptable provided all damage is repaired after
measurements have been taken.
6.1.2 Non-destructive Method
The use of magnetic induction or eddy current gauges for the measurement of paint dry film thickness has
been common for many years. More recently gauges have become available that will measure up to 50 mm
thickness of coating on ferrous or non-ferrous substrates.
6.2 Calibration of Electromagnetic gauge
In all cases the manufacturer’s instructions should be used to determine the correct method for use and
calibration. Where electromagnetic gauges are concerned particular note should be taken regarding their
limited accuracy at edges and corners.
Magnetic gauges should be capable of providing accurate readings at a thickness in excess of the maximum
DFT to be measured. Ideally the gauge should be capable of storing data and determining statistical
information (mean, minimum, maximum, etc.).
Calibration should be carried out using the designated smooth steel plate provided with the instrument.
Smooth plastic shims specifically designed for calibration and traceable to a national standard must be
used. Two shims should be chosen, one having a thickness no more than 50% above the maximum, the
other no more than 50% below the minimum of the DFT range to be measured. Gauge accuracy should be
determined by measuring, on the smooth steel calibration plate, a further traceable calibration shim of
known thickness within the previously calibrated range.
Primer DFT should be determined prior to application of Pitt-Char XP.
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Pitt-Char XP DFT should be determined prior to application of topcoat. Failure to do this may require topcoat
to be removed should the DFTs prove to be under specification. Where reinforcement is required mid film, or
where more than one coat is to be applied it may be considered appropriate, or dictated by project
specification, to measure the dry film thickness of Pitt-Char XP at an intermediate stage. Knowledge of the
interim DFT will allow greater control of the subsequent coats of Pitt-Char XP.
6.3 Frequency of Measurements
The following information is given for guidance only and does not seek to override any project specific
requirement for dry film thickness measurement. Where possible reference should always be made to
client’s project specifications or recognised standards such as NACE, SSPC, BS, ISO etc.
6.3.1 Structural Steelwork
As a minimum all open (H, T or channel section) or closed profile (RHS, SHS) structural members should
have thickness readings taken every 1 m along the length of each coated face. In the case of CHS readings
should be taken on at least 4 equidistant points around the circumference and every 1 m along the length of
the section.
6.3.2 Flat Plate, Decks and Bulkheads
As a minimum on flat plate and large diameter vessels two or three thickness readings should be taken
every 1 m2. If deck and bulkheads are stiffened, readings should be taken at no more than 1 m intervals
along the length of the flat area between the stiffeners. The stiffeners themselves should be measured as
per channel sections in 6.3.1 above.
6.4 Acceptance Criteria
These criteria are PPG’s preferred requirements but in most cases the client’s project specifications will take
precedence.
6.4.1
The average of all readings in the defined measurement area must be equal to or greater than the
specified Pitt-Char XP dry film thickness.
6.4.2
Where any single thickness reading is found to be no less than 80% of the specified DFT, further
readings in the area of the low reading should be taken as follows:
6.4.2.1
Where the web, flange or other face is wide enough then three, nominally equidistant readings
should be taken at a distance of 150 – 300 mm away from the low reading.
6.4.2.2
Where the web, flange or other face is not wide enough to allow the above, then two nominally
equidistant readings should be taken at a distance of 150 – 300 mm away from the low
reading.
6.4.2.3
For CHS, 2 additional readings should be taken nominally equally spaced at a distance of 150 –
300 mm from the low reading along the length of the CHS.
6.4.2.4
If one or more of these additional readings are also no less than 80% of the specified thickness,
further readings should be taken to establish the extent of the low area. The whole area should
then be brought up to the required dry film thickness by application of more Pitt-Char XP.
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6.4.3
Individual thickness readings of less than 80% of the specified thickness are not acceptable.
6.4.4
Maximum thickness of Pitt-Char XP.
Where Pitt-Char XP has been applied without the use of solvent thinning, application significantly
above the required DFT does not normally pose a problem. For the purposes of providing some
broad guidance, the average of all readings in the defined measurement area should not exceed the
specified DFT by more than 10%. No individual reading in the defined measurement area should
exceed the specified DFT by more than 50%.
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7.0 Topcoat Selection
Although Pitt-Char XP has a high degree of exterior durability in its own right, decorative appearance will be
enhanced if a topcoat is applied. Suitable topcoats are discussed below and detailed in the table given at
Appendix 1.
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Appendix 1 Recommended Topcoats for Pitt-Char XP
General areas – exposed to weathering up to C5-I or C5-M
a.
b.
c.
d.
e.
SigmaCover 456, recoatable epoxy coating
SigmaDur 520, semigloss polyurethane
SigmaDur 550 / Pitthane Ultra, gloss polyurethane
SigmaDur 1800, gloss polymeric urethane
Sigma PSX 700, polysiloxane
75 µm
50 µm
50 - 75 µm
75 µm
75 µm
Note : All dry film thickness measurements are nominal
For detailed topcoat recommendations in splash regions and areas subject to wear and tear such as walk
ways and decks please contact PPG
Non-skid properties can be obtained by adding 10% by weight of a special silica (such as Minigrain No. IV)
or fine coconut shells to the topoat. In case of contamination with oil or lubricants a very coarse material,
like Minigrain No. 1, can be used to further enhance non-skid properties. In this case an extra coat is
necessary to ensure adhesion of the embedded anti-skid material.
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Appendix 2 Pitt-Char XP Repair Sketch
Protective & Marine
Coatings
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Appendix 3 Reinforcement and Retention Details
Appendix 3.1 I-Sections Details Conforming LR and DNV – FM Fabric Mesh
Protective & Marine
Coatings
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Appendix 3.2 I-Sections Details Conforming LR and DNV – Metal Mesh
Protective & Marine
Coatings
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Appendix 3.3 I-Sections Details Conforming LR and DNV – 60 and 120 Minutes
Protective & Marine
Coatings
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Appendix 3.4 I-Sections Details Conforming UL – Fibre Glass and Metal Mesh
Protective & Marine
Coatings
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Appendix 3.5 I-Sections and Other Open Profiles – General Reinforcement Requirements
Protective & Marine
Coatings
page 43/49
PASSIVE FIRE PROTECTION
INFORMATION
PROTECTION OF STEEL FROM HYDROCARBON FIRES
PITT-CHAR XP APPLICATION GUIDELINES
1202
August 2010
Appendix 3.6 Underdecks and Bulkhead Details Conforming LR and DNV
Protective & Marine
Coatings
page 44/49
PASSIVE FIRE PROTECTION
INFORMATION
PROTECTION OF STEEL FROM HYDROCARBON FIRES
PITT-CHAR XP APPLICATION GUIDELINES
1202
August 2010
Appendix 3.7 PG-Box Details
Protective & Marine
Coatings
page 45/49
PASSIVE FIRE PROTECTION
INFORMATION
PROTECTION OF STEEL FROM HYDROCARBON FIRES
PITT-CHAR XP APPLICATION GUIDELINES
1202
August 2010
Appendix 3.8 Spheres
Protective & Marine
Coatings
page 46/49
PASSIVE FIRE PROTECTION
INFORMATION
PROTECTION OF STEEL FROM HYDROCARBON FIRES
PITT-CHAR XP APPLICATION GUIDELINES
1202
August 2010
Appendix 4 Typical Coatback Details
Appendix 4.1 I-Section To I-Section
Protective & Marine
Coatings
page 47/49
PASSIVE FIRE PROTECTION
INFORMATION
PROTECTION OF STEEL FROM HYDROCARBON FIRES
PITT-CHAR XP APPLICATION GUIDELINES
1202
August 2010
Appendix 4.2 Circular Hollow Section To Circular Hollow Section
Protective & Marine
Coatings
page 48/49
PASSIVE FIRE PROTECTION
INFORMATION
PROTECTION OF STEEL FROM HYDROCARBON FIRES
PITT-CHAR XP APPLICATION GUIDELINES
August 2010
Limitation of Liability - The information in this data sheet is based upon laboratory tests we believe to be accurate and is intended
for guidance only. All recommendations or suggestions relating to the use of the coating products made by PPG Protective &
Marine Coatings, whether in technical documentation, or in response to a specific enquiry, or otherwise, are based on data which
to the best of our knowledge are reliable. The products and information are designed for users having the requisite knowledge
and industrial skills and it is the end-user's responsibility to determine the suitability of the product for its intended use.
PPG Protective & Marine Coatings has no control over either the quality or condition of the substrate, or the many factors
affecting the use and application of the product. PPG Protective & Marine Coatings does therefore not accept any liability arising
from loss, injury or damage resulting from such use or the contents of this data sheet (unless there are written agreements
stating otherwise).
The data contained herein are liable to modification as a result of practical experience and continuous product development.
This data sheet replaces and annuls all previous issues and it is therefore the user’s responsibility to ensure that this sheet is
current prior to using the product.
page 49/49
INFORMATION
1410
CONVERSION TABLES
a four page issue
GENERAL
1 atmosphere
1 foot
1 Imp. gallon
1 litre
1 litre
1 metre
1 sq. foot
1 sq. metre
1 US gallon
1 yard
1 metre
degree C
degree F
June 2002
revision of 10-1999
PRESSURE
=
=
=
=
=
=
=
=
=
=
=
=
=
14.223 lb/sq.in.
0.305 metre
4.546 litres
0.220 Imp. gallon
0.264 US gallon
3.281 feet
0.093 sq. metre
10.765 sq. feet
3.785 litres
0.915 metre
1.0936 yard
5/9 x (degree F - 32)
9/5 x degree C + 32
VOLUME
(kg/cm²)
atmosphere
(bar)
(p.s.i.)
lb/sq.in.
1
2
3
4
5
6
7
8
9
10
14.2
28.4
42.7
56.9
71.1
85.3
99.6
113.8
128.0
142.2
(kg/cm²)
atmosphere
(bar)
100
110
120
130
140
150
160
170
180
190
200
(p.s.i.)
lb/sq.in.
1420
1560
1710
1850
1990
2130
2280
2420
2560
2700
2840
DRY FILM THICKNESS
1 Imperial gallon =
=
1 litre
=
=
1 US gallon
=
=
4.55 litre
1.2 US gallons
0.22 Imperial gallon
0.26 US gallon
3.79 litre
0.83 Imperial gallon
litres
Imperial
gallons
US gallons
1
2
3
4
5
6
7
8
9
10
15
20
50
100
0.22
0.44
0.66
0.88
1.10
1.32
1.54
1.76
1.98
2.20
3.30
4.40
11.00
22.00
0.26
0.53
0.79
1.06
1.32
1.58
1.85
2.11
2.38
2.64
3.96
5.28
13.21
26.42
microns
(µm) mils
microns
(µm) mils
microns
(µm) mils
microns
(µm) mils
8
10
15
20
25
30
35
40
45
50
55
60
65
70
75
80
85
90
95
100
105
110
115
120
125
130
135
140
145
150
155
160
165
170
175
180
185
190
195
200
205
210
215
220
225
230
235
240
245
250
255
260
265
270
275
280
285
290
295
300
305
310
315
320
325
330
335
340
345
350
355
360
365
370
375
380
385
390
395
400
0.3
0.4
0.6
0.8
1.0
1.2
1.4
1.6
1.8
2.0
2.2
2.4
2.6
2.8
3.0
3.2
3.4
3.6
3.8
4.0
page 1/4
4.2
4.4
4.6
4.8
5.0
5.2
5.4
5.6
5.8
6.0
6.2
6.4
6.6
6.8
7.0
7.2
7.4
7.6
7.8
8.0
8.2
8.4
8.6
8.8
9.0
9.2
9.4
9.6
9.8
10.0
10.2
10.4
10.6
10.8
11.0
11.2
11.4
11.6
11.8
12.0
12.2
12.4
12.6
12.8
13.0
13.2
13.4
13.6
13.8
14.0
14.2
14.4
14.6
14.8
15.0
15.2
15.4
15.6
15.8
16.0
INFORMATION
1410
CONVERSION TABLES
June 2002
SPREADING RATE
Sq.m./l
Sq.ft./
Imp.gal
sq.ft./
US gal
Sq.m./l
Sq.ft./
Imp.gal
sq.ft./
US gal
Sq.m./l
Sq.ft./
Imp.gal
sq.ft./
US gal
1.0
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9
2.0
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
2.9
3.0
3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
3.9
4.0
4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.8
4.9
49
54
59
64
68
73
78
83
88
93
98
103
108
112
117
122
127
132
137
142
147
152
156
161
166
171
176
181
186
191
196
200
205
210
215
220
225
230
235
240
41
45
49
53
57
61
65
69
73
77
81
85
89
94
98
102
106
110
114
118
122
126
130
134
138
142
146
151
155
159
163
167
171
175
179
183
187
191
195
199
5.0
5.1
5.2
5.3
5.4
5.5
5.6
5.7
5.8
5.9
6.0
6.1
6.2
6.3
6.4
6.5
6.6
6.7
6.8
6.9
7.0
7.1
7.2
7.3
7.4
7.5
7.6
7.7
7.8
7.9
8.0
8.1
8.2
8.3
8.4
8.5
8.6
8.7
8.8
8.9
244
249
254
259
264
269
274
279
284
288
293
298
303
308
313
318
323
328
332
337
342
347
352
357
362
367
372
376
381
386
391
396
401
406
411
416
420
425
430
435
203
208
212
216
220
224
228
232
236
240
244
248
252
256
260
265
269
273
277
281
285
289
293
297
301
305
309
313
317
321
325
330
334
338
342
346
350
354
358
362
9.0
9.1
9.2
9.3
9.4
9.5
9.6
9.7
9.8
9.9
10.0
10.5
11.0
11.5
12.0
12.5
13.0
13.5
14.0
14.5
15.0
15.5
16.0
16.5
17.0
17.5
18.0
18.5
19.0
19.5
20.0
20.5
21.0
21.5
22.0
22.5
23.0
23.5
24.0
24.5
440
445
450
455
460
464
469
474
479
484
490
515
540
560
585
610
635
660
685
710
735
760
780
805
830
855
880
905
930
955
980
1000
1025
1050
1075
1100
1125
1150
1175
1200
366
370
374
378
383
387
391
395
399
403
405
425
450
470
490
510
530
550
570
590
610
630
650
670
690
710
735
755
775
795
815
835
855
875
895
915
935
955
975
995
page 2/4
INFORMATION
1410
CONVERSION TABLES
June 2002
VISCOSITY IN SECONDS
DIN
cup 4
Ford
cup 4
Afnor
coupe 4
B.S.
cup 4
DIN
cup 4
Ford
cup 4
Afnor
coupe 4
B.S.
cup 4
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
32
34
36
38
40
42
15
17
18
19
21
22
23
25
26
28
29
30
31
33
34
35
38
40
43
45
48
51
17
18
20
21
23
24
25
27
28
30
31
32
34
35
36
38
40
43
46
48
51
54
19
20
22
23
25
26
28
29
31
32
33
34
36
37
38
40
43
46
49
52
54
57
44
46
48
50
55
60
65
70
75
80
85
90
95
100
110
120
130
140
150
160
170
180
53
55
58
60
67
73
79
86
92
98
104
111
117
123
136
148
160
173
185
198
210
223
56
59
62
64
71
78
84
91
97
104
110
117
124
130
144
157
171
184
197
210
224
237
60
63
66
69
75
82
89
96
105
109
116
123
130
138
152
166
180
194
207
221
235
249
page 3/4
INFORMATION
1410
CONVERSION TABLES
June 2002
TEMPERATURE
°C = ( °F - 32 ) x 5/9
°C
°F
°C
°F
°C
°F
°C
°F
–10
– 9
– 8
– 7
– 6
– 5
– 4
– 3
– 2
– 1
0
1
2
3
4
5
6
7
14.0
15.8
17.6
19.4
21.2
23.0
24.8
26.6
28.4
30.2
32.0
33.8
35.6
37.4
39.2
41.0
42.8
44.6
8
9
10
11
12
13
14
15
16
17
18
19
20
22
24
26
28
30
46.4
48.2
50.0
51.8
53.6
55.4
57.2
59.0
60.8
62.6
64.4
66.2
68.0
72.0
75.0
79.0
82.0
86.0
32
34
36
38
40
42
44
46
48
50
55
60
65
70
75
80
85
90
90
93
97
100
104
108
111
115
118
122
131
140
149
158
167
176
185
194
95
100
110
120
130
140
150
160
170
180
190
200
250
300
350
400
450
500
203
212
230
248
266
284
302
320
338
356
374
392
482
572
662
752
842
932
Limitation of Liability - The information in this data sheet is based upon laboratory tests we believe to be accurate and is
intended for guidance only. All recommendations or suggestions relating to the use of the Sigma Coatings products made by PPG
Protective & Marine Coatings, whether in technical documentation, or in response to a specific enquiry, or otherwise, are based
on data which to the best of our knowledge are reliable. The products and information are designed for users having the requisite
knowledge and industrial skills and it is the end-user's responsibility to determine the suitability of the product for its intended
use.
PPG Protective & Marine Coatings has no control over either the quality or condition of the substrate, or the many factors
affecting the use and application of the product. PPG Protective & Marine Coatings does therefore not accept any liability arising
from loss, injury or damage resulting from such use or the contents of this data sheet (unless there are written agreements
stating otherwise).
The data contained herein are liable to modification as a result of practical experience and continuous product development.
This data sheet replaces and annuls all previous issues and it is therefore the user’s responsibility to ensure that this sheet is
current prior to using the product.
page 4/4
INFORMATION
EXPLANATION TO PRODUCT DATA SHEETS
an eight page issue
1411
July 2007
revision of November 2006
GENERAL
For ease of reference figures are usually stated in one unit only. Equivalents are given in the conversion
tables. See sheets 1410 Conversion tables, 1412 Nomograph conversion from english units to metric units
and 1413 S.I. units.
All values are given for temperature of 20°C (68°F) and relative humidity of 70%, unless stated otherwise.
GLOSS
With a ‘Lange’ gloss gauge 5 ranges of gloss have been determined, compared with a standard sheet of
black polished glass. The gloss values are determined on Lange gloss gauge (angle 60°) according to ISO
2813 (= ASTM D-523). The expressions used in the data sheets are:
Flat
corresponds with 0- 15%
Eggshell
corresponds with 15- 30%
Semi-gloss corresponds with 30- 60%
Gloss
corresponds with 60- 80%
High-gloss corresponds with 80-100% (at 20° angle above 70%)
In practice, the level of gloss and surface finish will be dependent upon a number of factors, including
application and the condition of the surface to be overcoated.
COLOUR
For products supplied in different colours three colour quality levels exist:
1. Good
For finishes in general, especially based on polyurethane, this quality matches the colour
standard
2. Approximate For undercoats and low gloss topcoats in general, this quality level is close to the colour
standard
3. Best Match For primers in general, this quality level is near to the colour standard
MICACEOUS IRON OXIDE AND/OR ALUMINIUM CONTAINING PAINTS
Micaceous iron oxide and/or aluminium containing paints show different appearance and colour impression
depending on thickness and application method. A touch-up by brushing may be visible on a sprayed area.
SHELF LIFE
The period from the date of manufacture during which the paint can be transported and stored in
undamaged and unopened packing at temperatures between 10-30°C, without any influence on the
application or performance of the paint.
After exceeding this period the paint is subject to reinspection.
Water-borne products must be protected from freezing at all times during storage and/or transport.
SUBSTRATE CONDITIONS AND TEMPERATURES
Unless stated otherwise in the relevant product data sheet, the maximum substrate temperature should not
exceed 40°C and/or maximum RH of 80% is allowed
see sheet 1490 – Cleaning of steel and removal of rust
see sheet 1650 – Relative humidity - Substrate temperature - Air temperature
page 1/8
INFORMATION
EXPLANATION TO PRODUCT DATA SHEETS
1411
July 2007
FULL CURE
‘Full cure’ means, that the properties of a paint as described in the product data sheet are achieved (suitable
for service). However, in case of dry bulk carriage an extra curing time may be required before the coating
has reached its full mechanical strength and is suitable for carriage of hard angular cargoes
FLASH POINT
For paints the flash point is determined according to ISO 1523 (= ASTM D-3278, corresponding to Sigma
method SM 311-41) or calculated.
For thinners the flash point is determined according to DIN 51755 (corresponding to Sigma method
SM 311-42) or calculated.
Please always refer to the latest Material Safety Data Sheet for the paint and thinners.
OVERCOATING TABLE
The data given is a fair indication for normal conditions, longer drying times are necessary at lower
temperatures and under unfavourable weather and/or ventilation conditions and higher dry film thicknesses.
For epoxy coatings the minimum curing time for the recommended dft is given in the data sheets.
For average dfts 50% higher, the minimum overcoating time should be multiplied by 1,5 and for average
dfts 100% higher the multiplication factor is 2,5.
Recoating data are based on atmospheric exposure, for other exposure conditions contact your nearest
sales office.
TOUCH DRY
The touch dry time corresponds with the tack free time measured in accordance with ASTM D-1640
(corresponding with Sigma method SM 315-01). The touch dry time will be influenced by dft, ventilation
conditions and substrate temperature.
DRY TO HANDLE
The dry to handle time corresponds with the dry-through time measured in accordance with ASTM D-1640
(corresponding with Sigma method SM 315-01) and indicates the time when walking over is possible.
The dry-to-handle time will be influenced by dft, ventilation conditions and substrate temperature and
should not be necessarily interpreted as ready for transportation due to the likelihood of excessive damage.
DRY FILM THICKNESS (dft) / WET FILM THICKNESS (wft)
The dry film thickness can be calculated from the applied wet film thickness:
dft x 100
dft = wft x % volume solids
wft =
100
% volume solids
Recommended dft
The dry film thickness for a paint system indicated in our system sheets is the recommended dft for the
specific exposure conditions and based on airless spray application.
Dft specifications referred to herein are valid for the coatings and coating systems in this manual unless
mentioned otherwise in the respective product and system sheets.
page 2/8
INFORMATION
EXPLANATION TO PRODUCT DATA SHEETS
1411
July 2007
Minimum dft for application
The minimum dft of a paint system (also a one coat system) should follow the 90/10 rule (e.g. 90% of the
recommended dft is acceptable for up to 10% of the readings only), whilst for individual coats the
minimum dft should not be lower than 80% of the recommended dft, and must form a closed film.
Maximum dft for application - General
Application of a paint at thicknesses in excess of the dft recommended on the product data sheet may result
in performance problems. Such problems include solvent retention and a reduction in cohesive strength in
association with certain types of topcoat.
In a coating system, the dft of a primer is of the utmost importance. In general, Sigma Coatings would
restrict the dft of any primer to 1.5 times that specified on the product data sheet.
For a coating system, including the individual coats (except the primer), the maximum dft is 2 times the
recommended dft, whereas for the critical areas of a painted structure, 10% of the readings can be between
2 and 2.2 times the recommended dft. Critical areas are e.g. weld seams, edges, bolts, corners, nuts and
areas of difficult access.
For coating specifications requiring coating thicknesses which exceed the recommended dfts as mentioned
in the product and system sheets, the maximum dft allowed should be established per project prior to startup.
Over-application and its consequences is a complex subject and is dependent on the generic type of
system, recommended dft and number of coats, as well as the intended exposure.
Please refer to your local Sigma Coatings office if you should have any questions on this important issue.
The life time of any protective coating system is also determined by the dry film thickness applied to critical
areas. The dft of all of these critical areas should be closely monitored and controlled by the application of
stripe coats with the same material as the consecutive coat of the system (or as recommended otherwise by
Sigma Coatings). Please note that if a solvented coating has been applied over the specified dft then the
minimum overcoating time must be increased to ensure that sufficient time is given for solvent evaporation.
Care must also be taken to avoid over-application on critical areas during the progress of the job. Overapplication does not lead to enhanced performance life time of the coating system.
Maximum dft for application - Linings
For linings for severe exposure conditions or reinforced solvent free systems, the dft of the primer and the
subsequent coatings can be more critical. Dft limitations are detailed in the respective system / product data
sheets.
page 3/8
INFORMATION
EXPLANATION TO PRODUCT DATA SHEETS
1411
July 2007
VOC
Until further notice, the heavy duty Marine and PC coatings industries in Europe must comply with the VOC
Directive 1999/13/EC (SED).
VOC values (in g/kg) to assist with the annual calculation of the solvent limits related to the SED
requirements, are mentioned on each Product Datasheet as well as on the label of all products.
For decorative, functional and protective coatings used in ‘buildings,’ the VOC Directive 2004/42/EC applies.
This is based on compliant coatings.
Label Example:
1999/13/EC : 320 g/kg
2004/42/IIa (i) 600 (2007) 360
Explanation Label Example:
1999/13/EC : 320 g/kg
2004/42/IIa (i)
600 (2007)
360
Max VOC according to Directive 1999/13/EC for material in the can.
Reference to the sub-category according to Directive 2004/42/IIa
Threshold limit for sub-category according to Directive 2004/42/IIa from
1.1.2007 till 1.1.2010
The max content of VOC in g/l of the product in a ready to use condition
(including maximum amount of thinner according to Product Datasheet).
SOLIDS CONTENT BY VOLUME
This value is given in the product data sheet. It can be determined by a laboratory test, Sigma Method 31410 corresponding to ISO method 3233 (= ASTM method D 2697) or calculated from the formulation.
The calculated theoretical solids content by volume is in general lower than the determined solids content
by volume. The latter approximates best to practice, assuming that the table for spreading rate losses is
used correctly. Diluents with a high boiling point and low vapour pressure are widely used in solvent free
coatings, they will remain in the cured film under normal ambient conditions and will therefore have
negligible effect on the volume solids of these specific products. Furthermore, due to the relative high
boiling point and rather low vapor pressure of these diluents, the ventilation requirements when using
solvent free coatings in confined spaces to maintain the internal atmosphere at 10% of the Lower Explosion
Limit, will be unchanged.
TOLERANCES
Values given for specific gravity, theoretical spreading rate and solids content are averages from standard
production batches; these values can vary slightly, also for colours of one product.
page 4/8
INFORMATION
EXPLANATION TO PRODUCT DATA SHEETS
1411
July 2007
VENTILATION
Adequate ventilation during application and curing of the coating is not only required for health and safety
reasons but also to ensure that the coating gives optimal performance.
Stagnant air/high vapour concentrations in confined spaces must be avoided. Forced ventilation will help to
avoid high vapour concentrations and possible solvent entrapment in the coating which may produce a
temporary plasticising effect. Ventilation with cold, humid air in the drying stage should be avoided.
Also avoid ventilation with heated air during the wet film forming stage as this approach may give skinning
and increased solvent entrapment.
For more information, see the following data sheets:
1430 Safety indications
1431 Safety in confined spaces and health safety, explosion hazard - toxic hazard
1434 Directives for ventilation practice
THEORETICAL SPREADING RATE
The theoretical spreading rate m²/l for a given dry film thickness can be calculated from:
m²/l = % volume solids x 10
dry film thickness (in µm)
PRACTICAL SPREADING RATE
The practical spreading rate depends on a number of factors:
surface condition and profile, application method, normal, high build or solvent-free paint, skill of labour and
weather conditions. It is often estimated at about 70 % of the theoretical spreading rate but under many
conditions this is still far too high. For calculation purposes the following table has been composed in which
spreading rate LOSSES are compiled.
Substrates like wood and concrete are not included because they present too many other variable factors,
especially in the preparation, the filling of pores, etc.
RECOMMENDED THINNERS
This product must only be thinned using the recommended Sigma thinners. The use of alternative thinners,
particularly these containing alcohols, can severely inhibit the curing mechanism of certain coating types
and will influence the performance. In case of the use of other thinners than advised, Sigma Coatings will
not accept any responsibility.
page 5/8
INFORMATION
1411
EXPLANATION TO PRODUCT DATA SHEETS
July 2007
ESTIMATED LOSSES IN PERCENTAGES
ALL FIGURES ± 10 DEPENDING ON CIRCUMSTANCES (AS GUIDE ONLY)
Type of surface and
application method
1)
2)
3)
4)
BARE STEEL/FIRST COAT 4)
COATED STEEL/NEXT COAT
NEW
blast-cleaned
A-B-C
ISO-Sa2½
NEW
including
shop primer
OLD
derusted
C St 3 / D
ISO-Sa2½
OLD
due for
maintenance
inside
outside inside
outside inside
outside inside
outside
LARGE 1)
airless spray
air-spray
roller
30
40
35
40
50
35
40
50
40
50
60
40
25
35
30
35
45
30
35
45
40
45
55
40
SMALL 2)
airless spray
air-spray
roller-brush
45
50
25
55
60
25
55
65
25
65
65
30
40
45
20
50
55
20
50
60
30
60
60
30
FRAMEWORK 3)
airless spray
brush
85
20
85
20
85
20
85
20
85
20
85
20
85
30
85
30
LARGE SURFACES
SMALL SURFACES
FRAMEWORK
PRIMERS
:
:
:
:
hull, decks, deckhouses, tanks, holds
masts, water ways, machinery, structural steel and complex structures
ladders, piping and railings
consumption of first coat is always higher than for subsequent coats because of the steel profile
Estimation of volume of paint necessary for a paint job can be calculated from:
10 x A x DFT = Q
VS x (100-W)
EXAMPLE
Q
A
DFT
VS
W
=
=
=
=
=
quantity in litre
area in m²
dry film thickness
% volume solids (see data sheet)
estimated losses (see table)
Q
A
DFT
VS
W
=
=
=
=
=
Q
= 10 x 1000 x 100 =
50 x (100-40)
page 6/8
to be calculated
1000 m²
100 µm
50%
40%
333 ltr.
INFORMATION
1411
EXPLANATION TO PRODUCT DATA SHEETS
July 2007
NOZZLE ORIFICE AND SPRAY ANGLE
In the product data sheets only the recommended orifice is stated. The choice of the spray angle depends
very much on the practical situation. The table below compares orifice and angle with the corresponding
codes of various manufacturers. Please consult other manufacturers for their corresponding codes.
WIWA - Spray Tips 1)
ORIFICE
Inches
mm's
Angle
0,007
0.18
40°
0,009
0,009
0.23
0.23
0,011
0,011
0,011
GRACO - Spray Tips 2)
Contractor
Finish
018/40
--
163-407
40°
65°
023/40
--
---
163-409
163-609
0.28
0.28
0.28
25°
40°
65°
028/25
028/40
028/65
269-211
269-411
--
163-211
163-411
163-611
0,013
0,013
0,013
0,013
0.33
0.33
0.33
0.33
25°
50°
65°
80°
033/25
033/50
033/65
033/80
269-213
269-513
269-613
--
163-213
163-513
163-613
163-813
0,015
0,015
0,015
0.38
0.38
0.38
40°
65°
80°
038/40
038/65
--
269-415
163-415
269-615
269-815
163-615
163-815
0,018
0,018
0.46
0.46
65°
80°
046/65
--
---
163-618
163-818
0,021
0,021
0.53
0.53
65°
80°
053/65
--
269-621
269-821
163-621
163-821
0,026
0,026
0,026
0.66
0.66
0.66
40°
65°
95°
066/40
066/65
--
----
163-426
163-626
163-926
0,036
0,036
0.91
0.91
40°
80°
091/40
091/80
---
---
1) In
the WIWA number the relation between orifice and angle is clear
2) Orifice
Size determines how many liters per minute can be atomized through the airless spray tip.
The last two digits of the part number tell the Orifice Size in thousandths of an inch.
In this example, the orifice is 0.381 mm (015"). For ordering use the complete number.
Orifice
Tip No. 163-415
Orifice
or
Spray Width
Tip No. 269-415
Spray Width
Spray Width is based on spraying distance 305 mm (12") from the surface. Double the fourth digit of the
tip part number to determine the approximate minimum Spray Width in inches. Add two inches to that
number for maximum width. In this example, this tip size produces a 203-254 mm (8-10") spray pattern
(width) at 305 mm (12") distance from the surface.
page 7/8
INFORMATION
EXPLANATION TO PRODUCT DATA SHEETS
1411
July 2007
MIXING RATIO - twin-feed products
The mix ratios in volume for twin-feed applied products should be retrieved from specific data sheets.
It is very important that right ratios are maintained but deviations up to max. 3% are acceptable unless
otherwise stated on specific data sheets.
These products are generally supplied ready for use after mixing of components as extra diluting is not
allowed.
INDUCTION TIME
If mentioned on the product data sheet the coating should be thoroughly mixed and left for the
recommended time for the particular temperature conditions at application. This induction time or precuring of the product ensures that the coating will give the required performance and application properties.
POT LIFE
This gives the time interval after mixing of the components of the coating during which the material can be
applied, without change of application and performance properties of the coating. For solvent containing
coatings an extra addition of thinner up to 5% is allowed. For solvent free coatings addition of thinner is not
permitted. For solvent free and high solid coatings an exothermic reaction occurs, resulting in gelation
shortly after reaching the end of the pot life. It is important to clean equipment with the recommended
cleaning thinner before the pot life has expired and/or directly after completion of application of the paint.
Limitation of Liability - The information in this data sheet is based upon laboratory tests we believe to be accurate and is
intended for guidance only. All recommendations or suggestions relating to the use of the Sigma Coatings products made by PPG
Protective & Marine Coatings, whether in technical documentation, or in response to a specific enquiry, or otherwise, are based
on data which to the best of our knowledge are reliable. The products and information are designed for users having the requisite
knowledge and industrial skills and it is the end-user's responsibility to determine the suitability of the product for its intended
use.
PPG Protective & Marine Coatings has no control over either the quality or condition of the substrate, or the many factors
affecting the use and application of the product. PPG Protective & Marine Coatings does therefore not accept any liability arising
from loss, injury or damage resulting from such use or the contents of this data sheet (unless there are written agreements
stating otherwise).
The data contained herein are liable to modification as a result of practical experience and continuous product development.
This data sheet replaces and annuls all previous issues and it is therefore the user’s responsibility to ensure that this sheet is
current prior to using the product.
page 8/8
INFORMATION
1430
SAFETY INDICATIONS
a three page issue
October 1999
revision of 1-1995
Most paints contain flammable solvents and some contain materials which can harm the skin, or damage
the health if swallowed or inhaled. Whilst most countries have developed regulations to control labelling,
storage and use of toxic or hazardous material as yet there is no agreed international code or system.
Sigma Coatings will adopt the local requirements in any country where their products are sold, but since it is
quite impossible and even confusing to apply all the marks which could be required for every country,
a Sigma Coatings system has been developed which is standard for our products throughout the world.
We will then add local regulation markings in addition, if required.
Two major classes of risk must be controlled and precautions defined which will reduce the risk to
acceptable levels:
A) Health risks, these include: –
1. Gases or vapours. These could include solvent evaporation during the drying period, or perhaps formed
during heating of the painted object.
2. Liquids in the paint. These might be solvents, or perhaps binders, which may be toxic if swallowed or
inhaled as spray droplets, or dermatitic or toxic in contact with the skin.
3. Powders or dusts. These can be formed during heating painted objects (e.g. flame cutting or welding
painted steel), or be present in powder formed during sanding operations, or in spray mist.
B) Fire or explosion risks, these include: –
1. Fire risk during storage or transport. Most paints other than water based products can be ignited and will
support flame.
2. Explosion hazard during application. Flammable solvents in mixture with oxygen in air can explode within
certain concentration limits if ignited or detonated.
The following sentences are used to define the classes of hazard and this data sheet gives details of
precautions which should be taken in each case.
page 1/3
INFORMATION
1430
SAFETY INDICATIONS
October 1999
Relatively harmless paint
Normal measures which are always applicable are:
– Wash hands regularly and thoroughly with warm water/soap.
– Immediately cover any wound or cut.
– Do not roll cigarettes, smoke, or eat with dirty hands.
– Beware of possible dust or fumes resulting from sand papering or
burning.
– Check carefully that there is no possible fire or explosion risk.
– Check whether extra ventilation is required.
Highly flammable paint.
Flash point up to and
including 23°C (DIN 53213).
Flash point of paints and solvents is stated in all our product data sheets.
This is the lowest temperature at which a mixture of the material with air
can ignite or explode. If the temperature of the air is near, or above, the
flash point it is essential that sufficient ventilation air is provided to reduce
the concentration of solvent well below the lower explosive limit (L.E.L.).
Mixtures of solvent and air can only explode when the concentration lies
between the lower and upper explosive limits.
These limits vary from one solvent to another but the LEL is usually about
50 g per 1 m³ of air.
This is described in detail in sheet 1431.
In brief 200 m³ ventilation air is required per kilo of solvent to maintain an
atmosphere below 10% of LEL.
Such a mixture is safe even at temperatures above the flash point.
Gloves recommended
Solvents and other components in some paints can irritate the skin, and
although in normal paints this may only be a minor and temporary irritation,
dermatitis of sensitive skins can be caused by solvents or chemicals in
some paints. These are indicated by this ‘glove’ sentence. Barrier creams
together with gloves, goggles and possibly face masks should be used.
In all cases, however, the habit of using solvents to clean the skin after
painting should be discouraged.
Contact of paint with the skin should be avoided by use of barrier creams
and protective gloves. Any paint on the skin should be removed at once with
skin cleaning liquids or jellies and then washed with water.
Paint which irritates or
affects skin or mucous
membranes.
Mask recommended
Inhalation of dust and
spraymist is harmful.
Dust, smoke and spray mist can be filtered by face masks containing a dust
filter cartridge. Cartridges are also available which absorb both dust and
solvents. These are only effective whilst there is no apparent smell of
solvent. The filter is exhausted when the odour of solvent can be detected
and the filter should then be changed. It is most important that the correct
filter for the class of work should be used. These are described by the
manufacturers of the face mask and filter.
page 2/3
INFORMATION
1430
SAFETY INDICATIONS
October 1999
Fresh Air Mask recommended Toxic substances in paints usually enter the body by inhalation of gases,
vapours, fumes, dusts or spray mists. An indication of the level of hazard is
Inhalation of vapour and
the Threshold Limits Value (T.L.V.), at one time called Maximum Allowable
dust is harmful.
Concentration (M.A.C.). This is the concentration which can be tolerated by
a healthy worker for 8 hours a day without adverse effects. The lower the
figure, the more toxic the substance.
The concentrations are given either as parts per million (ppm), i.e. cm³ of
vapour per m³ of air, or for solid dusts as mg per m³. The minimum volume
for air required to achieve this safe level of concentration will be given in our
data sheets. This volume may in some cases be as much as 20 times that
required to reach 10% of LEL and in some classes of work it may be
impractical to supply the volume of air required to allow the required rate of
usage of paint in the compartment. In such cases it is essential that
operators are supplied with, and required to use, fresh air masks or
respirators fed with clean air at positive pressure. It is important that the
mask has a good facial fit. See also sheet 1431.
Paint contains heavy toxic
Keep skin covered as far as possible, wear gloves and protect the eyes.
substances and is dangerous. Avoid contamination of the skin. Provide very good ventilation and wear
fresh air mask. Change all overclothes and shoes immediately after finishing
the work. Keep dirty cloths and other objects separate, destroy or clean
contaminated clothes with care. Wash the hands very thoroughly.
Handle empty containers with care and avoid contamination of the
environment with any poisonous paint or waste.
THE SIGMA WARNING SYSTEM will show one, or a combination of more than one, of the described
sentences. The safety code required in each country will be added to drums used in that country.
Limitation of Liability - The information in this data sheet is based upon laboratory tests we believe to be accurate and is
intended for guidance only. All recommendations or suggestions relating to the use of the Sigma Coatings products made by PPG
Protective & Marine Coatings, whether in technical documentation, or in response to a specific enquiry, or otherwise, are based
on data which to the best of our knowledge are reliable. The products and information are designed for users having the requisite
knowledge and industrial skills and it is the end-user's responsibility to determine the suitability of the product for its intended
use.
PPG Protective & Marine Coatings has no control over either the quality or condition of the substrate, or the many factors
affecting the use and application of the product. PPG Protective & Marine Coatings does therefore not accept any liability arising
from loss, injury or damage resulting from such use or the contents of this data sheet (unless there are written agreements
stating otherwise).
The data contained herein are liable to modification as a result of practical experience and continuous product development.
This data sheet replaces and annuls all previous issues and it is therefore the user’s responsibility to ensure that this sheet is
current prior to using the product.
page 3/3
INFORMATION
SAFETY IN CONFINED SPACES AND HEALTH SAFETY
EXPLOSION HAZARD - TOXIC HAZARD
a five page issue
1431
October 1999
revision of 1-1995
When paints containing solvents are applied in enclosed or confined spaces, two hazards can exist,
explosion and toxicity and precautions must be taken to eliminate them.
General aspects of explosion hazards
The nature of this hazard is explained in detail below. The essential precaution to be taken is that sufficient
ventilation air must be provided to maintain the ratio of vapour/air at no more than 10% of the lower
explosive limit. The method for calculation is given below and data on minimum ventilation air quantity is
given in product data sheets. If the flash point of the solvent is above the working temperature, then an
explosion cannot occur. However, it may still be necessary to ventilate to provide a clean working
atmosphere or to eliminate toxic hazard.
An explosion is simply very rapid burning of a flammable mixture (in the case of paint, it is the burning of
solvent vapour in oxygen contained in the air). The speed of combustion is so great that there is extremely
rapid development of heat and pressure (6 to 9 times the original pressure). This can lead to destruction of
the compartment and injury to work people. Three factors must be present to create an explosion.
a. The mixture of vapour and air must be between the lower explosive limit (LEL) and the upper explosive
limit.
b. The mixture must be at a temperature above the flash point temperature of the vapour.
c. A source of ignition with high enough temperature and energy must be present to initiate the explosion
reaction.
These three factors explain the reasons for the safety precautions.
Ventilation to provide an atmosphere below LEL
It is usual to specify that ventilation should be provided to reduce vapour concentration to less than 10% of
LEL. This large safety margin is required to allow for variations in ventilation in all parts of a compartment.
(P x A) + (Q x B)
The minimum ventilation air in m³ per minute may be calculated from the formula:
t
Calculation
P
Q
A
B
t
=
=
=
=
=
volume of paint applied in the compartment in litres during time t minutes.
volume of added solvent used in the paint applied in the compartment in litres in time t minutes.
ventilation air quantity for 1 litre of paint to reach 10% LEL.
ventilation air quantity for 1 litre of solvent to reach 10% LEL.
time of application in minutes of volume P of paint.
page 1/5
INFORMATION
SAFETY IN CONFINED SPACES AND HEALTH SAFETY
EXPLOSION HAZARD - TOXIC HAZARD
1431
October 1999
Example
100 litres of paint (P) plus 5 litres of thinner (Q) are used within 45 minutes (t).
Value A is e.g. 60 m³ (given in product data sheet).
Value B is e.g. 130 m³ (given in product data sheet).
Ventilation air quantity m³ per minute to reach 10% LEL is:
(100 x 60) + (5 x 130) = 147.7 m³ per minute.
45
Remarks
This quantity of ventilation air must be maintained throughout the application of the paint and also during
the period of evaporation of solvent.
The ventilation must be arranged so that all parts of the compartment are properly ventilated. It is necessary
for the applicator or the contractor to check vapour concentrations (in varying positions) regularly with an
explosion meter. If the concentration rises above 10% LEL, painting must stop until the vapour
concentration is reduced to a safe level again.
Flash point
If possible paints with flash points above the ambient temperature should be used. This often is not
possible, particularly in compartments heated up by strong sunlight in summer. In such cases it is even
more essential that ventilation below 10% LEL is maintained.
Sources of ignition
Sparks, hot surfaces, flames and all other sources of ignition must be absolutely prevented. Flame proof
lighting and electrical equipment must be used, spark proof tools and clothing should be used and all work
must be prohibited in adjacent compartments. All equipment, whether electrical or not electrical
(e.g. pneumatic pumps, spray tips, etc.) must be adequately earthed to ensure no accumulation of static
electrical charge.
TOXIC HAZARD
page 2/5
INFORMATION
SAFETY IN CONFINED SPACES AND HEALTH SAFETY
EXPLOSION HAZARD - TOXIC HAZARD
1431
October 1999
General aspects of toxic hazard
Many solvents used in paint have some degree of toxicity and it is necessary to provide sufficient ventilation
air to maintain safe atmosphere below the threshold limit value (TLV). With many common solvents this may
be impractical when applying large volumes of paint in a short time. In such cases ventilation to give a clear
visibility and safety from explosion will still be necessary. It will also be necessary to provide operators in
the compartment with fresh air masks or hoods. Barrier creams and protective clothing may also be
necessary. Full details are given below and data for calculation of RAQ (required air quantity) are also
provided.
It is necessary to keep certain rules when using any paint since all can be harmful (even ordinary emulsion
paints are dangerous if swallowed!). The following are basic safety precautions:
Inhalation of dust and fumes
This must be avoided by the use of ventilation or extraction.
– products should be used in well ventilated areas
– forced ventilation or fresh air masks should be used in confined spaces
– a face mask should be worn when spraying, sanding or blast cleaning
Skin contact
Some substances used in paint may cause irritation after repeated or prolonged contact with the skin and in
susceptible cases there is a risk of dermatitis.
– operatives with a history of skin sensitivity should not be employed in processes where skin contact can
occur
– prolonged or repeated contact of paint with the skin should be avoided
– barrier cream should be supplied and used
– gloves should be worn
– do not wash hands with solvent
– use a proprietary hand cleanser
Ingestion
The ingestion (swallowing) of paint must always be avoided.
– food should not be brought into or consumed in the work area where coatings are stored or used
– thorough washing of hands and face is essential after applying paint, particularly before eating or
smoking
– if paint or thinners should accidently be swallowed, seek medical attention immediately
page 3/5
INFORMATION
SAFETY IN CONFINED SPACES AND HEALTH SAFETY
EXPLOSION HAZARD - TOXIC HAZARD
1431
October 1999
Eye protection
Steps should be taken to prevent material entering the eyes.
– goggles should be worn whenever necessary
– if the eyes become contaminated they should be irrigated with water; seek medical attention
immediately
Theoretical ventilation requirements
In the product data sheets, data are given for the minimum required ventilation air quantity (RAQ) in cubic
metres when 1 litre of paint is applied or when 1 litre of thinner is used. The TLV (=threshold limit value) for
the mixture of components and solvents in the paint or for the mixture of solvents used in thinners has been
calculated.
Calculation
The quantity of ventilation air required in m³ per minute during application and drying can be calculated
from the formula:
(P x M) + (Q x N)
t
P
Q
M
N
t
=
=
=
=
=
quantity of paint consumed in litres.
quantity of thinner consumed in litres.
min. ventilation air quantity needed to reach TLV of 1 litre of paint.
min. ventilation air quantity needed to reach TLV of 1 litre of thinner.
application time in minutes.
Example
100 litres of paint (P) are consumed in 45 minutes (t). 5 Litres of thinner (Q) were added to thin down the
paint to the prescribed application viscosity. Value M is e.g. 780 m³ (see product data sheet).
Value N is e.g. 2170 m³ (see product data sheet).
The ventilation air quantity required during application and drying to reach TLV is:
(100 x 780) + (5 x 2170) = 1974 m³ per minute
45
Remarks
In semi-confined areas such as rooms with open doors and windows or the super structure of a ship,
natural ventilation will be about 2 to 5 times the content of the room or space per hour, depending on
weather conditions.
The amount of fresh air necessary to reach TLV will be approximately 10 to 20 times the amount of fresh air
necessary to reach 10% of LEL. When it is impractical to ventilate in such a way that TLV is not reached
then fresh air masks must be used.
page 4/5
INFORMATION
SAFETY IN CONFINED SPACES AND HEALTH SAFETY
EXPLOSION HAZARD - TOXIC HAZARD
1431
October 1999
Emergency procedure
It may be necessary to enter an atmosphere which is unsafe. (You may have to rescue somebody). Before
entering a confined space or tank ensure that:
– you wear breathing apparatus
– you wear a lifeline
– the lifeline is properly tended
– a watch is kept on you
– a means of communication exists
– a system of signals is agreed
– you and everybody else involved understand the signals
You must also make sure that:
– a back-up or rescue squad is equipped to render assistance
– resuscitation equipment is on hand
If you have to keep watch or tend a lifeline:
– keep a careful watch on your men below
If you cannot see them:
– call out to them from time to time
– make sure they answer
If they do not answer repeated calls or if they show signs of drunkenness or unusual behaviour:
– RAISE THE ALARM IMMEDIATELY
– DO NOT ATTEMPT TO RESCUE THE VICTIM BY YOURSELF
– DO NOT BECOME A VICTIM
Limitation of Liability - The information in this data sheet is based upon laboratory tests we believe to be accurate and is
intended for guidance only. All recommendations or suggestions relating to the use of the Sigma Coatings products made by PPG
Protective & Marine Coatings, whether in technical documentation, or in response to a specific enquiry, or otherwise, are based
on data which to the best of our knowledge are reliable. The products and information are designed for users having the requisite
knowledge and industrial skills and it is the end-user's responsibility to determine the suitability of the product for its intended
use.
PPG Protective & Marine Coatings has no control over either the quality or condition of the substrate, or the many factors
affecting the use and application of the product. PPG Protective & Marine Coatings does therefore not accept any liability arising
from loss, injury or damage resulting from such use or the contents of this data sheet (unless there are written agreements
stating otherwise).
The data contained herein are liable to modification as a result of practical experience and continuous product development.
This data sheet replaces and annuls all previous issues and it is therefore the user’s responsibility to ensure that this sheet is
current prior to using the product.
page 5/5
INFORMATION
DIRECTIVES FOR VENTILATION PRACTICE
a two page issue
1434
October 1999
revision of 1-1995
Ventilation is required for reasons of health and safety. In addition for solvent containing coatings the quality
of a coating system is greatly affected by the amount and type of residual solvent in the layer when the
coating dries or cures.
Adhesion, water resistance, mechanical and chemical properties can all be adversely affected when
solvents remain trapped in the paint film. Very slow evaporation of trapped solvents can also develop
internal stresses due to shrinkage.
The ventilation must be maintained throughout the application process at a minimum level of 10% of LEL
value and for a period after application is completed when the paint cures or dries. As a guide line for good
ventilation after application the confined space should be ventilated 4 to 5 times its contents per hour.
Product data sheets indicate when any special ventilation requirements are required.
Hot ventilation: Ventilating air with too high temperature can cause surface curing of epoxy coatings and
although it may be necessary to produce a dry substrate before painting, the steel and air temperature
should be such that when the application starts, the temperature of the ventilation (dehumidifier/heater)
should be dropped so that the conditions stay stable. Hot ventilation air should be replaced by cool dry
ventilation air as soon as possible after application of any coat is completed.
Good ventilation consists of at least extraction at the lowest areas, but in most cases when controlled
conditions are needed, also of air input (dry and/or heated). The combination of in and output must be
correctly balanced.
The opening of the extraction hose should be close to the bottom of the tank (approx 30-60 cm).
Ventilation air should be directed to the bottom of the tank or compartment and should be extracted by
exhaust fans of correctly balanced capacity.
For complex structures the ventilation should be distributed over all compartments and confined spaces in
order to facilitate good ventilation in all areas.
BALLAST TANKS AND OTHER CONFINED SPACES.
Due to regulations of the shipbuilding industry ballast tanks and double skin tanks count for many square
meters confined spaces. Therefore it is necessary to pay good attention to the ventilation conditions during
application, drying and curing of the coating on these areas.
Depending on the structure of the ballast tanks, forced ventilation or natural ventilation is used during
coating of the new building blocks.
However, natural ventilation in many cases is not sufficient due to half open box conditions and can cause
serious drawbacks related to health and safety as well as curing and performance of the coating.
When ventilation is not sufficient solvents will not be removed, but will drift to the lower part of the section.
As normally first the upperparts of a section will be painted, the solvents evaporating from the applied
coating will drift to the lower part where it will attack the earlier applied coating (not yet fully cured) and this
coating will absorb part of the solvents and swell. This coating will then be overcoated and problems related
to bad adhesion, curing, water resistance etc. will result.
In case of waterborne paints, this advice is not valid. Water vapour rises to the upper areas of the tank and
may give condensation. Therefore it is recommended to position an extra exhaust outlet at the top of the
tank.
page 1/2
INFORMATION
DIRECTIVES FOR VENTILATION PRACTICE
1434
October 1999
Also in this case ventilation is of utmost importance as drying under insufficient ventilation will prevent paint
film formation.
Practices recommended
Limitation of Liability - The information in this data sheet is based upon laboratory tests we believe to be accurate and is
intended for guidance only. All recommendations or suggestions relating to the use of the Sigma Coatings products made by PPG
Protective & Marine Coatings, whether in technical documentation, or in response to a specific enquiry, or otherwise, are based
on data which to the best of our knowledge are reliable. The products and information are designed for users having the requisite
knowledge and industrial skills and it is the end-user's responsibility to determine the suitability of the product for its intended
use.
PPG Protective & Marine Coatings has no control over either the quality or condition of the substrate, or the many factors
affecting the use and application of the product. PPG Protective & Marine Coatings does therefore not accept any liability arising
from loss, injury or damage resulting from such use or the contents of this data sheet (unless there are written agreements
stating otherwise).
The data contained herein are liable to modification as a result of practical experience and continuous product development.
This data sheet replaces and annuls all previous issues and it is therefore the user’s responsibility to ensure that this sheet is
current prior to using the product.
page 2/2
INFORMATION
CLEANING OF STEEL AND REMOVAL OF RUST
an eight page issue
DERUSTING METHODS
1490
June 2007
revision of January 2007
The effective life time of a coating applied onto a steel surface is dependent
to a very large extent on how thoroughly the surface has been prepared
prior to painting.
Surface preparation consists of primary surface preparation which aims to
remove mill scale, rust and foreign matter from a steel surface prior to the
application of a shop primer (prefabrication primer) or primer.
Secondary surface preparation aims to remove rust and foreign matter,
if any, from a steel surface coated with a shop primer (prefabrication primer)
or primer prior to application of the anticorrosive paint system.
A steel surface can be derusted in the following ways.
Wire brushing
Wire brushing, usually done with rotating wire brushes, is a conventional
method, not suitable for the removal of mill scale, but suitable for the
preparation of weld seams. The main disadvantage is, that treated surfaces
are often not completely free of corrosion products and tend to become
polished and contaminated with oil. This decreases the adhesion of priming
paints and the performance of a paint system.
Chipping
Chipping or mechanical chipping is usually done in combination with wirebrushing. It is sometimes suitable for local repairs with conventional or
special formulated paint systems. It is not suitable for general preparation of
surfaces to be coated with epoxy or chlorinated rubber paints. It can be
used for the removal of thick rust scale and economises in later blasting
operations.
Needle hammer
To remove rust, paint etc. from corners and angles in order to achieve a
cleaned surface with a profile.
Flame cleaning
Flame cleaning involves derusting by thermal treatment making use of
burning equipment (acetylene or propane and oxygen). It removes almost all
mill scale, but rust to a lesser extent. Therefore this method cannot meet the
requirements of modern paint systems.
Disc sanding
Disc sanding involves use of rotating discs covered with abrasive material.
It is used for local repairs. The quality of these discs has been very much
improved, and these can give good standards of preparation.
page 1/8
INFORMATION
CLEANING OF STEEL AND REMOVAL OF RUST
1490
June 2007
Sweep blasting
A hand operated form of superficial blast cleaning in which a primed or
coated steel surface is roughened and is free of almost all visible
contamination. (except oil contamination or traces of rust)
A: light sweep, purpose: roughening of intact coating and improving the
adhesion of subsequent coats
Abrasive: fine (0,2-0,5 mm) is most suitable when the paint surface
under treatment is not to be destroyed
B: heavy sweep (approx ISO-Sa1), purpose: removing of not sound coating
areas - layers
Abrasive: small to medium (0,2-0,5/0,2-1,5 mm)
Reference: Repainting of old metallic structures, limited blast cleaning scale
Technical Guide, November 1993
Laboratoire Central des Ponts et Chaussées 58,
bd Lefebvre, F 75732 Paris Cedex 15
Dry blast cleaning
The impingement of a high kinetic energy stream of abrasive onto the
surface to be prepared. It is either hand operated by jet or automatically by
impeller and is the most thorough method of derusting. Centrifugal blast
cleaning, compressed air blast cleaning and vacuum blast cleaning are well
known types.
Shot
The particles are as far as practical spherical and solid and should not
contain more than the minimum practical amount of ‘tails’ and irregular
shapes.
Primers to be used for shot blasted steel should be checked on
performance.
Grit
The particles show good angularity form with sharp cutting edges and
should be substantially free from ‘half-rounds’ (i.e. shot split in half).
Unless otherwise stated in the specifications a mineral grit should be used.
page 2/8
INFORMATION
1490
CLEANING OF STEEL AND REMOVAL OF RUST
June 2007
Water (abrasive)
cleaning/jetting
(Terminology NACE)
Different types of water (abrasive) cleaning/jetting are in use
Below you will find the most commonly used ones
For more info see also information sheet 1498 (Hydrojetting)
Water (abrasive)
blast cleaning
Some examples of these techniques are given below, not pretending to be
complete. New developments with wet blasting methods are presented
regularly, improving the efficiency and reducing the amount of water or grit.
– LOW PRESSURE WATER ABRASIVE BLAST CLEANING
Pressure = 6-8 bar
Water consumption = 90-300 l/hour
Cleaning speed = 10-16 m²/hour, depending on material to be removed
Result: a surface cleanliness and blasting profile as required can be
obtained.
– LOW PRESSURE HUMIDIFIED ABRASIVE BLAST CLEANING
Pressure = 6-8 bar
Water consumption = 5-60 l/hour
Cleaning speed = 10-16 m²/hour, depending on material to be removed
Result: a surface cleanliness and blasting profile as required can be
obtained.
– ULTRA HIGH PRESSURE WATER JETTING (UHPWJ)
Pressure - more than 1700 bar
Use: Complete removal of all coatings and rust.
The result can be compared with dry abrasive blast cleaning, but with
flash rust after drying.
The original blasting profile will be maintained.
– HIGH PRESSURE WATER JETTING (HPWJ)
Pressure - from 700 to 1700 bar
Use: Most paints and corrosion products will be removed, Magnetite and
hard tightly adherent coating may be left but can be removed with
difficulty.
The original blasting profile will be maintained.
page 3/8
INFORMATION
CLEANING OF STEEL AND REMOVAL OF RUST
1490
June 2007
Water cleaning
– LOW PRESSURE WATER CLEANING (LPWC)
Pressure - lower than 350 bar
Use: Removal of salt, dirt and poorly adherent surface contamination.
Mainly washing of surface
– HIGH PRESSURE WATER CLEANING (HPWC)
Pressure - from 350 to 700 bar
Use: Loose paint, rust, debris and material in pits will be removed, but
black iron oxide (Magnetite) will remain. A uniform matte finish
cannot be achieved.
– STEAM CLEANING
Pressure = 100-120 bar
Use: Removal of water soluble or water emulsified contamination; the
substrate dries quicker compared to a water rinsed substrate.
ISO STANDARDS
When specifying a precise degree of derusting and cleaning of a steel
surface prior to painting, Sigma uses the ISO standard
ISO 8501-1-1988 and ISO 8504-1992.
ISO 8501-1
This indicates the following rust grades:
Applicable to bare
mill-scaled or rusty steel
A = steel surface largely covered with adherent mill
scale but little, if any, rust.
B = steel surface which has begun to rust and from which the mill scale
has begun to flake.
C = steel surface on which the mill scale has rusted away or from which
it can be scraped, but with slight pitting visible when viewed
normally.
D = steel surface on which the mill scale has rusted away and on which
general pitting is visible when viewed normally.
page 4/8
INFORMATION
CLEANING OF STEEL AND REMOVAL OF RUST
1490
June 2007
DEGREES OF PRIMARY
SURFACE PREPARATION
The ISO standard indicates six preparation degrees.
The following standards are often used in specifications:
ISO-St
Hand and power tool
cleaning
Surface preparation by hand and power tool cleaning, such as scraping,
wire-brushing, machine-brushing and grinding, is designated by the letters
‘St’.
Prior to hand and power tool cleaning, any heavy layers of rust shall be
removed by chipping. Visible oil, grease and dirt shall also be removed.
After hand and power tool cleaning, the surface shall be cleaned from loose
dust and debris.
ISO-St2
Thorough hand and
power tool cleaning
When viewed without magnification, the surface shall be free from visible
oil, grease and dirt, and from poorly adhering mill scale, rust, paint coatings
and foreign matter.
ISO-St3
Very thorough hand
and power tool cleaning
As for St2, but the surface shall be treated much more thoroughly to give a
metallicsheen arising from the metallic substrate.
ISO-Sa
Blast cleaning
Surface preparation by blast cleaning is designated by the letters ‘Sa’.
Prior to blast cleaning, any heavy layers of rust shall be removed by
chipping. Visible oil, grease and dirt shall also be removed.
After blast cleaning, the surface shall be cleaned from loose dust and
debris.
ISO-Sa1
Light blast cleaning
When viewed without magnification, the surface shall be free from visible
oil, grease and dirt, and from poorly adhering mill scale, rust, paint coatings
and foreign matter.
ISO-Sa2
Thorough blast cleaning
When viewed without magnification, the surface shall be free from visible
oil, grease and dirt and from most of the mill scale, rust, paint coatings and
foreign matter. Any residual contamination shall be firmly adhering.
ISO-Sa2½
Very thorough blast
cleaning
When viewed without magnification, the surface shall be free from visible
oil, grease and dirt and from mill scale, rust, paint coatings and foreign
matter. Any remaining traces of contamination shall show only as slight
stains in the form of spots or stripes.
ISO-Sa3
blast cleaning to
visually clean steel
When viewed without magnification, the surface shall be free from visible
oil, grease and dirt and shall be free from mill scale, rust, paint coatings
and foreign matter. It shall have a uniform metallic colour.
page 5/8
INFORMATION
1490
CLEANING OF STEEL AND REMOVAL OF RUST
June 2007
Remark
The photographs in the ISO Standard publication are given as illustration
only. They do not represent the complete preparation degree, which also
includes a cleaning operation which is not visible in the photographs.
(colourless contamination).
Equivalents
As far as blast cleaning is concerned, equivalents according to British and
American standards are given in the following table.
ISO 8501-01
Sa3
Sa2½
Sa2
BS 4232
SSPC-Vis 1 *
1st quality
2nd quality
3rd quality
White metal
Near white
Commercial
SP 5
SP 10
SP 6
* for more details
see SSPC-SP com
Roughness of
blast cleaned steel
To specify the roughness, a variety of values is used.
Such as Rz, Rt and Ra.
Rz = average peak to valley height = blasting profile
Rt = maximum peak to valley height
Ra = average distance to an imaginary centre line which can be drawn
between peaks and valleys = C.L.A. = Centre Line Average (ISO 3274)
Normally Sigma Coatings uses Rz values.
Blasting Profile (Rz) = 4 to 6 times C.L.A. (Ra).
The direct measuring of the dft of primers applied onto blast cleaned steel in
a thickness up to 30 µm is very inaccurate. A primer dft of 30 µm and more
gives an average thickness and not the thickness present on the peaks.
When in the specifications blast cleaning to ISO-Sa2½ is mentioned a
blasting profile Rz of 35-50 µm should be obtained using mineral grit unless
otherwise mentioned.
Above a Ra roughness of 17 µm (= blasting profile Rz of 100 µm) it is
recommended to use an additional coat of primer to cover the roughness.
A roughness profile above 100 µm often results if heavily rusted steel is
blast cleaned.
JAPANESE STANDARDS
Standard for the preparation
of steel surface prior to
painting SPSS-1984
These establish a systematic standard for secondary surface preparation
prior to protective painting when shop primers (prefabrication primers) are
used in the construction process of hull or steel structures.
page 6/8
INFORMATION
1490
CLEANING OF STEEL AND REMOVAL OF RUST
June 2007
Surface condition
H
A
F
D
R
=
=
=
=
=
shop primed steel surface in way of hand welding
shop primed steel in way of automatic welding
shop primed steel surface in way of gas-burning
shop primed steel surface having white zinc salt
shop primed steel surface having rust in the form of spots
GRADES OF SECONDARY
SURFACE PREPARATION
The Japanese Standard indicates six preparation degrees.
The following standards are often used in specifications.
SPSS-Pt2
Surface prepared by wire brushing for the surface condition A, D and R,
by wire brushing and disc sander for the surface condition H,
by disc sander for the surface condition F. Almost all rust and foreign
matter are fairly removed.
If mentioned for other surface conditions (e.g. primed or coated steel),
almost all rust and foreign matter, have to be removed by wire brushing
and/or disc sander.
SPSS-Pt3
Surface prepared by wire brushing and (in combination with!)
disc sander for the surface condition H and A
and by disc sander for the surface condition F, R and D.
Rust and foreign matter are removed to the extent that the surface has a
uniform metallic sheen.
If mentioned for other surfaces conditions (e.g. primed or coated steel) all
rust and foreign matter has to be removed to the extent that the surface has
a uniform metallic sheen.
Also used for the preparation of primed or coated substrate to remove rust
from small areas such as scratches, pinpoints or areas of mechanical
damage.
SPSS-Ss
Surface prepared by light blast cleaning of slug sands or grits.
(Shop primer (prefabrication primer) with the little trace of rust is
noticeable.)
Also used for the preparation of a primed or coated substrates or galvanized
steel to roughen the surface and to remove contamination or traces of rust.
Remarks
In the Japanese Standard the expressions Sd2 and Sd3 are used, which are
equivalent to the Swedish expressions Sa2 and Sa3.
ISO 8501-3
Grade P2
Preparation grades of welds, cut edges and other area with surface
imperfections.
See illustrations in the standard
page 7/8
INFORMATION
1490
CLEANING OF STEEL AND REMOVAL OF RUST
June 2007
Degree of cleanliness
The ISO and the Japanese Standards give a visual impression of the quality
of the derusted steel. However, chemical contamination like water soluble
salts etc. are not visible and remains partly on the surface. Presence of
excessive amounts of water soluble salts can cause blistering of the coating
by osmosis.
Water soluble salts in mineral abrasives.
For tankcoatings the maximum value of water soluble salts in mineral
abrasives is 250 µS/cm (conductivity) (ISO 11127-6 1993).
See further sheet 1491
Water soluble salts on the steel surface (ISO 8502-9 1998).
Our maximum acceptable levels of water soluble salts, calculated as sodium
chloride, on treated substrate prior to coating application depends on the
area and expected service conditions.
equivalent sodium chloride
conductivity (V=15 ml)
60 mg/m²
80 mg/m²
100 mg/m²
(10.0 µS/cm)
(13.3 µS/cm)
(16.7 µS/cm)
Cargo tanks
Immersed areas
Dry cargo holds
Note
Determination of water soluble salts: see information sheet 1468
For water ballast tank areas to be treated in accordance with IMO
resolution MSC 215(82): water soluble salts limit equivalent to sodium
chloride after blasting/grinding must be equal to or lower than 50 mg/m² of
sodium chloride.
For areas exposed to atmosphere conditions We recommend the limit
per dry cargo holds as noted in the table. Prior to treatment the substrate
should be High Pressure Washed with Fresh (clean) water.
As a guidance we recommend that the conductivity of abrasives prior to
treatment should not be higher than 250 µS/cm.
REFERENCES
Determination of water soluble salts according to the
Bresle method (ISO 8502-6 1995)
Specification for mineral abrasives
Hydrojetting
see information sheet 1468
see information sheet 1491
see information sheet 1498
Limitation of Liability - The information in this data sheet is based upon laboratory tests we believe to be accurate and is
intended for guidance only. All recommendations or suggestions relating to the use of the Sigma Coatings products made by PPG
Protective & Marine Coatings, whether in technical documentation, or in response to a specific enquiry, or otherwise, are based
on data which to the best of our knowledge are reliable. The products and information are designed for users having the requisite
knowledge and industrial skills and it is the end-user's responsibility to determine the suitability of the product for its intended
use.
PPG Protective & Marine Coatings has no control over either the quality or condition of the substrate, or the many factors
affecting the use and application of the product. PPG Protective & Marine Coatings does therefore not accept any liability arising
from loss, injury or damage resulting from such use or the contents of this data sheet (unless there are written agreements
stating otherwise).
The data contained herein are liable to modification as a result of practical experience and continuous product development.
This data sheet replaces and annuls all previous issues and it is therefore the user’s responsibility to ensure that this sheet is
current prior to using the product.
page 8/8
INFORMATION
SPECIFICATION FOR MINERAL ABRASIVES (ISO 11126)
a two page issue
1491
June 2007
revision of October1999
SCOPE
This specification covers mineral abrasives such as corundum, aluminium silicate slag, or any slag mixtures
which are suitable for removing rust, scale, old paint or shop primer from steel by blast cleaning and giving
a satisfactory anchor pattern.
This specification covers only those abrasives commonly known as utility grades.
REQUIREMENTS
Material – The abrasive may be any material meeting the requirements of this specification. It shall be
composed of clean, sound, hard particles free from foreign substances such as dirt, oil, grease, toxic
substances, organic matter and water soluble salts.
The abrasive supplier shall certify that any product to be delivered conforms to all requirements stated
herein.
pH – 100 gram of a representative abrasive sample is crushed using a mortar and pestle. Approximately 50
grams of the crushed sample is added to 200 ml de-ionized water. The pH of this slurry is then determined
through the use of an electronic pH meter with an accuracy of ± 0.01 pH unit.
A slurry mixture prepared in this way shall not have a pH below 6.20.
Water Soluble Salts (ISO 11127-6 1993) – The abrasive is mixed with de-ionized water, conductivity max.
1 µS/cm, in the proportion 1:1, e.g. 100 g abrasive to 100 cm³ water. The mixture is shaken for 5 minutes,
allowed to settle for at least 1 hour and then shaken again for 5 minutes. Some of the water is decanted, the
temperature is recorded and the conductivity measured by a conductivity gauge.
If the conductivity gauge does not have any temperature compensation adjustment, the conductivity should
be converted to 20°C or measurement should be carried out at this temperature.
If the conductivity exceeds 250 µS/cm the abrasive is rejected.
If the abrasive is to be used for High Pressure Wet Abrasive Blastcleaning the total amount of water soluble
matter should be below 0,5% by weight.
Moisture Content – Approximately 200 grams of abrasive shall be weighed to the nearest 0.1 g in a tared
weighing dish and dried at 105 to 110°C for 3 hours or more until successive weighings after additional 1
hour heating periods show a weight change of not more than 0.1%. The percentage of moisture is
calculated as follows:
percent moisture = original weight - final weight x 100
original weight of sample
The moisture content for material deliverd in bags or in bulk shall not exceed 0.5% by weight.
Oil and Grease – The abrasive shall not be contaminated with oil and grease. 10 cm³ abrasive is shaken
with 10 cm³ methylene chloride for about 5 minutes. 5 drops of the solvent are applied to a clean glass
plate. After complete evaporation of the solvent the glass plate is exposed to ultraviolet light in total
darkness.
If there is blue fluorescence the abrasive is rejected.
page 1/2
INFORMATION
SPECIFICATION FOR MINERAL ABRASIVES (ISO 11126)
1491
June 2007
Hardness – Examine the abrasive material under a low-power microscope (10 x) and, if grains of different
colour or character are present, select a few grains of each. Separately place the grains thus differentiated
between two glass microscope slides. While applying pressure, slowly move one slide over the other with a
reciprocating motion for 10 seconds. Examine the glass surface and, if scratched, the material shall be
considered as having a minimum hardness of 6 on Moh’s scale. If any grains that fail to scratch glass are
present, in any appreciable quantity, the total batch is rejected.
Grain Shape – The individual abrasive grains shall be angular in shape.
Surface Profile – The abrasive material shall produce a prescribed blasting profile Rz value (varying
between 30-100 µm)
Limitation of Liability - The information in this data sheet is based upon laboratory tests we believe to be accurate and is
intended for guidance only. All recommendations or suggestions relating to the use of the Sigma Coatings products made by PPG
Protective & Marine Coatings, whether in technical documentation, or in response to a specific enquiry, or otherwise, are based
on data which to the best of our knowledge are reliable. The products and information are designed for users having the requisite
knowledge and industrial skills and it is the end-user's responsibility to determine the suitability of the product for its intended
use.
PPG Protective & Marine Coatings has no control over either the quality or condition of the substrate, or the many factors
affecting the use and application of the product. PPG Protective & Marine Coatings does therefore not accept any liability arising
from loss, injury or damage resulting from such use or the contents of this data sheet (unless there are written agreements
stating otherwise).
The data contained herein are liable to modification as a result of practical experience and continuous product development.
This data sheet replaces and annuls all previous issues and it is therefore the user’s responsibility to ensure that this sheet is
current prior to using the product.
page 2/2
INFORMATION
RELATIVE HUMIDITY - SUBSTRATE TEMPERATURE AIR TEMPERATURE
a four page issue
1650
October 1999
revision of 1-1995
RELATIONSHIP BETWEEN (VENTILATION) AIR-TEMPERATURE, SUBSTRATE TEMPERATURE AND
RELATIVE HUMIDITY
To achieve optimum results in coating work it is essential to ensure that no condensation occurs on the
substrate or in-between coats during the painting process. Air at a given temperature can only contain a
certain (maximum) amount of water vapour. This amount is lower at lower temperatures.
The maximum water content of air at different temperatures is given in the next table:
Degrees Centigrade
Maximum water content g/m³
0
5
10
15
20
25
30
35
40
45
4,8
6,8
9,5
12,8
17,3
23,0
30,4
39,6
51,1
65,0
From these figures the relationship between dew point, air temperature and relative humidity can be
calculated. This relationship is given in the next table:
Relation between dew point, air temperature and relative humidity
Air
Temperature
°C
50%
55%
60%
65%
70%
75%
80%
85%
90%
5
6
7
8
9
10
11
12
13
14
15
–4.1
–3.2
–2.4
–1.6
–0.8
0.1
1.0
1.9
2.8
3.7
4.7
–2.9
–2.1
–1.3
–0.4
0.4
1.3
2.3
3.2
4.2
5.1
6.1
–1.8
–1.0
–0.2
0.8
1.7
2.6
3.5
4.5
5.4
6.4
7.3
–0.9
–0.1
0.8
1.8
2.7
3.7
4.6
5.6
6.6
7.5
8.5
0.0
0.9
1.8
2.8
3.8
4.7
5.6
6.6
7.6
8.6
9.5
0.9
1.8
2.8
3.8
4.7
5.7
6.7
7.7
8.6
9.6
10.6
1.8
2.8
3.7
4.7
5.7
6.7
7.6
8.6
9.6
10.6
11.5
2.7
3.7
4.6
5.6
6.6
7.6
8.6
9.6
10.6
11.5
12.5
3.6
4.5
5.5
6.5
7.5
8.4
9.4
10.4
11.4
12.4
13.4
Dew point in °C at a relative humidity of:
page 1/4
INFORMATION
RELATIVE HUMIDITY - SUBSTRATE TEMPERATURE AIR TEMPERATURE
1650
October 1999
Air
Temperature
°C
50%
55%
60%
65%
70%
75%
80%
85%
90%
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
5.6
6.5
7.4
8.3
9.3
10.2
11.1
12.0
12.9
13.8
14.8
15.7
16.6
17.5
18.4
7.0
7.9
8.8
9.7
10.7
11.6
12.5
13.5
14.4
15.3
16.2
17.2
18.1
19.1
20.0
8.3
9.2
10.2
11.1
12.0
12.9
13.8
14.8
15.7
16.7
17.6
18.6
19.5
20.5
21.4
9.5
10.4
11.4
12.3
13.3
14.2
15.2
16.1
17.0
17.9
18.8
19.8
20.8
21.7
22.7
10.5
11.5
12.4
13.4
14.4
15.3
16.3
17.2
18.2
19.1
20.1
21.1
22.0
22.9
23.9
11.6
12.5
13.5
14.5
15.4
16.4
17.4
18.4
19.3
20.3
21.2
22.2
23.2
24.1
25.1
12.5
13.5
14.5
15.5
16.4
17.4
18.4
19.4
20.3
21.3
22.3
23.2
24.2
25.2
26.2
13.5
14.5
15.4
16.4
17.4
18.4
19.4
20.3
21.3
22.3
23.3
24.3
25.2
26.2
27.2
14.4
15.3
16.3
17.3
18.3
19.3
20.3
21.3
22.3
23.2
24.2
25.2
26.2
27.2
28.2
Dew point in °C at a relative humidity of:
Using these figures curves can be drawn which give the relationship between air temperature, relative
humidity and dew point. (See graph).
To allow a sensible safety margin normally the substrate temperature must be at least 3 degrees centigrade
above the dew point. The dew point is the temperature of a given air-water vapour mixture at which
condensation starts, since at that temperature the maximum water content of the air is reached.
Many important conclusions can be drawn from the graph, e.g.:
– at a relative humidity of 85% the lowest acceptable substrate temperature is approximately equal to the
temperature of the (ventilation) air. For this reason outdoor paintwork must normally be carried out at a
relative humidity below 85%.
– at a relative humidity of 90% the difference in temperature between substrate and dew point will be only
2°C, which means that the safety margin is narrowed. This can be overcome by raising the substrate
temperature by approx. 1°C.
– at a relative humidity of 70% the relationship between the acceptable substrate temperature and the
temperature of the (ventilation) air is given by the following table:
air temperature °C
5
10
20
30
dew point °C
0,0
4,7
14,4
23,9
lowest acceptable substrate temperature °C
3,0
7,7
17,4
26,9
page 2/4
INFORMATION
RELATIVE HUMIDITY - SUBSTRATE TEMPERATURE AIR TEMPERATURE
1650
October 1999
Although the substrate temperatures given in this table are well below the temperature of the surrounding
air no condensation will occur under the stated prevailing conditions.
– if the lowest acceptable substrate temperature is for example 5°C and the temperature of the atmosphere
is also 5°C than the ventilation air can be heated and relative humidity will then be reduced according to
the following table:
air temperature °C
5
10
20
30
40
relative humidity %
85
60
32
18
11
In general reduction in temperature leads to risk of condensation.
For instance steel cooled down during the night will often show condensation and this will not evaporate
until the steel is heated up again by sunlight or other means.
Limitation of Liability - The information in this data sheet is based upon laboratory tests we believe to be accurate and is
intended for guidance only. All recommendations or suggestions relating to the use of the Sigma Coatings products made by PPG
Protective & Marine Coatings, whether in technical documentation, or in response to a specific enquiry, or otherwise, are based
on data which to the best of our knowledge are reliable. The products and information are designed for users having the requisite
knowledge and industrial skills and it is the end-user's responsibility to determine the suitability of the product for its intended
use.
PPG Protective & Marine Coatings has no control over either the quality or condition of the substrate, or the many factors
affecting the use and application of the product. PPG Protective & Marine Coatings does therefore not accept any liability arising
from loss, injury or damage resulting from such use or the contents of this data sheet (unless there are written agreements
stating otherwise).
The data contained herein are liable to modification as a result of practical experience and continuous product development.
This data sheet replaces and annuls all previous issues and it is therefore the user’s responsibility to ensure that this sheet is
current prior to using the product.
page 3/4
INFORMATION
RELATIVE HUMIDITY - SUBSTRATE TEMPERATURE AIR TEMPERATURE
1650
October 1999
page 4/4
PASSIVE FIRE PROTECTION
INFORMATION
PITT-CHAR XP FIRE PROTECTION CERTIFICATES
a four page issue
1897A
June 2010
PRODUCT NAME
a–
b–
c–
d–
INSTITUTE
DATE OF REPORT/REF.
VALIDITY
PRODUCT SHEET/REF.
CONCLUSION
Pitt-Char XP
a–
b–
c–
d–
Bureau Veritas
16-12-2009 / 21472/A0 BV
16-12-2014
7589
A-60 Bulkhead
Pitt-Char XP
a–
b–
c–
d–
Bureau Veritas
16-12-2009 / 21850/A0 BV
16-12-2014
7589
H-0, H-60, H-120 Bulkheads
Pitt-Char XP
a–
b–
c–
d–
Bureau Veritas
16-12-2009 / 21852/A0 BV
16-12-2014
7589
H-60, H-120 Decks
Pitt-Char XP
a–
b–
c–
d–
Bureau Veritas
27-01-2010 / 21853/A0 BV
27-01-2015
7589
Structural Steel “I”-Sections
Pitt-Char XP
a–
b–
c–
d–
Bureau Veritas
27-01-2010 / 21855/A0 BV
27-01-2015
7589
Structural Steel Hollow Sections
Pitt-Char XP
a–
b–
c–
d–
Bureau Veritas
16-03-2010 / 21856/A0 BV
16-03-2015
7589
Structural Steel Jet Fire Protection
Pitt-Char XP
a–
b–
c–
d–
Det Norske Veritas
17-09-2007 / F-18493
31-12-2011
7589
A-60 Bulkhead
Pitt-Char XP
a–
b–
c–
d–
Det Norske Veritas
23-11-1998
-7589
Statement: A-60 Underdeck
page 1/4
PASSIVE FIRE PROTECTION
INFORMATION
PITT-CHAR XP FIRE PROTECTION CERTIFICATES
1897A
PRODUCT NAME
a–
b–
c–
d–
INSTITUTE
DATE OF REPORT/REF.
VALIDITY
PRODUCT SHEET/REF.
CONCLUSION
Pitt-Char XP
a–
b–
c–
d–
Det Norske Veritas
26-10-2009 / F-19149
31-12-2013
7589
Class H-0, H-60, H-120 Bulkheads
Pitt-Char XP
a–
b–
c–
d–
Det Norske Veritas
26-10-2009 / F-19148
31-12-2013
7589
Class H-60, H-120 Underdecks
Pitt-Char XP
a–
b–
c–
d–
Det Norske Veritas
26-10-2009 / F-19147
31-12-2013
7589
Structural Fire Protection –
“I” Sections
Pitt-Char XP
a–
b–
c–
d–
Det Norske Veritas
26-10-2009 / F-19146”
31-12-2013
7589
Structural Fire Protection –
“Hollow” Sections
Pitt-Char XP
a–
b–
c–
d–
Lloyd’s Register
22-02-2010 / SAS F10059
21-02-2011
7589
Structural Steel Jet Fire Protection
Pitt-Char XP
a–
b–
c–
d–
Lloyd’s Register
22-02-2010 / SAS F10060
21-02-2011
7589
Structural Steel Hydrocarbon Fire
Protection – “I” Sections
(low section factor)
Pitt-Char XP
a–
b–
c–
d–
Lloyd’s Register
22-02-2010 / SAS F10062
21-02-2011
7589
Structural Steel Hydrocarbon Fire
Protection – “I” Sections
(high section factor)
Pitt-Char XP
a–
b–
c–
d–
Lloyd’s Register
22-02-2010 / SAS F10061
21-02-2011
7589
Structural Steel Hydrocarbon Fire
Protection – Hollow Sections
page 2/4
PASSIVE FIRE PROTECTION
INFORMATION
PITT-CHAR XP FIRE PROTECTION CERTIFICATES
1897A
June 2010
PRODUCT NAME
a–
b–
c–
d–
INSTITUTE
DATE OF REPORT/REF.
VALIDITY
PRODUCT SHEET/REF.
CONCLUSION
Pitt-Char XP
a–
b–
c–
d–
Lloyd’s Register
15-07-2008 / SAS F080162
14-07-2013
7589
A-60 Bulkhead
Pitt-Char XP
a–
b–
c–
d–
Lloyd’s Register
15-07-2008 / SAS F080163
14-07-2013
7589
Structural Steel Bulkhead
Pitt-Char XP
a–
b–
c–
d–
Lloyd’s Register
15-07-2008 / SAS F080164
14-07-2013
7589
H-60 & H-120 Deck
Pitt-Char XP
a–
b–
c–
d–
Lloyd’s Register
15-07-2008 / SAS F080161
16-07-2013
7589
H-60 & H-120 Bulkhead
Pitt-Char XP
a–
b–
c–
d–
Underwriters Laboratories
17-01-2000 / BXUV.N612
-7589
UL 263
Restrained Beam Rating – 4 h
Unrestrained Beam Rating – 3 h
Pitt-Char XP
a–
b–
c–
d–
Underwriters Laboratories
09-02-2006 / BYUV.XR612
-7589
UL 1709
“I” Sections, 1 to 3 h Ratings
Pitt-Char XP
a–
b–
c–
d–
Underwriters Laboratories
09-02-2006 / BXUV.X623
-7589
UL 263
“I” Sections, 1 to 3 h Ratings
Pitt-Char XP
a–
b–
c–
d–
Underwriters Laboratories
14-10-2003 / BXUV.X651
-7589
UL 263
Hollow Section, 3 h Rating
page 3/4
PASSIVE FIRE PROTECTION
INFORMATION
PITT-CHAR XP FIRE PROTECTION CERTIFICATES
1897A
June 2010
PRODUCT NAME
a–
b–
c–
d–
INSTITUTE
DATE OF REPORT/REF.
VALIDITY
PRODUCT SHEET/REF.
CONCLUSION
Limitation of Liability - The information in this data sheet is based upon laboratory tests we believe to be accurate and is
intended for guidance only. All recommendations or suggestions relating to the use of the coating products made by PPG
Protective & Marine Coatings, whether in technical documentation, or in response to a specific enquiry, or otherwise, are based
on data which to the best of our knowledge are reliable. The products and information are designed for users having the requisite
knowledge and industrial skills and it is the end-user's responsibility to determine the suitability of the product for its intended
use.
PPG Protective & Marine Coatings has no control over either the quality or condition of the substrate, or the many factors
affecting the use and application of the product. PPG Protective & Marine Coatings does therefore not accept any liability arising
from loss, injury or damage resulting from such use or the contents of this data sheet (unless there are written agreements
stating otherwise).
The data contained herein are liable to modification as a result of practical experience and continuous product development.
This data sheet replaces and annuls all previous issues and it is therefore the user’s responsibility to ensure that this sheet is
current prior to using the product.
page 4/4
PASSIVE FIRE PROTECTION
INFORMATION
PROTECTION OF STEEL FROM HYDROCARBON FIRES
PITT-CHAR XP Requirements for Applicator Training Courses
a three page issue
Day 1
Theoretical Training
− computer projector and screen
− white board or flip chart
− room suitable for number of candidates
Day 2
Practical Training
Equipment:
−
−
−
−
−
−
Services:
−
−
1203
January 2009
plural component type spray unit
and / or
single component spray pump (see separate specification)
CD stud welding machine
air agitator (for mixing material)
weighing scales (digital to 2 decimal places – range of 0 - 25 kg if possible)
all relevant airline hoses and electrical extension leads
−
air, for pump
electrical supply suitable for plural component type spray unit grinder and
stud welder etc.
fresh water supply
Consumables:
−
−
−
−
−
−
−
−
−
−
−
−
sections of blasted & primed steel (I-section, CHS and plate)
38 mm x 2 mm copper coated stud welding pins (approx. 100)
4” angle grinder (c/w grinding disc)
plasterers trowels (see sketch 1)
plasterers floats (see sketch 2)
7” medium pile lambswool rollers complete
4” radiator rollers complete
wire snips
basic hand tools (hammers, screwdrivers etc.)
masking materials
2 liter measuring jug
empty containers
Materials:
−
−
−
−
−
units of Pitt-Char XP (26.4 kg or 70 kg units depending on spray equipment)
Sigma Thinner 60-30 or 97-733 (thinning)
Sigma Thinner 90-53 (cleaning)
fibre glass and / or FM fabric mesh
wire mesh
page 1/3
PASSIVE FIRE PROTECTION
INFORMATION
PROTECTION OF STEEL FROM HYDROCARBON FIRES
PITT-CHAR XP Requirements for Applicator Training Courses
1203
January 2009
Pre-measuring and mixing of Pitt-Char XP for single component application
Weighing out of Pitt-Char XP if the product has been supplied in 70 kg units.
For single component application the kit size should be 26.4 kg.
To weigh out in the correct ratio (3.25 : 1) carry out the following procedure:
1.
2.
3.
4.
Use a clean container of 25 liter size, place on the scales and zero reading.
Pour the base component of Pitt-Char XP into a clean container until the scales read 20.2 kg.
As 1 above with another clean container
Pour the hardener component of Pitt-Char XP into a clean container until the scales read 6.2 kg.
The above will give, when mixed one 26.4 kg kit of Pitt-Char XP.
To premix for use as single component application, it is necessary to measure and mix in 97-733 or
Sigma thinner 60-30.
The amount of 97-733 or Sigma thinner 60-30 added shall not exceed 10% by weight!
Tests will have to be conducted for exact amount as this can be dependant on ambient temperatures, but in
general it is found to be in the range of 5 – 7%. Half the required volume of 97-733 or Sigma Thinner 60-30
shall be added to the base component and mixed until homogeneous. To facilitate the removal of Pitt-Char
XP hardener form the drum the other half of the thinner may be added. Work the thinner around the walls of
the drum with a long spatula.
DO NOT MIX !!
Add the entire contents of the pail to the base component and mix until a uniform grey colour is obtained.
The material can then be used in the conventional method as with all 2-pack epoxy materials.
page 2/3
PASSIVE FIRE PROTECTION
INFORMATION
PROTECTION OF STEEL FROM HYDROCARBON FIRES
PITT-CHAR XP Requirements for Applicator Training Courses
1203
January 2009
Pump Unit Specification For Single Component Application
Unit:
−
−
air driven pump of 75:1 ratio
ram fed and complete with wiper plate and blade suitable for 25 liter pails
Material Delivery Hose:
−
−
−
¾” hose – 15 meters long
½” whip – 5 meters long
½” swivel fitting at one end for gun connection
Spray Gun:
−
Gun suitable for the application of epoxy passive fire protection materials
(e.g. WIWA 500 or Covercat PFP1)
revers-a-clean tip
tip sizes 531 / 533 / 535 / 537
−
−
Limitation of Liability - The information in this data sheet is based upon laboratory tests we believe to be accurate and is
intended for guidance only. All recommendations or suggestions relating to the use of the Sigma Coatings products made by PPG
Protective & Marine Coatings, whether in technical documentation, or in response to a specific enquiry, or otherwise, are based
on data which to the best of our knowledge are reliable. The products and information are designed for users having the requisite
knowledge and industrial skills and it is the end-user's responsibility to determine the suitability of the product for its intended
use.
PPG Protective & Marine Coatings has no control over either the quality or condition of the substrate, or the many factors
affecting the use and application of the product. PPG Protective & Marine Coatings does therefore not accept any liability arising
from loss, injury or damage resulting from such use or the contents of this data sheet (unless there are written agreements
stating otherwise).
The data contained herein are liable to modification as a result of practical experience and continuous product development.
This data sheet replaces and annuls all previous issues and it is therefore the user’s responsibility to ensure that this sheet is
current prior to using the product.
page 3/3
PASSIVE FIRE PROTECTION
INFORMATION
PROTECTION OF STEEL FROM HYDROCARBON FIRES
PITT-CHAR XP QUALIFIED PRIMERS - PPG
a one page issue
1204
June 2010
Rev. of January 2009
This sheet contains a listing of PPG primers and primer systems qualified for Pitt-Char XP.
For the recommended dry film thicknesses, the application conditions and the surface preparation please
see the relevant product data sheets.
The dry film thickness of a primer or primer system should not exceed 150 µm.
If the primer or primer system you are looking for is not included, please contact PPG.
Primer / Primer System
Generic Type / Comment
Amercoat 71
epoxy
Amercoat 385
epoxy
Amerlock 2
Epoxy
Pitt-Guard DTR 97-145
epoxy
SigmaCover 280
epoxy
SigmaCover 456 HS
epoxy
SigmaPrime 200
epoxy
Amercoat 68 series
zinc rich epoxy
Amercoat 132E
SigmaZinc 102
SigmaZinc 102 HS
SigmaZinc 109 HS
Amercoat 68 series / Amercoat 71
zinc rich epoxy + tie coat
SigmaZinc 102 / SigmaCover 522
SigmaZinc 109 HS / SigmaCover 435
Dimetcote 9 series / Amercoat 71
zinc silicate + tie coat
SigmaZinc 158 / SigmaCover 435
zinc silicate + tie coat
SigmaZinc 158 / SigmaCover 522
zinc silicate + tie coat
DFT Range
50 - 75 µm
50 - 75 µm
50 - 75 µm
50 - 75 µm
50 - 75 µm
75 - 100 µm
75 - 100 µm
50 - 75 µm
50 - 75 µm
25 - 50 µm
60 - 75 µm
75 - 100 µm
75 - 100 µm
50 - 75 µm
100 - 150 µm
75 - 100 µm
75 - 100 µm
75 - 100 µm
For primers from other manufacturers please contact PPG.
Limitation of Liability - The information in this data sheet is based upon laboratory tests we believe to be accurate and is
intended for guidance only. All recommendations or suggestions relating to the use of the coating products made by PPG
Protective & Marine Coatings, whether in technical documentation, or in response to a specific enquiry, or otherwise, are based
on data which to the best of our knowledge are reliable. The products and information are designed for users having the requisite
knowledge and industrial skills and it is the end-user's responsibility to determine the suitability of the product for its intended
use.
PPG Protective & Marine Coatings has no control over either the quality or condition of the substrate, or the many factors
affecting the use and application of the product. PPG Protective & Marine Coatings does therefore not accept any liability arising
from loss, injury or damage resulting from such use or the contents of this data sheet (unless there are written agreements
stating otherwise).
The data contained herein are liable to modification as a result of practical experience and continuous product development.
This data sheet replaces and annuls all previous issues and it is therefore the user’s responsibility to ensure that this sheet is
current prior to using the product.
PASSIVE FIRE PROTECTION
DATA
PROTECTION OF STEEL FROM HYDROCARBON FIRES
PITT-CHAR XP PRIMER QUALIFICATION FORM
a three page issue
1205
January 2009
In a fire situation it is essential that Pitt-Char XP remains adhered to the substrate for the duration of the
expected protection period. In most cases the substrate will be primed and hence good bonding of
Pitt-Char XP to the primer must be verified.
For this reason only primers and coating systems satisfactorily tested and qualified by PPG shall be used
under Pitt-Chart XP.
The qualification process consists essentially of impact and lap shear testing under various climatic
conditions designed to establish any potential weaknesses in the total system composition. For certain types
of product additional fire testing is carried out.
The qualification process is free of charge, requiring the primer manufacturer to provide either a ‘wet
sample’ of the relevant product for us to apply, or a minimum of four plates prepared and coated with the
primer as per the relevant site conditions.
In all cases the application form (see page 2) shall be completed and sent to PPG along with either the wet
samples or the test plates. A copy of the form may be sent in advance by fax, e-mail or post.
Where wet samples are supplied then both the MSDS and Product Data Sheet for each product MUST be
supplied to ensure correct application and safe handling. If the project specified primer DFT is different from
that quoted on the Product Data Sheet, then it is this thickness that should be identified on the application
form.
Where test plates are provided, these should be approximately 200 mm x 150 mm with a minimum
thickness of 3 mm but preferably 5 mm thick. Plates thinner than 3 mm are likely to give a ‘false fail’ result
when impact tested. The actual dry film thickness of each coat applied to the plates should be identified,
since in a multi-coat system we would only be able to confirm the total DFT.
If panels are supplied rather than wet paint, then it is strongly recommended that an additional set of four
plates be provided with the primer applied at the maximum thickness expected on the project. Otherwise
qualification will be restricted to the nominal specified DFT and there will be no scope to accommodate
over-application on site.
page 1/3
PASSIVE FIRE PROTECTION
DATA
PROTECTION OF STEEL FROM HYDROCARBON FIRES
PITT-CHAR XP PRIMER QUALIFICATION FORM
1205
January 2009
PPG Protective and Marine Coatings
Passive Fire Protection Department
Attn. Dr. Daniel Brosch
Fax No: 0031 20 407 5059
e-mail: [email protected]
mobile: 0049 175 934 1376
Primer qualification for Pitt-Char XP
Paint Manufacturers Name:
Technical data sheet supplied?
Safety Data Sheet supplied?
Sample plate details: Steel or other
Coat 1
Product name
Product Reference: Base
Hardener
Colour
Batch number: Base
Hardener
Thinners: Reference
Vol. % added
Panel
Coat
DFT
No.
No.
[µm]
#1
1
2
3
4
#2
1
2
3
4
#3
1
2
3
4
#4
1
2
3
4
Date applied
YES / NO (Delete as appropriate)
YES / NO (Delete as appropriate)
Size LxWxT(mm)
Coat 2
Coat 3
Curing conditions
[°C / %RH]
page 2/3
Coat 4
Application
method
PASSIVE FIRE PROTECTION
DATA
PROTECTION OF STEEL FROM HYDROCARBON FIRES
PITT-CHAR XP PRIMER QUALIFICATION FORM
1205
January 2009
Limitation of Liability - The information in this data sheet is based upon laboratory tests we believe to be accurate and is
intended for guidance only. All recommendations or suggestions relating to the use of the Sigma Coatings products made by PPG
Protective & Marine Coatings, whether in technical documentation, or in response to a specific enquiry, or otherwise, are based
on data which to the best of our knowledge are reliable. The products and information are designed for users having the requisite
knowledge and industrial skills and it is the end-user's responsibility to determine the suitability of the product for its intended
use.
PPG Protective & Marine Coatings has no control over either the quality or condition of the substrate, or the many factors
affecting the use and application of the product. PPG Protective & Marine Coatings does therefore not accept any liability arising
from loss, injury or damage resulting from such use or the contents of this data sheet (unless there are written agreements
stating otherwise).
The data contained herein are liable to modification as a result of practical experience and continuous product development.
This data sheet replaces and annuls all previous issues and it is therefore the user’s responsibility to ensure that this sheet is
current prior to using the product.
page 3/3
PASSIVE FIRE PROTECTION
INFORMATION
PROTECTION OF STEEL FROM HYDROCARBON FIRES
PITT-CHAR XP PROJECT INFORMATION SHEET
a two page issue
December 2008
Product
Pitt-Char XP
Project Name:
Client:
Project Details:
Date:
Fire Case
Duration [min]
Limiting Temperature [oC]
Hydrocarbon/Jet Fire
… Lloyds
Certifying Body
… DNV
… UL
… GASAFE
… Other ---> Please State Other:
Substrate Details
…
…
…
Drawings Supplied
Client Itemised List Supplied
Specification Supplied
1207
Heat Flux [kW/m2]
Drawings Nos. / List ID
List Identification No.
Specification No.
Attach List of Section Sizes. Information Must Include That Shown Plus Lenghts and Number of Each Unit
I-Section
CHS
Plate
…
…
…
…
…
…
…
…
…
…
Height
RHS / SHS
Width
Flange
Web
Mass
Diameter
RSC
Wall Thickness
Mass
Thickness
RSA
Mass
…
…
…
…
…
…
…
…
…
…
…
…
…
…
…
Height
Width
Wall Thickness
Wall Thickness
Mass
Height
Width
Flange
Web
Mass
Height
Width
Flange
Web
Mass
Other Information:
RHS - Rectangular Hollow Section; SHS - Square Hollow Section; CHS - Circular Hollow Section
RSC - Rolled Steel Channel; RSA - Rolled Steel Angle
page 1/2
PASSIVE FIRE PROTECTION
INFORMATION
PROTECTION OF STEEL FROM HYDROCARBON FIRES
PITT-CHAR XP PROJECT INFORMATION SHEET
1207
December 2008
Limitation of Liability - The information in this data sheet is based upon laboratory tests we believe to be accurate and is
intended for guidance only. All recommendations or suggestions relating to the use of the Sigma Coatings products made by PPG
Protective & Marine Coatings, whether in technical documentation, or in response to a specific enquiry, or otherwise, are based
on data which to the best of our knowledge are reliable. The products and information are designed for users having the requisite
knowledge and industrial skills and it is the end-user's responsibility to determine the suitability of the product for its intended
use.
PPG Protective & Marine Coatings has no control over either the quality or condition of the substrate, or the many factors
affecting the use and application of the product. PPG Protective & Marine Coatings does therefore not accept any liability arising
from loss, injury or damage resulting from such use or the contents of this data sheet (unless there are written agreements
stating otherwise).
The data contained herein are liable to modification as a result of practical experience and continuous product development.
This data sheet replaces and annuls all previous issues and it is therefore the user’s responsibility to ensure that this sheet is
current prior to using the product.
page 2/2