Chartek 7 8+1709 Application Manual Rev0 010507

ID Rev.
Date
APP MAN UK 0 01/05/07 Chartek® Application Manual
Application Manual
Chartek Fire Protection
Prepared by:
International Paint Ltd.
©International Paint Limited, 2007

This document and its contents are the copyright of International Paint Limited and may not be reproduced in whole or in part without the express permission of International Paint Limited. All
products supplied and technical advice or recommendations given are subject to our standard Conditions of Sale.
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APP MAN UK Chartek® Application Manual Page 1 of 29
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Table of Contents
SECTION A – GENERAL (ALL PRODUCTS) .......................................................................... 10

Contact Information ............................................................................................................. 11
Chartek Application Manual Revisions .............................................................................. 12
A1.0 INTRODUCTION............................................................................................................... 13
A1.1 Purpose ........................................................................................................................ 13
A1.2 System Description ..................................................................................................... 13
A1.3 Quality Control Requirements .................................................................................... 13
A2.0 SURFACE PREPARATION .............................................................................................. 14
A2.1 Introduction.................................................................................................................. 14
A2.2 Degreasing ................................................................................................................... 14
Table A1: Chartek Surface Preparation Requirements .................................................... 17
A3.0 PRIMERS .......................................................................................................................... 18
Table A2: Primer System Maximum Dry Film Thicknesses............................................. 18
A4.0 QUALIFIED CHARTEK APPLICATION CONTRACTORS............................................... 20
A4.1 Chartek Products Not Applied Within Two Years ..................................................... 20
A5.0 CHARTEK THICKNESS MEASUREMENT ...................................................................... 21
A5.1 Thickness Measurement ............................................................................................. 21
A6.0 TOPCOATS ...................................................................................................................... 23
A6.1 Special Applications.................................................................................................... 24
A7.0 REMOVAL AND REPAIR, ADDITIONAL WORK, WELD CUTBACK AND REPAIR OF
DAMAGED AREAS................................................................................................................... 25
A7.1 Removal........................................................................................................................ 25
A7.2 Weld Cutback ............................................................................................................... 25
A8.0 SAFETY AND ENVIRONMENT ........................................................................................ 27
A9.0 SPECIAL APPLICATIONS ............................................................................................... 28
A9.1 Repair Procedure for Damaged or Delaminated Chartek......................................... 28
A9.2 Coatbacks .................................................................................................................... 28

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SECTION B – CHARTEK 7......................................................................................................... 1

B1.0 CHARTEK PACKAGING AND STORAGE......................................................................... 2
B1.1 50kg (110lb) Kit .............................................................................................................. 2
B1.2 20kg (44.1lb) Kit ............................................................................................................. 2
B1.3 Cast Grade ..................................................................................................................... 2
B1.4 Storage Conditions for Chartek.................................................................................... 2
B2.0 CARBON FIBRE MESH REINFORCEMENT ..................................................................... 3
B2.1 Meshing Designs ........................................................................................................... 3
Table B1: Mesh Requirements ............................................................................................. 3
B2.2 HK-1TM and HK-1 (M)TM Carbon Fibre Mesh Reinforcement ....................................... 3
B2.3 Packaging of HK-1 and HK-1 (M) Carbon Fibre Mesh Reinforcement....................... 3
B2.4 General Rules for Meshing ........................................................................................... 3
B3.0 METAL MESH REINFORCEMENT..................................................................................... 4
B3.1 Metal Mesh Reinforcement Uses.................................................................................. 4
B3.2 Metal Mesh Reinforcement Types ................................................................................ 4
B3.3 Installation of Pins......................................................................................................... 4
B3.4 General Rules for Metal Meshing ................................................................................. 5
Table B2: Meshing Designs for Structural Members and Tanks....................................... 5
B4.0 CHARTEK APPLICATION WITH SINGLE LEG AIRLESS SPRAY EQUIPMENT ............. 6
B4.1 Ambient Conditions....................................................................................................... 6
B4.2 Surface Cleanliness....................................................................................................... 6
B4.3 Primer and Surface Preparation ................................................................................... 6
B4.4 Kit Size............................................................................................................................ 7
B4.5 Material Preparation for Single Leg Airless Spray Application ................................. 7
B4.6 Heated Storage Units .................................................................................................... 8
B4.7 Mixing Equipment.......................................................................................................... 9
B4.8 Use of Solvent.............................................................................................................. 10
B4.9 Mixing Procedure......................................................................................................... 11
B4.10 Single Leg Airless Spray Equipment ....................................................................... 11
B4.11 Single Leg Spray Application Method ..................................................................... 13

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

B4.13 Surface Finish ............................................................................................................ 14
B4.14 Terminations .............................................................................................................. 15
B5.0 CHARTEK APPLICATION WITH PLURAL SPRAY EQUIPMENT................................... 16
B5.1 Ambient Conditions..................................................................................................... 16
B5.2 Surface Cleanliness..................................................................................................... 16
B5.3 Primer and Surface Preparation ................................................................................. 16
B5.4 Material Preparation for Plural Component Spray Application ............................... 17
B5.5 Plural Component Spray Equipment ......................................................................... 17
Table B3: Operating Parameters for Plural Component Spray Machines ....................... 18
B5.6 Ratio Checks ................................................................................................................ 19
B5.7 Plural Spray Application Method................................................................................ 19
B5.8 Water Contamination................................................................................................... 21
B5.9 Surface Finish .............................................................................................................. 21
B5.10 Terminations .............................................................................................................. 21
B6.0 HAND TROWEL APPLICATION ...................................................................................... 22
B6.1 Ambient Conditions..................................................................................................... 22
B6.2 Surface Cleanliness..................................................................................................... 22
B6.3 Primer and Surface Preparation ................................................................................. 22
B6.4 Material Preparation for Hand Trowel Application ................................................... 23
B6.5 Mixing ........................................................................................................................... 23
B6.6 Hand Trowel Application Method ............................................................................... 24
B6.7 Mixing of Partial Kits ................................................................................................... 24
B6.8 Water Contamination................................................................................................... 25
B6.9 Surface Finish .............................................................................................................. 25
B6.10 Terminations .............................................................................................................. 25

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APPENDICES ........................................................................................................................... 26
APPENDIX A – HK-1TM Meshing Arrangements....................................................................................27
APPENDIX B – Metal Meshing Arrangements ......................................................................................31
APPENDIX C – Certified Thicknesses - Bulkheads and Decks...........................................................35
APPENDIX D – Typical Standards of Finish and Mesh Overlap Photographic Reference...............40
APPENDIX E – Chartek Checklist ..........................................................................................................44
APPENDIX F – Procedure for Inspection, Test and Replacement of Failed Fire Protection............46
APPENDIX G – Technical Note TN/F/083 “Overcoating of aged and zinc primers” .........................51
APPENDIX H – Technical Note TN/F/101 “Disposal of Chartek” ........................................................55
APPENDIX I – Definitions and Abbreviations.......................................................................................57

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SECTION C – CHARTEK 8......................................................................................................... 1

C1.0 CHARTEK PACKAGING AND STORAGE......................................................................... 2
C1.1 50kg (110lb) Kit .............................................................................................................. 2
C1.2 20kg (44.1lb) Kit ............................................................................................................. 2
C1.3 Cast Grade ..................................................................................................................... 2
C1.4 Storage Conditions for Chartek.................................................................................... 2
C2.0 CARBON FIBRE MESH REINFORCEMENT ..................................................................... 3
C2.1 Meshing Designs ........................................................................................................... 3
Table C1: Mesh Requirements .............................................................................................. 3
C2.2 HK-1TM and HK-1 (M)TM Carbon Fibre Mesh Reinforcement ....................................... 3
C2.3 Packaging of HK-1 and HK-1 (M) Carbon Fibre Mesh Reinforcement....................... 3
C2.4 General Rules for Meshing ........................................................................................... 3
C3.0 APPLICATION WITH SINGLE LEG AIRLESS SPRAY EQUIPMENT ............................... 5
C3.1 Ambient Conditions....................................................................................................... 5
C3.2 Surface Cleanliness....................................................................................................... 5
C3.3 Primer and Surface Preparation ................................................................................... 5
C3.4 Kit Size............................................................................................................................ 6
C3.5 Material Preparation for Single Leg Airless Spray Application ................................. 6
C3.6 Heated Storage Units .................................................................................................... 7
C3.7 Mixing Equipment.......................................................................................................... 8
C3.8 Use of Solvent................................................................................................................ 9
C3.9 Mixing Procedure......................................................................................................... 10
C3.10 Single Leg Airless Spray Equipment ....................................................................... 10
C3.11 Single Leg Spray Application Method ..................................................................... 12
C3.12 Water Contamination................................................................................................. 13
C3.13 Surface Finish ............................................................................................................ 13
C3.14 Terminations .............................................................................................................. 14
C4.0 CHARTEK APPLICATION WITH PLURAL SPRAY EQUIPMENT................................... 15
C4.1 Ambient Conditions..................................................................................................... 15
C4.2 Surface Cleanliness..................................................................................................... 15

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

C4.4 Material Preparation for Plural Component Spray Application ............................... 16
C4.5 Plural Component Spray Equipment ......................................................................... 16
Table C2: Operating Parameters for Plural Component Spray Machines ....................... 17
C4.6 Ratio Checks ................................................................................................................ 18
C4.7 Plural Spray Application Method................................................................................ 18
C4.8 Water Contamination................................................................................................... 20
C4.9 Surface Finish .............................................................................................................. 20
C4.10 Terminations .............................................................................................................. 20
C5.0 HAND TROWEL APPLICATION ...................................................................................... 21
C5.1 Ambient Conditions..................................................................................................... 21
C5.2 Surface Cleanliness..................................................................................................... 21
C5.3 Primer and Surface Preparation ................................................................................. 21
C5.4 Material Preparation for Hand Trowel Application ................................................... 22
C5.5 Mixing ........................................................................................................................... 22
C5.6 Hand Trowel Application Method ............................................................................... 23
C5.7 Mixing of Partial Kits ................................................................................................... 23
C5.8 Water Contamination................................................................................................... 24
C5.9 Surface Finish .............................................................................................................. 24
C5.10 Terminations .............................................................................................................. 24
APPENDICES ........................................................................................................................... 25
APPENDIX A – HK-1TM Meshing Detail ..................................................................................................26
APPENDIX B – Not Applicable ...............................................................................................................30
APPENDIX C – Certified Thicknesses - Bulkheads and Decks...........................................................31
APPENDIX I – Definitions and Abbreviations........................................................................ 53

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SECTION D – CHARTEK 1709 ................................................................................................... 1

D1.0 CHARTEK PACKAGING AND STORAGE......................................................................... 2
D1.1 50kg (110 lb) Kit ............................................................................................................. 2
D1.2 20kg (44.1 lb) Kit ............................................................................................................ 2
D1.3 Cast Grade ..................................................................................................................... 2
D1.4 General Storage Conditions for Chartek ..................................................................... 2
D1.4.1 Storage Conditions ................................................................................................. 2
D1.4.2 Storage Temperature .............................................................................................. 2
D2.0 HK-1TM CARBON FIBRE MESH REINFORCEMENT......................................................... 4
D2.1 Meshing Designs ........................................................................................................... 4
Table D1: HK-1 Mesh Requirements.................................................................................... 4
D2.2 HK-1 and HK-1 (M) Carbon Fibre Mesh Reinforcement.............................................. 4
D2.3 Packaging of HK-1TM and HK-1 (M)TM Carbon Fibre Mesh Reinforcement................ 4
D2.4 General Rules for HK-1 Meshing (where required*).................................................... 4
D3.0 METAL MESH REINFORCEMENT..................................................................................... 5
D3.1 Metal Mesh Reinforcement Requirements .................................................................. 5
D4.0 APPLICATION WITH SINGLE LEG AIRLESS SPRAY EQUIPMENT ............................... 6
D4.1 Ambient Conditions....................................................................................................... 6
D4.2 Surface Cleanliness....................................................................................................... 6
D4.3 Primer and Surface Preparation ................................................................................... 6
D4.4 Kit Size............................................................................................................................ 7
D4.5 Material Preparation for Single Leg Airless Spray Application ................................. 7
D4.6 Heated Storage Units .................................................................................................... 8
D4.7 Mixing Equipment.......................................................................................................... 9
D4.8 Use of Solvent.............................................................................................................. 10
D4.9 Mixing Procedure......................................................................................................... 11
D4.10 Single Leg Airless Spray Equipment ....................................................................... 11
D4.11 Single Leg Spray Application Method ..................................................................... 13
D4.12 Water Contamination................................................................................................. 14
D4.13 Surface Finish ............................................................................................................ 14
D4.14 Terminations .............................................................................................................. 15

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

D5.1 Ambient Conditions..................................................................................................... 16
D5.2 Surface Cleanliness..................................................................................................... 16
D5.3 Primer and Surface Preparation ................................................................................. 16
D5.4 Material Preparation for Plural Component Spray Application ............................... 17
D5.5 Plural Component Spray Equipment ......................................................................... 17
Table D2: Operating Parameters for Plural Component Spray Machines ....................... 18
D5.6 Ratio Checks ................................................................................................................ 19
D5.7 Plural Spray Application Method................................................................................ 19
D5.8 Water Contamination................................................................................................... 21
D5.9 Surface Finish .............................................................................................................. 21
D5.10 Terminations .............................................................................................................. 21
D6.0 HAND TROWEL APPLICATION ...................................................................................... 22
D6.4 Material Preparation for Hand Trowel Application ................................................... 23
D6.5 Mixing ........................................................................................................................... 23
D6.6 Hand Trowel Application Method ............................................................................... 24
D6.7 Mixing of Partial Kits ................................................................................................... 24
D6.9 Surface Finish .............................................................................................................. 25
D6.10 Terminations .............................................................................................................. 25

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

D5.4 Material Preparation for Plural Component Spray Application ............................... 17
D5.5 Plural Component Spray Equipment ......................................................................... 17
Table D2: Operating Parameters for Plural Component Spray Machines ....................... 18
D5.6 Ratio Checks ................................................................................................................ 19
D5.7 Plural Spray Application Method................................................................................ 19
D5.9 Surface Finish .............................................................................................................. 21
D5.10 Terminations .............................................................................................................. 21
D6.0 HAND TROWEL APPLICATION ...................................................................................... 22
D6.4 Material Preparation for Hand Trowel Application ................................................... 23
D6.5 Mixing ........................................................................................................................... 23
D6.6 Hand Trowel Application Method ............................................................................... 24
D6.7 Mixing of Partial Kits ................................................................................................... 24
D6.9 Surface Finish .............................................................................................................. 25
D6.10 Terminations .............................................................................................................. 25

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APPENDICES ........................................................................................................................... 26
APPENDIX A – HK-1TM Meshing Details ................................................................................................27
APPENDIX B – Not Applicable ...............................................................................................................31
APPENDIX C – Not Applicable ...............................................................................................................32
APPENDIX I – Definitions and Abbreviations........................................................................ 50

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SECTION A – GENERAL (ALL

PRODUCTS)

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Contact Information
Region Office Address Telephone/Fax
Head Office and Essex House Tel: +44 (0)1277 229192
141 Kings Road
Europe, Middle East & Africa Fax: +44 (0 1277 228745
Brentwood
Essex
CM14 4DR
United Kingdom
Scandinavia Karistoe 13 Tel: +47 95 40 21 35
4045 Hafrsfjord
Norway Fax: +47 51 59 36 78
India, South East Asia & China 3 Neythal Road Tel: +65 6663 3050
Jurong Town
Fax: +65 6261 8125
628570
Singapore
The Americas 6001 Antoine Drive Tel: +1 713 684 1223

77091 Houston
Fax: +1 713 684 1514
Texas
USA
Korea 17th Floor Tel: +82 51 5806150

National Pension Building
Fax: +82 52 2342377
#1422-8 Yeonsan-dong
Yeonje-gu
Busan
South Korea
Australasia 115 Hyde Road Tel: +61 738928887

Yeronga
Fax: +61 738923642
Brisbane
Queensland, 4140
Australia
Websites: www.chartek.com www.international-pc.com

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Chartek Application Manual Revisions

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

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A1.0 INTRODUCTION
A1.1 Purpose
This Application Manual contains instructions on how to install Chartek fireproofing systems.
Passive fireproofing materials prevent potentially catastrophic structural failures from occurring by
providing an insulating shield against the intense heat of a fire. The Chartek fireproofing systems
are the result of over 30 years of research and development and possess extensive certification for
a wide range of fire protection ratings.
Since both fire protection performance and pre-fire durability critically depend on the correct
application of the system, International Protective Coatings requires that the Chartek fireproofing
systems are installed only by qualified applicators in strict accordance with the instructions
contained in this Application Manual.
Our Regional Office Technical Service Managers provide the support necessary to ensure that
Chartek fireproofing projects are carried out in accordance with the instructions of this manual and
any additional project specific requirements.
A1.2 System Description

The Chartek passive fireproofing system consists of an epoxy intumescent coating designed to
protect substrates from fire and corrosion. Dependent on the fire type, rating and design, Chartek
fireproofing systems may require mesh reinforcement.
Chartek provides effective fire protection to a wide range of structures, divisions and equipment in
almost any fire scenario. In a fire, Chartek fireproofing will intumesce (expand) to form an insulating
layer of char. It is this char and its formation that protects the substrate from the effects of fire.
A1.3 Quality Control Requirements

The quality control activities required to verify that application is carried out in accordance with this
manual are described in the Quality Control Manual for Chartek Fireproofing Systems, which is
available to customers and applicators upon request.

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A2.0 SURFACE PREPARATION

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

• to provide the best bond possible between the metallic substrate and chosen (qualified)
primer
• to produce a surface roughness that will maximise the bond between substrate, primer and
Chartek
• to guarantee effective corrosion resistance of the whole system
Acceptable surface preparation standards include, but are not limited to:
• ISO 8501: Preparation of steel substrates before application of paints and related products
(visual assessment of surface cleanliness)
• ISO 8503: Preparation of steel substrates before application of paints and related products
(surface roughness characteristics of blast cleaned substrates)
• SSPC (The Society for Protective Coatings) - surface preparation standards)
• NACE (The National Association of Corrosion Engineers) - surface preparation standards
Applicators should be familiar with surface preparation techniques and have access to the
measurement instruments required to verify the specified surface preparation requirements.
For a range of definitions and abbreviations refer to Appendix I.
The particular method of surface preparation required depends on the type of substrate being
coated. Table A1: Chartek Surface Preparation Requirements (at the end of this section)
summarises the requirements for most substrates. Where there are special conditions not shown
International should be consulted for advice.
Table A1 makes reference to a number of surface preparation operations that are defined below.
The correct interpretation and execution of these operations is required in order to achieve the
objectives mentioned above.
A2.2 Degreasing
The presence of surface oil or grease prevents a coating from properly adhering to the substrate
and can lead to rapid failure of the whole system. For this reason, all visible oil, grease and other
soluble contaminants must be removed before the application of both primer and Chartek.
Degreasing is also important before blast cleaning activities.

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

¾ steam cleaning using detergents or emulsion/alkaline cleaners followed by steam or fresh
water wash to remove detrimental residues
¾ wiping or scrubbing the surface with rags or brushes wetted with solvent (NB: use clean
solvent for the final wiping)
¾ vapour degreasing using stabilized chlorinated hydrocarbon solvents
The applicator must select the method most appropriate to the situation, giving due consideration to
applicable health and environmental regulations. In all cases, International recommends removing
any heavy oil or grease first by scraper and completing the degreasing activity with a thorough fresh
water rinse.
The primer manufacturer’s recommendations regarding degreasing must also be observed at all
times.
A2.3 Blast Cleaning

Blast cleaning is widely accepted as being the best way of preparing a metal substrate before
application of a protective coating and it is a very important part of the whole Chartek application
process. Chartek is very rarely applied directly to blast cleaned substrates due to the risk of flash
rusting. Therefore, when a primer is used, blast cleaning should be carried out in accordance with
the primer manufacturer’s instructions.
Definition of degrees of cleanliness:
Near white blast cleaning

The general requirement prior to Chartek application is near-white blast cleaning. A near white
blast cleaned surface, when viewed without magnification, shall be free of all visible oil, grease,
dust, dirt, mill scale, rust, coating, oxides, corrosion products and other foreign matter except for
staining (light shadows, streaks or discolorations caused by stains of rust, mill scale or previously
applied coatings) limited to no more than 5% of the surface (Sa 2½, SSPC-SP10, NACE No. 2).
Sweep (Brush-off) blast

Removal of all loose mill scale, loose rust and loose coating with abrasive blast cleaning (Sa 1,
SSPC-SP 7, NACE No. 4).
Blast profile
For carbon steel substrates the blast profile (Rz) must be 50 to 75 microns (2 to 3 mils). Angular
abrasive should be used in order to produce a suitably sharp surface profile. The recommended
method for measuring the blast profile is with replica tape.

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For stainless steel substrates a suitable non-metallic abrasive should be used and a profile of 35 to
50 microns (1.5 to 2 mils) is required.
For aluminium a suitable non-metallic abrasive should be used and a deep profile of 75 to
100 microns (3 to 4.mils) is required.
For galvanised substrates a sweep (brush-off) blast to Sa 1 (ISO 8501-1), equivalent to SSPC-SP7
or NACE No. 4, is required, as a minimum, in order to produce a suitably roughened surface. The
blast profile (Rz) should be 50 to 75 microns (2 to 3 mils).
Wet abrasive blasting

Wet abrasive blasting is an acceptable method of surface preparation. Surface profile and
cleanliness shall be as detailed above. A qualified wet blast primer must be used with this method
of surface preparation.
Hydro-blasting (high pressure water jetting)

Hydro-blasting may be an acceptable method of surface preparation of previously coated
substrates. However, this is conditional on an adequate surface profile being revealed as detailed
above. Where a suitable surface profile is not revealed, then sweep blasting or abrasive blasting
will be required. A qualified wet blast primer must be used with this method of surface preparation.
A2.4 Power Tool Cleaning

It is not generally an acceptable method for preparing metal substrates for either primer or Chartek
application; however it may used for small areas of repair. Power tool cleaning may also be used to
abrade glass or fibre reinforced plastic substrates.
Definition:
Removal of all loose mill scale, loose rust, loose paint and other loose detrimental foreign matter
(SSPC-SP 3).
Small areas, for example, welds and local repair areas, may be prepared by power tool cleaning as
generally prescribed by ISO 8501-1 to surface finish ST3 (or SSPC-SP3). Power tool cleaning is
not acceptable for preparing larger surface areas.

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Table A1: Chartek Surface Preparation Requirements
Substrate
Operation
Glass Or Fibre
Required Steel Galvanised Steel Aluminium
Stainless
Reinforced
Steel
Plastics
Degreasing 9 9 9 9 9
Power Tool
Cleaning
See Note 2 See Note 2 See Note 2 See Note 2 9
Near White
Blast Cleaning
9 9 9
Sweep (brush-
off) Blast 9 9
Cleaning
Blow down 9 9 9 9 9
Epoxy
Primer 9 primer only
See Note 1 See Note 1
50 to 75 50 to 75 75 to 100 35 to 50 Abrade to
Blast Profile microns microns microns microns remove glaze
(2 to 3 mils) (2 to 3 mils) (3 to 4 mils) (1½ to 2 mils)
Note 1: If there is a risk of oxidisation of the surface prior to application of Chartek a suitable
primer should be used. Refer to Chartek Qualified Primer List.
Note 2: Power tool cleaning is not generally an acceptable method for preparing metal
substrates for either primer or Chartek application, however it may used for small areas
of repair (typically not exceeding 1m2 (10ft2), for example welds and local repair areas). It
should be carried out as described by ISO 8501-1 to surface finish ST3 (SSPC-SP3)

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

Normal Areas Overlap Areas
Epoxy primer:
Carbon steel substrate 50 to 75 microns (2 to 3 mils) 100 microns (4 mils)
Stainless steel substrate 35 to 50 microns (1.4 to 2 mils) 75 microns (3 mils)
Aluminium substrate 75 to 100 microns (3 to 4 mils) 150 microns (6 mils)
Epoxy zinc primer 50 to 75 microns (2 to 3 mils) 100 microns (4 mils)
Epoxy zinc primer plus tie coat 75 to 110 microns (3 to 4.4 mils) 125 microns (5 mils)

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NOTES:
• Epoxy tie coat (25 to 35 microns (1 to 1.4 mils) dft) should be used with zinc primers if Chartek is
not applied immediately after the primer has cured or if the primer is exposed to humid or outdoor
conditions prior to application of Chartek.
• “Overlap areas” refers to internal angles of structural sections and other areas where multiple
spray passes are unavoidable. Dft’s may be exceeded in stripe coat areas.
Reduction of Excessive Primer Thickness

Excessive primer thickness should be reduced to the dft’s indicated in the foregoing Table A2. The
preferred method to be used is abrasive sweep blasting. Sanding with P80-P100 grade aluminium
oxide abrasive paper may be suitable for small areas; however care should be taken to prevent
polishing of the surface which would lead to inadequate adhesion of the Chartek. Polishing must be
avoided and frequent changes of the abrasive paper should be made.
After primer reduction surfaces should be cleaned of dust and contaminants, potable water washed
and thoroughly dried prior to the application of Chartek.
Care should be taken to ensure that systems have reached sufficient levels of cure prior to overcoating
with Chartek. Generally this will not be less than three days. However, the primer manufacturer and
International should be consulted for minimum and maximum cure times. It should be recognized that a
thick film epoxy coating (Chartek) is being applied over the primer system.
The primer manufacturer’s application instructions should be followed.
It is the responsibility of the applicator installing the Chartek to assess the condition of the primer
coating before the Chartek is applied.
Should the primer’s suitability for the overcoating with Chartek be in doubt in any way, for example,
primer type, thickness, condition etc., the primer manufacturer and International should be consulted
before the application of Chartek.
Qualification of inorganic zinc primer systems requires testing to ASTM D-1002 and the system meeting
the minimum cohesive strength values set by International Protective Coatings.
International maintains a current list of qualified primers at each of its sales offices. It is the application
contractor’s responsibility to ensure that only these products are used.
NOTE: International Protective Coatings is able to offer a complete package of primer system,
fireproofing, thermal insulation (if required) and topcoat.

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A4.0 QUALIFIED CHARTEK APPLICATION CONTRACTORS

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

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A5.0 CHARTEK THICKNESS MEASUREMENT

A5.1 Thickness Measurement
As the fire protection rating is determined by the Chartek thickness, it is imperative that applicators
constantly measure and record thicknesses during application.
Chartek is a 100% volume solids product, so wet and dry film thicknesses are the same.
The following procedure for thickness measurement must be followed.
A. Method for measuring wet Chartek thickness:

The recommended method of measuring wet thickness is to use a pre-cut bridge gauge having a
width of approximately 25mm (1”), typically made from a putty knife. Notch or pin gauges are not
acceptable because they limit the measurement to one point. The gauge should just touch the
rolled Chartek surface. International strongly recommends the continuous use of the bridge gauge
by all members of the application team (sprayer, trowellers and rollers). This is the only way of
ensuring the design thickness will be applied to the whole surface.
B. Method of measuring dry Chartek thickness:

Dry film thickness can be measured by either of the following methods:
¾ drill small holes typically 2 to 3mm (1/8”) in diameter and checking the Chartek thickness
with a depth gauge (care must be taken not to damage the substrate and to refill the
holes with Chartek as soon as possible);
¾ using an electromagnetic or ultrasound thickness gauge (care must be taken to correctly
calibrate the gauge immediately before taking any readings on a smooth calibration
plate). Electromagnetic gauges cannot be used if the Chartek is reinforced with wire
mesh.
Measurement Criteria
It is recognized that the applied Chartek layer will never be perfectly even and that areas of lower
than specified design thickness (“valleys”) are compensated by areas of higher than design
thickness (“peaks”). Consequently, the following measurement criteria must be followed:
Location
It is recommended that no thickness measurements are taken within 25mm (1”) of the edge of
structural sections and divisions, or within 25mm (1”) of the join of flange to web of, for example, an
‘I’ section.
Thickness measurements should be taken randomly over the remaining areas of the coated
structural sections and divisions with a frequency described below.
Frequency
The number of thickness readings to be taken shall be agreed by all parties before application
commences.

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

Webs: 2 readings per metre length on each face
Outer flanges: 2 readings per metre length on each face
Inner flanges: 1 reading per metre length on each face
• Square or rectangular angles and hollow sections:

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

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

2 readings per 1m2
Acceptance Criteria
Unless specifically stated otherwise in the project documentation, the minimum acceptable
thickness at any point shall not be less than 85% of the design or certified thickness up to a
maximum of 1.5mm (1/16”) less than the design or certified thickness.
In other words, for thicknesses up to and including 10mm (3/8”) the minimum allowable thickness is
85% of the design or certified thickness. For thicknesses above 10mm (3/8”) the minimum allowable
thickness is the design or certified thickness less 1.5mm (1/16”).
In all cases, the average thickness must be at least the specified passive fireproofing design or
certified thickness.
Where any single thickness reading is found to be less than the 85% or 1.5mm criteria of the design
or certified thickness, a further 3 readings shall be taken within a 300mm radius of the low reading.
Should one or more of the additional readings also be less than the 85% or 1.5mm criteria, further
readings shall be taken to establish the extent of the area of under-thickness and the affected area
shall be brought up to the required thickness.
The above measurement criteria meets or exceeds the requirements specified in ASFP TGN 003:
Part 1, SSPC-PA2 and ASTM E605.
Thickness readings should be accurately recorded on suitable quality control forms. See the
Quality Control Manual for Chartek Fireproofing Systems Application for further details.

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A6.0 TOPCOATS
Chartek has been extensively tested to industry recognised standards to demonstrate its ability to
withstand weather and environmental exposure, both with and without topcoats.
Generally Chartek will be topcoated to meet owners’ colour schemes and finish requirements.
International Protective Coatings recommends the use of topcoats in all external applications.
There are specific situations where the use of a topcoat is considered mandatory and these include:
¾ Use of Chartek on offshore installations or where coastal location conditions are similar to
an offshore environment.
¾ Area of high UV exposure: like all epoxy products, Chartek may chalk when exposed to
high levels of UV for prolonged periods. This can result in fading of the original colour.
¾ Areas of high moisture exposure: where the Chartek is likely to be in continuous contact
with moisture, such as the upper surfaces of horizontal decks and flanges and areas in
the splash zone.
¾ Coarse sprayed finishes: a stippled finish may collect airborne contamination and result
in shading of the Chartek surfaces.
It is recommended that Chartek is topcoated when it is sufficiently cured and the surfaces are clean
and dry, and prior to any possible contamination.
Recommended minimum overcoating intervals:
Temperature Minimum
°C (°F) (hours)
15 (59) 12
25 (77) 6
40 (104) 4
Maximum overcoating times are dependent upon environmental exposure, type of topcoat system
used and other factors. The topcoat manufacturer should be consulted.
Excessive rollering with solvent can, in extreme cases, cause amine bloom on the surface of the
Chartek. This is not acceptable for application of topcoats. If amine bloom occurs, surfaces must
be suitably washed with one of the approved methods in Section A2.0, prior to application of any
topcoat.
Chartek can be overcoated with a wide range of suitable topcoats to meet specific requirements.
For example, International’s Interthane® 990 and Interfine® 878 are recommended topcoats.
For heavy duty protection and to prevent shading on stippled finishes, International recommends one of
the following topcoat systems:

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1. Two coats of Interthane® 990 or Interfine® 878 at 50 microns (2 mils) dft.

2. One coat of epoxy polyamide primer at 75 microns (3 mils) dft plus one coat of
Interthane 990 or Interfine 878 at 50 microns (2 mils) dft.
On all occasions, the recommendations of the topcoat manufacturer should be sought regarding
application and service conditions.
A6.1 Special Applications

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

¾ Interzone® 954 500 to 1000 microns (20 to 40 mils)
All the above products should incorporate an appropriate aggregate such as GMA132.
B. Heavy moisture exposure

For areas of heavy moisture exposure, such as the undersides of cold operating vessels or
upper horizontal areas, it is recommended that a topcoat of minimum 250 microns (10 mils) dft
be provided. For horizontal surfaces, the Chartek should be sloped sufficiently to avoid
ponding.
Note: For splash zone areas, there are specific instructions covered in Technical Note TN/F/058
“Use of Chartek in Way of the Splash Zone” available from International Protective Coatings or
www.chartek.com

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A7.0 REMOVAL AND REPAIR, ADDITIONAL WORK, WELD

CUTBACK AND REPAIR OF DAMAGED AREAS
A7.1 Removal
Chartek can be removed after application for additional work, e.g. welding of attachment, by the use
of handheld air driven pistol chisel using a sharp chisel bit of the appropriate width, usually 25 or
50mm. The tool should be used to split the bond between Chartek and the steel, taking care not to
gouge or damage the steel substrate.
N.B.: Operators should wear suitable dust masks and eye protection.
A7.2 Weld Cutback

For small weld operations, such as addition of clips and hangers, a cutback of 50mm from weld
area should be made. For large welds of heavy angle or other members, a cutback of 75mm should
be made. Chartek can be removed with a fair degree of accuracy on an identified cut line without
damage to surrounding material. After welding has taken place, the surrounding Chartek should
show no sign of discolouration or damage. If discolouration, change of applied colour or ‘browning’
is seen, then discoloured material should be removed back to sound material.
In the case of allowance of cutback for welding of structural members and structural members
themselves which are to be pre-coated with Chartek prior to assembly, the following
recommendation is made:
No weld preheat: 300mm either side of weld

Weld preheat: See following table
Preheat Duration Free Distance

°
C (°F) Hours mm (in)
100 (212) 4 to 8 750 (30)
100 (212) 9 to 12 1000 (40)
150 (302) 4 to 8 750 to1000 (30 to 40)
150 (302) 9 to 12 1000 to 1250 (40 to 50)
The above figures are expected to be conservative, actual distance is a combination of factors,
including mass of steel at weld junction and method of preheat.
As previously noted, discolouration of surrounding material will indicate insufficient cutback or

overheating of area and will have to be removed.
REPAIR OF DAMAGED AREAS – CUTBACK
Repair of damaged areas, in the fabrication yard or during service life, and cutback areas should
follow the undermentioned procedures:

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1. Application conditions must conform with specified conditions for primer topcoat and Chartek
application.
2. Repair of damaged primer system should conform with instructions of specification for surface
treatment and coatings. All traces of corrosion of substrate steel will have to be removed and
surface prepared to the required level.
3. Should the repair area be large and require mesh, as defined by requirements for mesh
application for Chartek, this should be attached as detailed in the Chartek Application Manual.
4. The ‘border’ area of surrounding Chartek should be checked for soundness and adhesion in the
joint area.
5. The surrounding ‘border’ area of 50-75mm of Chartek should be roughened by abrasives to

remove topcoat and/or ‘glazed’ finish of Chartek to ensure sound adhesion of new material.
After roughening, a suitable PMA solvent should be used to ensure that the area is clean.
6. Chartek should be applied to the repair area and interfaced with the existing material bringing
the repair area to the same coating thickness. Application should follow International Paint’s
procedures, noting that trowel application of Chartek is acceptable for repair areas.
7. Ensure the Chartek material used for repairs and patching meets the required specification in terms
of fire protection rating, reinforcement and thickness.
8. Topcoat replacement and repair should follow International Protective Coatings’ guidelines and
topcoat manufacturer’s instructions.

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A8.0 SAFETY AND ENVIRONMENT

Chartek is an epoxy based compound and can be a skin irritant to some people. It is therefore good
practice to keep covered up and avoid skin contact. Eye protection should always be worn. It is
important to stay as clean as possible. Periodic washing with soap and warm water is
recommended to minimise continued contact with the material. Appropriate Material Safety Data
Sheets and local Health & Safety personnel protection requirements must be observed.
PMA is a solvent that is benign in nature. However, in common with all solvents, care should be
taken during its use of PMA. Work areas should be adequately ventilated. Containers should be
kept closed and rollers only lightly sprayed with the solvent. If PMA comes into contact with the
eyes flushing with clear, clean water for 15 minutes is recommended followed by suitable medical
attention. Consult PMA manufacturer’s material safety data sheets for questions relating to health
and safety issues.
As Chartek is delivered primarily through high pressure spray equipment, there is always a
possibility that a fitting or line could fail. Therefore, any maintenance operation or changing of spray
tips should be done with all pressure off the machines. If it is suspected that spray lines have
become clogged, extreme caution should be used when unscrewing fittings, as it may not be
possible to vent the pressure.
Refer to the manufacturer’s specific instructions with regard to equipment safety.
For instruction on the disposal of Chartek refer to Appendix H.

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A9.0 SPECIAL APPLICATIONS

A9.1 Repair Procedure for Damaged or Delaminated Chartek
A. Mark out the area to be repaired.
B. Using a disc grinder, cut through the Chartek and mesh (take care not to damage substrate).
C. Using chosen tools (hammer and chisel or pneumatic chisel), cut into patch to remove damaged
Chartek. Make sure all uncured material is removed.
D. Alternatively, ultra high pressure water jetting (UHP) can be used to remove Chartek and is
recommended as the removal method when Chartek is applied to pressure vessels and piping.
E. Reinstate primer to specification. Small areas, for example, welds and local repair areas, may be
prepared by power brushing as generally prescribed by ISO 8501-1 to surface finish ST3 (or
SSPC-SP3). Power brushing should not be used as a primary surface preparation method for
large areas.
F. Abrade adjacent surfaces for a distance of 150mm (6”) from edge of repair area.
G. Reinstate mesh to specification. If the repair area is less than 150mm x 150mm (6 x 6”), meshing
is not necessary, except for jet fire areas.
H. Reinstate Chartek to specification, in terms of fire protection, reinforcement and thickness, taking
care to smooth over the repair area edges. Reference Section A7.0 of this Manual.
Appendix F, “Procedure for Inspection, Test and Replacement” for Chartek fireproofing systems contains
comprehensive instructions on the repair and replacement of passive fire protection systems. The
procedure should be used, as necessary, in association with the current Chartek Application Manual.
NOTES:
A. For repairs, Chartek may be applied directly to blast cleaned steel.
B. Masking should be done around the area to be repaired in a square or rectangular shape. This will
give the patch a clean appearance once completed.
C. If any existing mesh is left from original installation, whole or edge pieces, be sure that all loose
Chartek is removed from around or behind the mesh. This will prevent the formation of voids or
adhesion problems.
D. Refer to hand application for examples.
A9.2 Coatbacks
The coatback distance for all secondary attachments to primary members is typically 450mm (18in),
measured from the extremity of the primary member along the secondary attachment. However,
secondary members and minor attachments that either individually or collectively, in a typical length of
1 metre (for structural members) or 1m2 (for divisions), do not exceed 3000mm2 (4.65in2) in
cross-sectional area need not be provided with any coatback fire protection material.

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Summary of coatback requirements:
Cross-sectional area (per linear metre)

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

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SECTION B – CHARTEK 7

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B1.0 CHARTEK PACKAGING AND STORAGE

B1.1 50kg (110lb) Kit
For plural component spray equipment, Chartek is supplied in a 50kg (110lb) kit
comprising of two drums of grey coloured resin (Part A) and one drum of light
coloured hardener (Part B).
Part A 35.48kg (78.2 lb)

(2 Drums)
Part B 14.52kg (32.0 lb)
(1 Drum)
Total 50.00kg 110.2
NOTE: 50kg (110lb) kits are only suitable for use with plural spray equipment.
B1.2 20kg (44.1lb) Kit

For single component pumps and trowel application, Chartek is supplied in a 20kg
(44.1lb) kit comprising of one part filled drum of grey coloured resin (Part A) and one
plastic pail of light coloured hardener (Part B). This allows the hardener to be
decanted into the Part A resin for mixing.
Part A 14.2kg (31.3lb)

Part B 5.8kg (12.8lb)
Total 20.0kg (44.1lb)
NOTE: 20kg (44.1lb) kits can also be used with plural spray equipment.
B1.3 Cast Grade

For casting work a less viscous version, Chartek cast grade, is available. For further details contact
International Protective Coatings.
B1.4 Storage Conditions for Chartek

Chartek should be stored dry, indoors and out of direct sunlight. The following storage temperature
ranges must be maintained:
• Minimum 1°C (34°F), maximum 30°C (86°F)

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B2.0 CARBON FIBRE MESH REINFORCEMENT

B2.1 Meshing Designs
The meshing requirements are given below. Particular attention should be paid to the Chartek type
and thickness, and fire type. Refer to Appendix A for HK-1TM mesh design drawings.
Table B1: Mesh Requirements

Use Hydrocarbon (Pool) Fires Jet Fires
Structural steel I and Open HK-1 mesh installed at mid film HK-1 mesh installed at mid film
Sections thickness with 50mm (2”) overlaps. thickness with 150mm (6”) overlaps
Beams and columns with webs less and with 100% coverage.
than 250mm (10”) deep do not
require mesh on webs.
Structural steel Hollow Sections HK-1 mesh installed at mid film HK-1 mesh installed at mid film
thickness with 50mm (2”) overlaps thickness with 150mm (6”) overlaps
and with 100% coverage. and with 100% coverage.
Tanks, Vessels and Pipework HK-1 mesh installed at mid film HK-1 mesh installed at mid film
Divisions – Bulkheads And Decks HK-1 mesh installed at mid film HK-1 mesh installed at mid film
B2.2 HK-1TM and HK-1 (M)TM Carbon Fibre Mesh Reinforcement

HK-1 and HK-1 (M) carbon fibre meshes are knitted cloth of carbon filaments and glass thread.
Both meshes are equivalent to each other with respect to their construction and constituent
materials, and their performance. The designation of HK-1 and HK-1 (M) relates only to their
manufacturing source.
B2.3 Packaging of HK-1 and HK-1 (M) Carbon Fibre Mesh Reinforcement
HK-1 and HK-1 (M) are available from International Protective Coatings in 165m2 (1776ft2) and
167.3m2 (1800 ft2) rolls respectively.
B2.4 General Rules for Meshing

1. Cut mesh to required sizes before starting Chartek application.
2. Apply mesh to wet Chartek at approximately mid thickness.
3. Roll the mesh thoroughly into the wet Chartek with short nap rollers dampened with PMA
solvent.
4. Overlap adjacent pieces of mesh by at least 50mm (2”). For jet fire applications, overlap
by at least 150mm (6”).
5. To minimise waste the straight carbon (black) fibres are parallel to flange edges and the axis of
hollow sections.
6. After installing HK-1, either continue to build up the required thickness or spray a light coat of
Chartek over the mesh to leave a good key for subsequent coats.
7. For jet fire applications the minimum overlap shall be 150mm (6”) and the HK-1 shall cover all
surfaces (i.e. 100% coverage without any gaps) of the member regardless of dimensions.

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B3.0 METAL MESH REINFORCEMENT

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

The metal mesh reinforcement systems used are:
• 12.7 x 12.7mm (½” x ½”) square opening, 1mm diameter (19 gauge) galvanised wire mesh
(“hardware cloth”);
• 12.7mm hexagonal opening, 0.75 to 0.9mm diameter (20-22 gauge) galvanised wire mesh
(“poultry netting”).
In both cases, the mesh must be galvanised after manufacture. All wire mesh, mesh stand-off
devices (when required) and lacing wire must be galvanised.
For stainless steel substrates and jet fire applications where required by the project, stainless steel
mesh must be used. Stainless steel mesh should be Type 316 (18-10) with 12.7 x 12.7mm (½” x
½”) square openings of 1mm diameter (19 gauge) wire mesh. All pins, mesh stand-offs and lacing
wire must also be stainless steel.
B3.3 Installation of Pins

1. Weld pins shall be 25mm (1”) to 38mm (1½”) long and 3mm (1/8”) in diameter. (Note: 2mm (5/64”)
diameter pins may be used for Chartek 7 thicknesses up to 7mm (275 mils)).
2. Pins must be tested for weld integrity by achieving a 95% success rate on bend tests of at least
20 pins each day (see the Quality Control Manual for Chartek Fireproofing Systems
Application for details).
3. Spacing of pins should generally be no more than 300mm (12”) on centres in any direction,
unless the specific fire design allows less frequent spacing.
4. The normal method of pin attachment is by capacitance discharge welding.
5. Weld areas must be suitably ground before welding to remove all mill scale, rust and other
contamination.
6. Where grinding has been done in the paint system to facilitate welding, the area must be
cleaned and touched up with an International Protective Coatings’ qualified epoxy primer. NB: It
is more practical to install the pins prior to blasting and priming.
7. For carbon steel substrates, copper coated mild steel pins should be used. For aluminium or
stainless steel substrates, pins must be made of compatible materials.
8. The use of adhesive bonded pins or studs is not permitted.

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B3.4 General Rules for Metal Meshing

1. Adjacent pieces must not have more than 50mm (2”) gap between them.
For jet fires, adjacent pieces of mesh shall be installed as close as reasonably possible to
each other and, in all cases, gaps shall not exceed 25mm (1”). Effectively the mesh shall
provide 100% coverage including web depths of less than 250mm (10”).
2. Mesh shall be brought as close as possible to the point where the Chartek 7 terminates.
3. Chartek 7 shall be applied as soon after mesh installation as possible to avoid surface
contamination.
4. Chartek 7 shall always be trowelled to ensure that the mesh is fully encapsulated and no voids
around the strands of mesh are formed.
Table B2: Meshing Designs for Structural Members and Tanks
Metal Mesh Reinforcement
Chartek 7 Flange Edges Webs Over 250mm (10”) Hollow Sections and
Thickness in Depth Tanks
Up to 12mm A A A or C
13mm+ B B B or D
A = 12.7 x 12.7mm (½” x ½”) square opening 1mm diameter (19 gauge) galvanised wire mesh
(“hardware cloth”) pinned or tied to the surface
B = 12.7 x 12.7mm (½” x ½”) square opening 1mm diameter (19 gauge) galvanised wire mesh
(“hardware cloth”) stood off 3mm from the surface
C = 12.7mm (½”) hexagonal opening 0.75mm - 0.9mm (20-22 gauge) galvanised wire mesh
(“poultry netting”) pinned or tied to the surface
D = 12.7mm (½”) hexagonal opening 0.75mm to 0.9mm (20 to 22 gauge) galvanised wire mesh
(“poultry netting”) stood off 3mm (1/8”) from the surface
Note on NORSOK M-501 metal mesh requirements:

For projects where NORSOK Standard M-501 is specified there may be a requirement for welded
pins and metal mesh. The project specification should be closely consulted.
Note on jet fire metal mesh requirements:

Metal meshing designs for jet fire exposure are detailed in project specifications and in accordance
with classification society approvals.

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B4.0 CHARTEK APPLICATION WITH SINGLE LEG AIRLESS SPRAY

EQUIPMENT
B4.1 Ambient Conditions
Suitable application conditions are of critical importance for the successful application of Chartek.
Consequently, Chartek should only be applied when the ambient conditions are within the following
parameters:
• Air temperature: minimum 10°C (50°F)

• Relative humidity: maximum 85%
• Surface temperature: at least 3°C (5°F) above dew point temperature
However, Chartek may be applied at an air temperature minimum 5°C (41°F) using plural spray
equipment only, recognising that the time to cure will in such applications be extended.
Additionally, there may also be a higher propensity for amine bloom formation which would affect
overcoating with further layers of Chartek, where required, and may affect overcoating with
topcoats. For such low air temperature applications, plural equipment is the only recommended
dispensing method.
B4.2 Surface Cleanliness

To ensure proper adhesion of Chartek to the primed substrate, the surfaces to be coated must be
dry and free from oil, grease, dirt or any other contaminants that have been deposited since surface
preparations were completed.
It is the applicator’s responsibility to inspect all surfaces to be coated and clean them if
necessary (see the notes on degreasing in Section A2.2).
Ambient conditions are of critical importance for a successful application. If they cannot be kept
within the above parameters, Chartek application may only proceed if adequate environmental
protection is provided.
B4.3 Primer and Surface Preparation

It is the applicator’s responsibility to verify that the correct primer type (included in the list of
qualified primers), thickness (as specified in Section A3.0) requirements are complied with.
It is also the applicator’s responsibility to ensure that the preparation of the surface which is to
be overcoated with Chartek is in accordance with the requirements of this Application Manual and
other documents that may be applicable. For acceptance of the primed surface, checks shall
include, but not be limited to, the following:
(a) The surface profile is in accordance with this Application Manual and other documents that
may be applicable.
(b) The surface condition at the time of primer application, both in terms of degree of visual
cleanliness and presence of surface contaminants.
(c) That the primer is qualified by International for use with Chartek.

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(d) That the applicator has access to, and is familiar with, the primer manufacturer’s application
data, and that the application process and environmental conditions are in compliance with
the primer manufacturer’s requirements.
(e) Primer thickness values shall not exceed the tolerance levels stated in Section A3.0,
Table A2: “Primer System Maximum Dry Film Thicknesses”.
(f) Age and condition of primer at point of overcoating with Chartek. See Appendix G, Technical
Note TN/F/083 “Overcoating of aged and zinc primers”.
It is the applicator’s responsibility to ensure that the primed surface and the primer itself are in
an acceptable condition for overcoating with Chartek. Such factors as ageing of the primer
(degradation and surface chalking), contamination, rust bloom, etc. shall be considered when
determining a surface’s suitability before overcoating with Chartek. Where there is any doubt as to
a primer’s acceptance, the primer manufacturer should be consulted and International Protective
Coatings advised.
NB: Overcoating a primer system with a 100% solids epoxy material such as Chartek is different to
overcoating with further layers of material, especially solvented materials. Consequently, it is
important that the primer manufacturer should be fully informed of the overcoating system and
purpose of that system when directing any questions to the manufacturer concerning overcoating.
International should be consulted where any doubt exists.
B4.4 Kit Size

For single leg airless spray pump application, Chartek is supplied in a
20kg (44.1 lb) kit comprising of one part-filled drum of grey coloured
resin (Part A) and one plastic pail of light coloured hardener (Part B).
Use of this kit size ensures provides sufficient space in the drum to
allow the Part B hardener to be decanted into the Part A resin for
mixing. Only full kits should be mixed to ensure the material is mixed
in the correct ratio.
B4.5 Material Preparation for Single Leg Airless Spray Figure B1: 20kg (44.1 lb) Kit
Application
Material preparation for single leg airless spray application requires the Chartek to be brought up to
the ideal temperature for spraying. Temperature is critical to ensure the correct viscosity to allow
good spray application to be achieved.
This needs to be carefully monitored, too cold and the material will not atomise and spray, too hot
and the pot life will be reduced and there will be the risk of blockages and curing of materials in the
lines. For guidance on working pot life see the following table:

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25°C (77°F) 30°C (86°F)

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

a digital temperature probe type).
Best spray results will be achieved when the material temperature is

within the following range:
Optimum mixed temperature Figure B2: Digital

o
C thermometer and
30 to 35 probe.
Accelerated methods of heating the Chartek containers, such as electrical heaters in direct contact
with the containers or hot water baths, are not permitted. Such methods can cause overheating of
the outer layers of Chartek in the container, which may produce undesirable changes to its
properties (including shorter pot life).
B4.6 Heated Storage Units

To achieve the correct temperatures it may be necessary to use heated storage units, especially in
cold and temperate climates.
Such storage units are typically built from standard site storage containers. The container will
generally be lined with thermal insulation (see photographs below) and should be suitably
ventilated.

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

There are two critical aspects to mixing Chartek, firstly to ensure that the two components are
thoroughly mixed and secondly to undertake the mixing operation as quickly as possible to ensure
maximum working pot life is maintained.

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Utilising the correct equipment can assist the process greatly. Chartek is a high viscosity material
and is difficult to mix; normal paint mixers will not be able to mix Chartek sufficiently thoroughly or
quickly and should not be used.
The mixer should be a high torque, variable speed, paddle mixer of minimum 5 HP air motor or
1000W/110V electric motor. It should be equipped with 250mm (10”) diameter paddle.
For best results, the mixer should be mounted on a power ram base to ease the effort required and
to allow vertical movement of the paddle blade.
The mixer should incorporate a drum stand or clamp to ensure the drum is held firmly during the
mixing operation.
Figure B5: Suitable Chartek mixing equipment
Proprietary Chartek mixing equipment is available from a number of manufacturers.
B4.8 Use of Solvent

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

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The solvent is added to Part A (resin) of the Chartek kit. The amount of PMA solvent required
varies with initial material temperature but typically will be 0.5 litres (1 pint) per full 20kg (44.1 lb) kit
of Chartek. At most, a maximum of 1.0 litre (0.25 US gallons) may be used per full 20kg (44.1 lb)
kit of Chartek.
The solvent used for mixing should also be at room temperature (typically 20°C (68°F)) to prevent it
cooling down the Chartek when added.
B4.9 Mixing Procedure

Kits should not be mixed until they are ready to be used. Once mixed the kit should be sprayed as
soon as possible, ideally it should be loaded into the machine within a few minutes of mixing.
After addition of PMA solvent into part A it should be mixed to incorporate the solvent fully within the
resin. The mixing should begin slowly and speed built up gradually.
When Part A has reached a smooth consistency, Part B is then poured into the Part A container,
scraping the sides of the Part B container to empty it completely, ensuring correct ratio of material is
mixed. Only full kits should be mixed to ensure the material is mixed in the correct ratio.
Again, the mixing should begin slowly and speed built up gradually, mixing carefully until a smooth
texture and uniform colour are achieved.
The shearing action of mixing the material will cause the material to heat up so temperature should
be checked after mixing. In addition, once the material is in a mixed state and left in the drum, the
exothermic nature of the reaction will cause the material to continue to increase in temperature,
greatly reducing the available pot life. If spray operations are held up for any reason then extended
pot life can be achieved by emptying out mixed Chartek on to flat surfaces, spreading it out to
reduce exothermic reaction and using it for trowel application.
B4.10 Single Leg Airless Spray Equipment

Only airless single leg spray equipment qualified by International Protective Coatings should be
used.
Typical equipment specification would be as follows:
Pump Ratio to be a minimum of 68:1, ideally 74:1 or greater, fitted

Compression with check valve to eliminate spray fan fluctuation
Ratio
Figure B6: Modified Airless Spray Unit

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Air Motor Graco Premier (or equivalent) mounted on a power ram with
a follower or induction material feed plate
Fluid lines ¾” ID, 15 to 20 metres (50 to 65 feet) long, pressure rated
to meet the required high pressures of the pump. Insulated
if required.
Whip Line ½” ID, 4.5 metres (15 feet) long, pressure rated to meet the
required high pressures of the pump
Spray Gun High pressure airless spray gun fitted with swivel.
Spray Tip 0.035” to 0.041” I.D. “reverse-a-clean” or equivalent airless

spray tips.
For smaller structural steel a narrow spray fan pattern Figure B7: High Pressure Spray Gun
should be used, e.g. size 3 or 4 thou tip.
For larger structures and fire divisions a wider spray fan

pattern may be used, e.g. size 5 or 6 thou tip.
Notes on Spraying:
There should be sufficient area available to spray and enough manpower to service the application,
operate the unit and mixing of material. Frequently shutting down the spray unit will causes wasted
time and material.
During production if the machine starts to require more pressure and the spray fan diminishes, then
this is a good indication that cleaning or flush of the machine is necessary. International Protective
Coatings’ GTA007 solvent is recommended for cleaning and flushing of equipment.
Flushing the pump with cold solvent will cause the internals of the machine to be cooled down,
again this cooling effect will affect the sprayability of the Chartek when it is reintroduced into the
pump. It is therefore recommended that the solvent used for flushing should also be at room
temperature (typically 20°C (68°F)).
The addition of more solvent or increasing the pressure will not solve the problem but will only
reduce film build up and take the machine passed its safe working parameters.
The follower plate situated at the base of the leg should be removed prior to the unit being
introduced into solvent.
Inside every single leg spray unit there are areas known as “black spots”. Black spots accumulate
mixed material which cannot be dislodged with the flow of freshly mixed material, these black spots
are a function of the machine design and this problem is not unique to Chartek. Even with the
system being flushed with thinners every sixth or seventh kit, these areas will still have traces of
material trapped, this material will start to cure and restrict the movement of the leg’s shaft.
It is therefore highly recommended that the leg be fully striped and dismantled at the end of each
working shift and all moving parts be thoroughly cleaned either by steam cleaning or with solvent.

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During stoppages in the day’s production (lunch breaks, etc.) the machine must be circulated with
solvent (GTA007) and the spray gun and tip must also be removed and immersed in solvent.
B4.11 Single Leg Spray Application Method

In order to ensure trouble free operation of this type of pump the material must be maintained at the
correct temperature. It is therefore necessary to provide controlled heated storage for the Chartek
and advisable to place the machine in a modified insulated container for work at low air
temperatures.
There should be sufficient area available to spray and enough manpower to keep up with the gun.
Frequently shutting down spray machines causes wasted time and material spent cleaning and
causes pressure build up in the material lines and spray gun, which may represent a safety hazard.
The first coat of Chartek is sprayed and quickly trowelled into the surface to ensure good wetting
and even thickness. Trowelling also helps to thoroughly encapsulate any pre-installed mesh and
reduces the formation of air pockets.
With airless spray applications using qualified equipment and where HK-1TM or no mesh is being
used, trowelling the first coat may be eliminated. In these instances it is essential that there is
thorough atomisation achieving consistent even spray fan (no fingering) and 100% wetting of the
surface.
If trowelled, trowel marks and high points are knocked down with a short nap roller dampened with
PMA solvent. The real purpose of this rolling is to achieve a uniform thickness of the coat, which
allows uniform build up of subsequent coats and ultimately the correct final thickness. Rolling also
serves to produce a smooth surface finish, when required.
Two precautions to take with rolling are:
1. If the Chartek has not gelled (started to cure) sufficiently, it can sag or slump.
2. Too much solvent on the roller can reduce the cure rate if it is forced into the wet Chartek.
For subsequent coats, sufficient time must pass for the applied Chartek to gel (“set up” or partially
cure) in order to support the weight of the additional material.
Preferably, subsequent coats should be applied when the previous coat is still tacky. Where
practicalities prevent “wet on wet” application, overcoating time should be reduced to a minimum.
When the overcoating time is longer than 24 hours, a sprayed holding coat should be applied to
leave the Chartek with a good key to improve the adhesion of the next coat. The holding coat is
produced by raising the pump output pressure to give a wide fan and increased atomisation. The
spray pass is much faster than normal and the result is a coarse finish that promotes good bonding
with subsequent coats.

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Beyond 24 hours, surfaces must be suitably washed with one of the approved methods described in
Section A2. It is imperative that surfaces are clean and thoroughly dry before additional coats of
Chartek are applied.
When using HK-1 mesh and more than 24 hours is expected before overcoating, it is a requirement
that a sprayed holding coat is applied over the HK-1 mesh to prevent contamination entrapment.
The final coat, when applied to a ‘wet’ surface, should be sufficiently thick to allow good ‘flowing out’
and to minimise surface roughness and to achieve the specified final thickness.
In applying a final coat to a hardened surface the thickness should be no less than 3mm (1/8”) to
ensure adequate adhesion to the hardened surface.
When spraying in cold conditions, the pump should be located in a heated area, ideally the same
area that is used to store the Chartek at a sprayable temperature. Hoses may be insulated and
ambient temperature parameters must be frequently checked and maintained.
In hot conditions, the spray unit and Chartek must be located in an air-conditioned environment.
Hoses should be insulated and wrapped with heat reflecting tape. It may also be necessary to raise
hoses above the ground in extremely hot environments. High substrate temperatures should be
avoided by providing suitable shade cover and air-conditioning of the area immediately surrounding
the workface may also be necessary.
B4.12 Water Contamination

CAUTION: If rain or condensation occurs during application or shortly thereafter, moisture
may be absorbed into the uncured material. In addition, an amine bloom may form on the
Chartek surface. These conditions will affect intercoat adhesion.
Take the following action if water contamination occurs:
Contamination Action
Cured Chartek (fresh water): Dry and solvent wipe
Cured Chartek (salt water): Warm water wash - maximum 60°C (140°F)
Dry and solvent wipe
Uncured Chartek: Remove source of moisture
Allow Chartek to cure
Remove and replace all uncured material
B4.13 Surface Finish

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

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

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B5.0 CHARTEK APPLICATION WITH PLURAL SPRAY EQUIPMENT

parameters:

equipment only, recognising that the time to cure will in such applications be extended. Additionally,
there may also be a higher propensity for amine bloom formation which would affect overcoating
with further layers of Chartek, where required, and may affect overcoating with topcoats. For such
low air temperature applications, plural equipment is the only recommended dispensing method.


qualified primers), thickness (as specified in Section A2.0, Table A1: Chartek Surface Preparation
Requirements) requirements are complied with.
a) The surface profile is in accordance with this Application Manual and other documents that
may be applicable.

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Coatings advised.
B5.4 Material Preparation for Plural Component Spray Application

Prior to spraying Chartek with plural component spray equipment, the material should be preheated
to the following requirement:
• 30 to 34°C (86 to 93°F) for 24 hours (maximum 48 hours) prior to use
WARNING:
Accelerated methods of heating the Chartek containers, such as electrical heaters in direct
contact with the containers or hot water baths, are not permitted. Such methods can cause
overheating of the outer layers of Chartek in the container, which may produce undesirable changes
to its properties (including shorter pot life).
B5.5 Plural Component Spray Equipment

As Chartek is a thixotropic material, it is most efficiently applied with purpose built hot spray plural
component pumps, which have the advantage of not requiring any premixing of the two parts.
Parts A and B of Chartek are pumped into separate pressurised heated tanks, equipped with high
torque paddle mixers, where they are brought up to temperature. From here, the separate parts are
drawn into a fixed ratio displacement pump that establishes the correct ratio in volume. The two
parts, still separate, are then pumped through electric in-line heaters and on through heated
insulated hoses to an in-line static mixer (“worm”). As the two parts are pushed through the worm
they are intimately mixed, then fed through a short whip line, typically 4.5 metres (15ft) long, to the
high pressure (minimum 500 bar (7250 psi)) airless spray gun. Too cool a gun exit temperature
may result in fingering of the spray pattern due to insufficient atomisation, while too hot a
temperature will produce too rapid a cure and make trowelling difficult.

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temperatures.
The importance of keeping all spray equipment clean and efficient cannot be overstated, as down
time is very costly. For this reason a skilled and experienced machine operator is a vital component
of the team.
Machines built to spray Chartek are supplied by a number of companies. Each supplier provides
instructions on machine operation and maintenance. International Protective Coatings should
always be consulted regarding the suitability of spray equipment.
Because of the larger volume of material delivered by these machines, crew sizes are larger to keep
up with the gun. The material is delivered hot and therefore must be worked more quickly than
conventional spray
Table B3: Operating Parameters for Plural Component Spray Machines
Operating Parameters
Storage tank temperatures Part A: max. 60°C (140°F )
Part B: max. 50°C (122°F )
In-line heater temperatures Part A: 60 to 70°C (140 to 158°F )
Part B: 45 to 55°C (113 to 131°F )
Hose heater temperature 60 to 70°C (140 to 158oF)
Gun exit temperature 57 to 63°C (135 to 145°F )
Storage tank pressures Part A: 5 bar (70 psi)
Part B: 4 bar (60 psi)
Tank stirrer speed Part A: 20rpm minimum
Part B: 15rpm minimum
Displacement pump pressure 175 to 240 bar (2500 to 3500 psi)
Fluid lines:
¾” I.D. fluid lines for Part A and ½” I.D. fluid lines for Part B.
Spray tips:
0.035” to 0.041” I.D. “reverse-a-clean” or equivalent airless spray tips. For smaller structural steel a
narrow spray fan pattern should be used, e.g. size 3 or 4 thou tip. For larger structures and fire
divisions a wider spray fan pattern may be used, e.g. size 5 or 6 thou tip.

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B5.6 Ratio Checks

It is important that the delivery ratio of plural spray pumps is regularly checked. As a minimum, a
ratio check by weight should be performed at the start up of each day’s production and again if the
machine is shut down and restarted for any reason. Use the following procedure for ratio checks by
weight:
1. Weigh clean empty Parts A and B containers and note the respective weights.
2. Place the containers under the ratio check valves located on the mixing block and open the
valves at exactly the same time.
3. Close the valves when the containers are at least half full at exactly the same time.
4. Find the net weight of each part by subtracting the weight of the containers.
5. Calculate the ratio of Part A to Part B as a percentage of the total weight.
In addition to the ratio checks, constant checking of the displacement pump pressure gauges and
the colour of the mixed Chartek should be carried out by the machine operator and sprayer
respectively.
Example Calculation
Part A empty container weight 2.3kg (5.0lb)
Part B empty container weight 1.2kg (2.6lb)
Part A full container weight 9.4kg (20.7lb)
Part B full container weight 4.1kg (9.0lb)
Part A net weight 7.1kg (15.7lb)
Part B net weight 2.9kg (6.4lb)
Calculated Parts A:B as a ratio of total weight 2.45:1
The acceptable ratio range of Part A to Part B 2.32:1 Minimum
2.56:1 Maximum
Calculated ratio A:B as a percentage of total weight 71.0:29.0
(Total combined =
100%)
The acceptable ratio range as a percentage Part A – 70% to 72%
Part B – 30% to 28%
B5.7 Plural Spray Application Method

and spray pump.
When spraying in cold conditions, the spray pump should be located in a heated area, ideally the
same area that is used to store the Chartek at a sprayable temperature. Hoses should be insulated
and heated and ambient temperature parameters must be frequently checked and maintained.

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In hot conditions, the spray pump and Chartek must be located in an air-conditioned environment.
and even thickness. With plural spray equipment applications and where HK-1TM or no mesh is
being used, trowelling the first coat may be eliminated provided there is thorough atomisation
achieving consistent even spray fan (no fingering) and 100% wetting of the surface. Trowelling also
helps to thoroughly encapsulate any pre-installed mesh and reduces the formation of air pockets.
PMA solvent. Rolling achieves a uniform thickness of the coat, which allows uniform build up of
subsequent coats and ultimately the correct final thickness. Rolling also serves to produce a
smoother surface finish, reducing high spots and stippled finish.
Two precautions to be taken with rolling are:
practicalities prevent “wet on wet” application, overcoating time should be reduced to a minimum
and a sprayed holding coat should be applied to leave the Chartek with a good key to improve the
adhesion of the next coat. In addition, a sprayed holding coat is applied over HK-1TM mesh to
prevent contamination entrapment when extended overcoating intervals are expected.
The holding coat is produced by boosting the Chartek temperature (in the plural component spray
equipment) and/or raising the pump output pressure to give a wide fan and increased atomisation.
The spray pass is much faster than normal and the result is a coarse finish that promotes good
bonding with subsequent coats.
Before spraying subsequent coats onto cured surfaces, they should be checked for cleanliness and,
if required, suitably cleaned with one of the approved methods described in Section A2.0 “Surface
Preparation”. It is imperative that surfaces are clean and thoroughly dry before additional coats of

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B5.9 Surface Finish

acceptable.
B5.10 Terminations

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B6.0 HAND TROWEL APPLICATION

parameters:



may be applicable.

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Coatings advised.
B6.4 Material Preparation for Hand Trowel Application

Prior to applying Chartek by hand trowel, the material should be preheated to the following
requirement:
• Warm enough to mix, typically 20 to 25oC (68 to 77°F)
Note: The higher the temperature the shorter the working pot life. Pot life durations are published
on the product data sheets
B6.5 Mixing
For hand application Chartek must be premixed. A small amount of PMA (propylene
methoxyacetate) thinner is added to Part A to reduce viscosity for mixing and application
International’s thinner GTA123 or GTA822 is recommended for this purpose.
The amount required varies with initial material temperature but up to 0.5 litres (0.13 US gallons)
may be used per full kit of Chartek.
When Part A has reached a smooth consistency, the Part B is then poured into the Part A container,
scraping the sides of the Part B container to empty it completely. The two parts are thoroughly
mixed together with a high torque variable speed paddle mixer, minimum 5 HP air motors (or
1000W/110V electric motor minimum) equipped with 250mm (10”) paddles. Mixing should continue
until a uniform colour is achieved

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to allow vertical movement of the paddle blade. The mixing should begin slowly and speed built up
gradually.
Mix carefully until a smooth texture and uniform colour are achieved. For a full kit this is
approximately 4 minutes. Kits should not be mixed until they are ready to be used.
B6.6 Hand Trowel Application Method

Chartek may be applied using plasterer’s trowels, which has the advantage of very little waste and
virtually eliminates the need for masking.
After a kit has been mixed, it may be spread out on flat clean boards or surfaces for each applicator
to work with. This prevents the material from curing too quickly and allows sufficient working time.
Alternatively the material may be applied directly from the pail.
Trowel marks and high points are knocked down with a short nap roller dampened with PMA
solvent. Rolling achieves a uniform thickness of the coat, which allows uniform build up of
practicalities prevent “wet on wet” application, overcoating time should be reduced to a minimum. In
addition, an encapsulating coat is applied over HK-1TM mesh to prevent contamination entrapment
when extended overcoating intervals are expected
B6.7 Mixing of Partial Kits

Often trowel application will require less than a full kit of Chartek. In these cases, the required
amounts of Parts A and B should be accurately weighed out into a clean container and thoroughly
mixed. The correct ratio by weight for Chartek is as follows:
When complete kits are to be split down the following method of calculation may be used:

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Worked Example
Parts A:B as a ratio of total 2.45:1
weight:
The acceptable ratio range of 2.32: 1 Minimum
Part A to Part B is: 2.56: 1 Maximum
Required Weight of Part B Measured Weight of Part A ÷ 2.45 (the Chartek 7 weight
calculated as follows: ratio)
e.g. 8kgs of Part A ÷ 2.45

= 3.27kgs of Part B
Therefore the required amount of Part B to be weighed out

and added to the 8kgs of Part A is 3.27kgs.

B6.9 Surface Finish

For trowel application a smooth, even and rolled finish should be achieved. Discontinuities,
pinholes, voids or isolated deposits of excess thickness in the coating are not acceptable.
B6.10 Terminations

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APPENDICES

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APPENDIX A – HK-1TM Meshing Arrangements

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APPENDIX B – Metal Meshing Arrangements

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APPENDIX C – Certified Thicknesses - Bulkheads and Decks

Chartek® 7
Certified Reinforcement and Thickness Arrangements
for Bulkhead and Decks
TABLE 1: BULKHEADS
Chartek 7
Reinforcement and Thickness
Design (mm)
American Bureau of
Lloyd’s Register Det Norske Veritas
Shipping
A-60 class 5.0

NC NC
(Insulated backface) HK-1 Mesh
5.0 5.0 6.5

H-0 class (400°C)
HK-1 mesh HK-1 mesh HK-1 mesh
7.0
H-30 class NC NC
HK-1 mesh
H-60 class 5.0 5.1

NC
(Insulated backface) HK-1 Mesh HK-1 mesh
10.0 9.0 10.0

H-60 class
H-120 class
NC NC NC
(Insulated backface)
13.0 13.0 14.0

H-120 class
HK-1 mesh HK-mesh HK-1 mesh

TABLE 2: DECKS
Chartek® 7
Reinforcement and Thickness
Design (mm)
American Bureau of
Shipping
8.0 8.0
A-60 class NC
HK-1 mesh HK-1 mesh
5.0 5.0 6.5

H-0 class (400°C)
HK-1 Mesh HK-1 Mesh HK-1 mesh
7.0
H-30 class NC NC
HK-1 mesh
H-60 class
NC NC NC
10.0 9.0 10.0

H-60 class
H-120 class
NC NC NC
15.0 15.0
H-120 class NC
HK-1 mesh HK-1 mesh
NC = Not Certified

ADDITIONAL THICKNESS FOR JET FIRES:
Notes:
The thickness of coating Chartek® for jet fire exposure may determined by adding a “jet fire erosion
thickness” as shown in Tables 3 or 4 (dependent on mesh type used) to the thickness required by
hydrocarbon testing as shown in Tables 1 and 2. In all instances the mesh type, position and
overlaps shall be strictly in accordance with the Chartek Application Manual and relevant
certification.
Table 3: Jet Fire Erosion Thickness – HK-1 Mesh
Additional Chartek 7 Thickness

Jet Fire Duration (mm)
Lloyd’s Register Det Norske Veritas American Bureau of Shipping
No Jet Fire +0 +0 NC
Up to 20 minutes jet fire +2 +1 NC
21 to 30 minutes jet fire +2 +2.5 NC
61 to 90 minutes jet fire +4 NC NC
91 to 120 minutes jet fire +5 NC NF
NC = Not Certified

Table 4: Jet Fire Erosion Thickness – Stainless Steel Mesh
Additional Chartek® 7
Jet Fire Duration Thickness (mm)
American Bureau of
Shipping
No Jet Fire +0 0 NC
Up to 20 minutes jet fire +1 +1 NC
21 to 30 minutes jet fire +1 +2 NC
NC = Not Certified

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APPENDIX D – Typical Standards of Finish and Mesh Overlap

Photographic Reference

Standards of Application Finish
Typical standard of uniform spray finish, additionally showing clean, straight, free
edge terminations
Material left in trowelled but unrolled finish

This document and its contents are the copyright of International Paint Limited and may not be reproduced in whole or in part without the express permission of International
Paint Limited. All products supplied and technical advice or recommendations given are subject to our standard Conditions of Sale.
Poor standard of surface finish showing unacceptable heavy spray and sags

Mesh Overlaps
HK-1TM mesh 50mm overlap
HK-1 mesh 150mm overlap for specific jet fire applications

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APPENDIX E – Chartek Checklist

Chartek 7 - Basic Installation Checklist
1. Clean surface 2. Prime surface 3. Inspect
Record QA details.
Blast to Sa 2½. Apply 50-75 microns (2-3 mils) i.e. weather, type
Record profile of qualified primer of primer, etc
4. Wetting coat of Chartek 5. Build up to mesh depth
2-3mm (70-110 mils) trowel in well.

Trowelling is not required if spray
thoroughly wets surface
6. Inspect for thickness and uniformity 7. Install HK-1 mesh on wet surface
Wet gauge or drill Ensure fibre orientation and

overlaps
8. Cover mesh with Chartek 9. Build up to final thickness
Where mesh
reinforcement is
required
10. Final inspection for 11. Document 12. Finish with recommended
uniformity of thickness topcoat as required. Record
measurements
type and QA details
For full details refer to the For alternative primers and topcoat, please
current Chartek Application contact International Paint
Manual. 1 October 2005_Rev.1
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APPENDIX F – Procedure for Inspection, Test and Replacement of

Failed Fire Protection

Technical Note
TN/F/077_Rev.0_130203
Procedure for Inspection, Test and Replacement

(PITR)
FAILED FIRE PROTECTION
Introduction
Based on the understanding that the previously applied passive fire protection (pfp)
material is to be thoroughly removed prior to reinstatement with Chartek® 7, the
following is the recommended inspection, test and replacement procedure to be
implemented.
Inspection and Test Plan (ITP)

An Inspection and Test Plan (ITP) should be developed based upon this document and
other documentation/specifications relating to the structure in question. The ITP should
include clear details of each stage of the process and ‘hold’ points for acceptance of
critical items.
1. Material Removal
1.1. The existing passive fire protection material must be completely removed from
the surface revealing clean and sound primer system prior to overcoating with
Chartek. Method of removal to be advised to International prior to work
commencing. Typically methods include hand tools, high pressure water jetting
and other mechanical methods.
2. Reinstatement of Existing Primer System

2.1 Generally it is anticipated that the primer system under the failing material will be
sufficiently degraded that full surface preparation and reinstatement of primer
system will be required. However, in the event of early failure (disbondment) of a
fire protection system, it may be that a sound primer system can be revealed. In
this situation the following procedure applies.
2.2 The cleanliness, condition, thickness and general soundness of the primer is
critical to the ultimate adhesion of the Chartek fireproofing and consequently
procedures relating to inspection and evaluation of primer soundness must be
thoroughly followed for the full surface area.
2.3 Dependent upon the method of removal of the failing fire protection material, the
inspection after treatment of the primer system may vary. Any departure or
change from the procedure recommended in this document must be reported to
International Paint for review and acceptance prior to the change being
implemented. Method used to be advised to International prior to work
commencing.

1
Technical Note
TN/F/077_Rev.0_130203
2.4 Damage to the primer system during removal of the failed pfp material must be
repaired by appropriate means (approved by International) to result in a sound
surface prior to Chartek® application. Generally this will require surface treatment
to ISO 8501-1 St 3 or SSPC-SP3 for limited areas of damage.
2.5 Key criteria for acceptance of the existing primer system are as follows:
• The primer system is of known origin and approved by International Paint

for use under Chartek fireproofing. The primer system must be a
recognised primer in accordance with the current acceptable primers list for
use with Chartek fireproofing, obtainable from International Paint, Fire &
Insulation Products.
• The primer thickness must be within the tolerable levels indicated in the
Chartek Application Manual, Section 4, a synopsis of which is as follows:
The maximum allowable primer system DFTs are summarized in the following
table.
Table 2. Primer system maximum DFTs
PRIMER SYSTEM DRY FILM THICKNESS

Epoxy primer 50–75 microns 100 microns

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

Epoxy zinc primer plus tie-coat 75–110 microns 125 microns

(3–4.4 mils) (5 mils)
2.6 The primer system must be sound with no evidence of breakdown, flaking, rust
breakthrough, contamination, or other defective condition which would indicate
that the primer may not be suitable for overcoating with Chartek fireproofing in
accordance with the Chartek 7 Fireproofing Application Manual.
2.6 Final cleaning and preparation of sound primer system will be obtained by high
pressure fresh water washing or, if required, solvent cleaning to SSPC SP1.
2.7 Test for the presence of soluble chloride salts using a method approved by
International Paint.

2
Technical Note
TN/F/077_Rev.0_130203
2.8 Adhesion and cohesive strength of the primer system are critical to the longevity
of the fire protection system. Consequently, random dolly pull-off tests in
accordance with ISO 4624 must be carried out at a frequency one test per 3m2.
The minimum acceptable pull-off value utilising this test procedure is:
Hydraulic PAT adhesion test: 10MPa

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

out the installation of fire protection to review all procedures utilised on the
foregoing 1.1 to 2.8 and to accept the surface as suitable for overcoating with
Chartek fireproofing. This may require obtaining acceptance of the owner or the
owner’s designated contractor.
3. Method to be Used for Surface Repreparation and/or Primer Replacement is

Required
3.1 In certain circumstances the inspection of the steel surface after removal of the
pfp material may reveal that a more thorough remedial treatment is required.
Typical situations include:
• the primer or coating system does not appear on the Chartek fireproofing
qualified primers list
• the thickness of the primer system is unacceptable
• the primer system is degraded to the point where significant corrosion is
present
• the general condition of the surface is such that anything other than full
surface treatment will not result in a surface that is acceptable for Chartek
application
3.2 The most acceptable form of surface repreparation is open abrasive blasting. It
is recognised that in certain situations, particularly on offshore installations, open
abrasive blasting is not permissible. Consequently, alternative methods of
preparation may be found including wet blasting and high pressure water jetting.
Methods which do not develop or reveal a surface profile are generally
unacceptable. Power tool cleaning is acceptable but only for limited areas.
NB: Methods used must be advised to International Paint and approved prior to
commencement of work.

3
Technical Note
TN/F/077_Rev.0_130203
3.3 Once the appropriate surface preparation method has been determined and
carried out, utilisation of an appropriate primer system should be employed. This
may include application of a specific primer system relevant to the surface
preparation method. Any new primer system used must be listed on the
Chartek® fireproofing qualified primers list.
3.4 Chartek fireproofing material must be installed by a Qualified Applicator using

equipment approved by International Paint and personnel who have been trained
at the Chartek fireproofing applicator school and who are in possession of a
certificate attesting to the fact that they have attended training.
3.5 Chartek fireproofing must be installed in strict accordance with the Chartek 7
Fireproofing Application Manual. Particular attention should be paid to the
environmental conditions during application of material.
3.6 Chartek material is to be installed to the correct thickness in accordance with the
specified material thickness to meet the installation’s fire criteria. It is the
responsibility of the Chartek fireproofing Qualified Applicator to ensure that the
correct thickness is applied to the specific area of the structure being fire
protected. Should there be doubt with reference to specified thicknesses, these
should be checked with the owner or the owner’s designated representative and
3.7 Application of Chartek fireproofing should not commence until acceptance for
overcoating of the prepared surface has been given as in 2.9 above. Where
required this will include acceptance by the Chartek fireproofing Field Service
Engineer as part of the fire protection installation audit procedure conducted by
NB: It is the responsibility of the International Paint’s Technical Service Engineer

to carry out an audit of the installation process. He is not responsible for the daily
inspection activities, which should be carried out by the Chartek fireproofing
Qualified Applicator.
4. Acceptance of Installed Surface and Topcoating

4.1 The Chartek fireproofing Qualified Applicator is responsible for obtaining
acceptance by the owner or the owner’s designated representative that the
installation is completed to the required standard and thicknesses prior to
application of topcoat.
4.2 Topcoating should be applied in accordance with the Chartek 7 Fireproofing

Application Manual in a timely fashion.

4
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APPENDIX G – Technical Note TN/F/083 “Overcoating of aged and

zinc primers”

Technical Note
TN/F/083_Rev.1_040205
Overcoating of Aged Primers and Zinc Primers

with Chartek® Fireproofing
Background
As a general rule it is good practice to overcoat primers used with Chartek as soon as the
primer is sufficiently cured to accept overcoating. Overcoating of primers in a timely fashion
reduces the risk of contamination prior to overcoating and risk of poor adhesion due to
deterioration of the primer generally.
At all times the following shall be strictly followed:
1. The primer manufacturer’s recommendation for overcoating of the primer in question with
a thick film epoxy fireproofing.
2. International Paint’s recommendations.
3. Project specifications and the Chartek Application Manual, primers section.
4. The primer or primer system is listed on the Chartek Qualified Primer Systems list, latest
edition.
Aged Primers
As primers age due to a number of factors there is no definitive rule as to maximum time that
a primer can be left prior to overcoating with Chartek. Factors such as UV exposure, humidity
and general environmental conditions can cause a wide variation in acceptability. UV
exposure in particular can cause surface chalking and crazing.
• In all cases the condition of the primer must be closely examined and the
recommendations of the primer manufacturer adhered to. Generally primer
manufacturers specify the recommended overcoating times in product data sheets, or the
manufacturer should be consulted for the overcoating limits. High UV exposure can
decrease these times considerably, emphasising the need for close inspection prior to
Chartek application.
NB: When consulting the primer manufacturer, they must be made aware that the product
being applied is a thick film (i.e. millimetres rather than microns) 100% solids epoxy system,
i.e. Chartek. It is likely that the manufacturer will consider overcoating with thick film epoxy
differently to overcoating with thin film solvented systems.
As the Chartek Qualified Applicator is responsible for the installation it is normally his
responsibility to accept or not accept the primed surface. International strongly encourages
other parties, such as the owner, engineer and fabricator, to require attention to condition of
primer and to ensure that project specifications, QA/QC and other relevant documents
correctly address these issues.

This document and its contents are the copyright of International Paint Limited and may not be reproduced in whole or in part without the express permission of International Paint Limited.
All products supplied and technical advice or recommendations given are subject to our standard Conditions of Sale.
Technical Note
TN/F/083_Rev.1_040205
Zinc Primers
Two types of zinc primers are used with Chartek®, they are (overcoating time typically within
5 days and 21 days with a tie coat):
• Inorganic Zinc Silicate

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

Technical Note
TN/F/083_Rev.1_040205
additional comment and advice. It should also be noted that the primers listed as qualified for
use with Chartek® fireproofing are qualified by their country of origin and additional care is
needed when utilising primers of the same designation from alternative locations. Contact
should be made with International Paint in these circumstances.

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

This document and its contents are the copyright of International Paint Limited and may not be reproduced in whole or in part without the express permission of International Paint
Limited. All products supplied and technical advice or recommendations given are subject to our standard Conditions of Sale.
Technical Note
TN/F/101_121104
Disposal of Chartek®
Mixed (Cured) Material
This Technical Note addresses the procedure for the disposal of Chartek Parts A and B when
mixed, that is cured material.
In the first instance, the local authorities under whose jurisdiction the disposal of waste
materials fall should be consulted as local regulations may differ in various parts of the world
and within different regions of a country. Additionally, disposal regulations are constantly
being changed or amended and the following can only be considered a guide.
Mixed, that is when cured, Chartek material may be incinerated and disposed of in a land-fill
site.
Chartek’s constituent components Parts A and B when mixed and cured are classified as
non-flammable and non-hazardous, and contain no toxins that would prevent land-fill
disposal.
Should there be components of Parts A and B they should be mixed together and allowed to
cure. All excess of each component should be removed from containers and the work site.
The solid material is classified as non-flammable and non-hazardous.
After a fire charred material may also be treated in the same way, as above.
There are no specific requirements for protective clothing. However, it is recommended that
as a precaution, during disposal, personnel wear overalls, gloves and a mask.

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APPENDIX I – Definitions and Abbreviations

a bcdefg
® ®
Protective Coatings
D e f i n i t i o n s a n d A b b re v i a t i o n s
TOLERANCES The numerical information quoted in this data manual has been derived from
laboratory test data obtained under controlled conditions for the products
described. Whilst every effort has been made to ensure accuracy, this information
will be subject to minor variations obtained in normal manufacturing tolerances,
and any fluctuations in ambient conditions during the application and curing
periods.
GLOSS LEVEL Typical gloss values have been determined in accordance with ISO 2813:1978 using a
60° gloss head. The categories used in the data sheet are:
Finish (Sheen) Gloss (60° Head)
Matt 0-15
Eggshell 16-30
Semi-Gloss 31-60
Gloss 61-85
High Gloss >85
In practice, the level of sheen and surface finish will be dependent upon a number
of factors, including application and the condition of the surface to be overcoated.
DRY FILM THICKNESS The measured thickness of the final dried film applied to the substrate.
(DFT)
WET FILM THICKNESS The initial thickness of the wet coating applied to the substrate.
(WFT)
VOLUME SOLIDS The volume solids figure given on the product data sheet is the percentage of the
wet film, which remains as the dry film, and is obtained from a given wet film
thickness under specified application method and conditions. These figures have
been determined under laboratory conditions using the test method described in
the Oil & Colour Chemists (OCCA) Monograph No. 4 - Determination of the Solid
Content of Paint (by Volume). This method is a modification of ASTM D-2697
which determines the volume solids of a coating using the recommended dry film
thickness of the coating quoted on the product data sheet, and a specified drying
schedule at ambient temperature, i.e. 7 days at 23°C ± 1°C.
DRYING TIME The drying times quoted in the product data sheet have been determined in the
laboratory using a typical dry film thickness, the ambient temperature quoted in the
relevant product data sheet, and the appropriate test method, i.e.
Touch Dry (ISO 1517-73) - The surface drying state of a coating when
Ballotini (small glass spheres) can be lightly brushed
away without damaging the surface of the coating.
Hard Dry (ISO 9117-90) - The condition of the film in which it is dry
throughout its thickness, as opposed to that
condition in which the surface of the film is dry but
the bulk of the coating is still mobile.
This through drying state is determined by the use of a “mechanical thumb” device
which, when applied using a specified gauge, under specified pressure, torsion and
time, does not mark or damage the film.
The drying times achieved in practice may show some slight fluctuation, particularly
in climatic conditions where the substrate temperature differs significantly from the
ambient air temperature.
O V E R C O AT I N G The product data sheet gives both a “minimum” and a “maximum” overcoating
I N T E R VA L interval and the figures quoted at the various temperatures are intended as
guidelines, consistent with good painting practices. Certain terms require
elaboration as follows:
Minimum
The “minimum overcoating time” quoted is an indication of the time required for
the coating to attain the necessary state of dryness and hardness to allow the
application of a further coat of paint. It assumes:
(i) the coating has been applied at the normal recommended thickness.
(ii) environmental conditions both during and after application were as

recommended for that particular coating, especially in respect of temperature,
relative humidity and ventilation.
(iii) the paint used for overcoating is suitable for that purpose.
(iv) an understanding of the “method of application”. For example, if a coating can

be applied by both brush or spray it is expected that overcoating may be
carried out more rapidly if sprayed and it is the “lowest” figure that is quoted.
If the above conditions are not met, the quoted minimum overcoating times are
liable to variation and will invariably have to be extended.
Maximum
The “maximum overcoating time” indicates the allowable time period within which
overcoating should take place in order to ensure acceptable intercoat adhesion is
achieved.
Extended
Where an “extended” overcoating time is stated, the anticipated level of intercoat

adhesion can only be achieved if:
(i) the coating has been applied in accordance with good painting practices and
at the specified film thickness.
(ii) the aged coating has the “intended” surface characteristics required for long
term overcoatability. For example, an over-applied epoxy MIO may not have
its usual “textured” surface and will no longer be overcoatable after ageing
unless it is abraded.
(iii) the condition of the coating to be overcoated must be in intact, tightly

adherent, clean, dry and free from all contaminants. For example, the rough
textured surface of an MIO may require “extensive” cleaning, especially in an
industrial and/or coastal environment.
(iv) coatings having a glossy surface which could have a detrimental effect on the
adhesion of subsequent coats should be treated by light surface abrasion,
sweep blasting, or other suitable processes which will not cut through or
detract from the performance of the underlying coating.
It should be recognised that the level of intercoat adhesion obtained is also

dependent upon the chemistry of the “topcoat”. By their nature, primers or
undercoats with acceptable pigment levels will have inherently better adhesion than
finish coats with lower pigment contents.
The measurement of ultimate “adhesive strength” can often be a difficult process,

and interpretation of results can be subjective. Excellent adhesion does not
necessarily mean good performance, nor does relatively poor adhesion necessarily
mean poor performance.
Although the adhesion of coatings applied to aged/cured coatings may be deemed

satisfactory for the specified end use, actual numerical values obtained for adhesion
may be less than with coatings applied within “minimum/short” overcoating
intervals. For further additional information on individual products, or coating
schemes, consult International Protective Coatings.
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® ®
Protective Coatings
FLASH POINT The minimum temperature at which a product, when confined in a Setaflash closed cup,
must be heated for the vapours emitted to ignite momentarily in the presence of a flame
(ISO 3679:1983).
V O L AT I L E O R G A N I C Volatile Organic Content (VOC) is the weight of organic solvent per litre of paint.
CONTENT (VOC)
Legislative requirements differ from country to country, and from region to region, and
are constantly being reviewed. Two values are quoted for VOC on the product data sheet
which have been determined practically in the laboratory using the following published
test methods:-
UK - PG6/23(92), Appendix 3
This test method was published in February 1992, by the UK Department of the
Environment as part of the Secretary of State’s Guidance Note (PG6/23(92)), issued as a
guide to local authorities on the appropriate techniques to control air pollution, in order
to achieve the objectives laid down in the Environmental Protection Act 1990. The
method described in Appendix 3 includes guidance on the method of measuring VOC of
coatings, as applied to demonstrate compliance with Clause 19 of the Guidance Note.
USA - EPA Federal Reference Method 24
The Environmental Protection Agency (EPA), published procedures for demonstration

of compliance with VOC limits under Federal Reference Method 24 “The Determination
of Volatile Matter Content, Density, Volume Solids and Weight Solids of Surface
Coatings”. This method was originally published in the Federal register in October 1980,
and coded 40 CFR, Part 60, Appendix A, and amended in 1992 to incorporate
instructions for detailing with multi-component systems, and a procedure for the
quantitative determination of VOC exempt solvent.
It is recommended that users check with local agencies for details of current VOC
regulations, to ensure compliance with any local legislative requirements when proposing
the use of any coating.
WORKING POT LIFE The maximum time during which the product supplied as separate components should be
used after they have been mixed together at the specified temperature (ISO 9514:1922).
The values quoted have been obtained from a combination of laboratory tests, and
application trials, and refer to the time periods under which satisfactory coating
performance will be achieved.
Application of any product after the working pot life has been exceeded will lead to
inferior product performance, and must NOT be attempted, even if the material in
question appears liquid in the can.
SHIPPING WEIGHT The shipping weights quoted refer to the total weight of the product supplied plus the
weight of the can. These weights are quoted for individual components, and do not take
into account any additional packaging weight attributable to cartons, etc.
SHELF LIFE The shelf life quoted on the product data sheets is generally a conservative value, and it is
probable that the coating can be applied without any deterioration in performance after
this period has elapsed. However, if the specified shelf life has been exceeded, it is
recommended that the condition of the material is checked before any large scale
application is undertaken using materials beyond the quoted shelf life.
For further information consult International Protective Coatings.
Disclaimer
The information given in this manual is for general guidance only and is not guaranteed as being wholly accurate or complete. Unless otherwise agreed in writing,
all products supplied and technical advice given by us are subject to our standard conditions of sale, a copy of which is available upon request.
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SECTION C – CHARTEK 8

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C1.0 CHARTEK PACKAGING AND STORAGE

C1.1 50kg (110lb) Kit
For plural component spray equipment, Chartek is supplied in a 50kg (110lb) kit
Part A 35.7 kg (78.7 lb)

(2 Drums)
Part B 14.3 kg (31.5 lb)
(1 Drum)
Total 50 kg 110.2 lb
NOTE: 50kg (110lb) kits are only suitable for use with plural spray equipment.
C1.2 20kg (44.1lb) Kit

(44.1lb) kit comprising of one part filled drum of grey coloured resin (Part A) and one
Part A 14.3kg (31.5lb)

Part B 5.7kg (12.6lb)
Total 20.0kg (44.1lb)
NOTE: 20kg (44.1lb) kits can also be used with plural spray equipment.
C1.3 Cast Grade

C1.4 Storage Conditions for Chartek

Chartek should be stored dry, indoors and out of direct sunlight. The following storage temperature
ranges must be maintained:
• Minimum 1°C (34°F), maximum 30°C (86°F)

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C2.0 CARBON FIBRE MESH REINFORCEMENT

C2.1 Meshing Designs
and thickness, and fire type. Refer to Appendix A for HK-1TM mesh design drawings.
Table C1: Mesh Requirements

Structural Steel I and Open For certified thicknesses over 7.2mm (284 Not suitable for Jet Fire
Sections mils) HK-1 mesh installed at mid film designs, use Chartek 7.
thickness with 50mm (2”) overlaps and with
100% coverage. For certified thicknesses
below 7.2mm (284 mils) no mesh required.
Beams and columns with webs less than
250mm (10”) deep do not require mesh on
webs.
Structural Steel Hollow Sections For certified thicknesses over 7.2mm (284 Not suitable for Jet Fire
mils) HK-1 mesh installed at mid film designs, use Chartek 7.
Tanks, Vessels and Pipework For certified thicknesses over 7.2mm (284 Not suitable for Jet Fire
mils) HK-1 mesh installed at mid film designs, use Chartek 7.
Divisions – Bulkheads and Decks No HK-1 mesh required for certified Not suitable for Jet Fire
thicknesses on Bulkheads and Divisions. designs, use Chartek 7.
C2.2 HK-1TM and HK-1 (M)TM Carbon Fibre Mesh Reinforcement

C2.3 Packaging of HK-1 and HK-1 (M) Carbon Fibre Mesh Reinforcement
C2.4 General Rules for Meshing

solvent.

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hollow sections.
7. For jet fire applications the minimum overlap shall be 150mm (6”) and the HK-1 shall cover all
surfaces (i.e. 100% coverage without any gaps) of the member regardless of dimensions.
NOTE:
For certified thickness values of 7.2mm (284 mils) and below, no mesh reinforcement is required.
For certified thickness values above 7.2mm (284 mils) mesh reinforcement is required. When
Chartek is applied in excess of 7.2mm (284 mils) and the design or certified thickness is 7.2mm
(284 mils) or less, no mesh is required. However, the applied thickness of Chartek without
mesh shall not exceed 8mm.

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C3.0 APPLICATION WITH SINGLE LEG AIRLESS SPRAY

EQUIPMENT
C3.1 Ambient Conditions
parameters:

dispensing method.
C3.2 Surface Cleanliness

C3.3 Primer and Surface Preparation

may be applicable.

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Coatings advised.
C3.4 Kit Size

C3.5 Material Preparation for Single Leg Airless Spray Figure C1: 20kg (44.1 lb) Kit
Application

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25°C (77°F) 30°C (86°F)



Material Optimum mixed temperature Figure C2: Digital

o
C thermometer and
Chartek 7 30 to 35 probe.
Chartek 1709 25 to 30
C3.6 Heated Storage Units

ventilated.

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Figure C3: Typical storage container, showing insulation on inside
Figure C4: Example fin tube heaters (heater type dependent on local regulations)
advice.
C3.7 Mixing Equipment


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mixing operation.
Figure C5: Suitable Chartek mixing equipment
C3.8 Use of Solvent

refilled.

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kit of Chartek.
C3.9 Mixing Procedure

C3.10 Single Leg Airless Spray Equipment

used.

Ratio
Figure C6: Modified Airless Spray Unit

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if required.

spray tips.
For smaller structural steel a narrow spray fan pattern Figure C7: High Pressure Spray Gun

Notes on Spraying:
time and material.

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C3.11 Single Leg Spray Application Method

temperatures.
surface.

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C3.12 Water Contamination

C3.13 Surface Finish

acceptable.

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C3.14 Terminations

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C4.0 CHARTEK APPLICATION WITH PLURAL SPRAY EQUIPMENT

parameters:



a) The surface profile is in accordance with this Application Manual and other documents that
may be applicable.

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Coatings advised.
C4.4 Material Preparation for Plural Component Spray Application

WARNING:
C4.5 Plural Component Spray Equipment


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temperatures.
of the team.
conventional spray
Table C2: Operating Parameters for Plural Component Spray Machines
Storage tank temperatures Part A: max. 60°C (140°F )
Part B: max. 50°C (122°F )
In-line heater temperatures Part A: 55 to 65°C (131 to 149°F )
Part B: 45 to 55°C (113 to 131°F )
Gun exit temperature 50 to 55°C (122 to 131°F )
Storage tank pressures Part A: 5.5 bar (80 psi)
Part B: 2.72 bar (40 psi)
Fluid lines:
Spray tips:

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C4.6 Ratio Checks

weight:
respectively.
Example Calculation
Part B full container weight 4.05kg (8.91lb)
2.61:1 Maximum
(Total combined = 100%)
Part B – 30% to 28%
C4.7 Plural Spray Application Method

and spray pump.

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C4.9 Surface Finish

acceptable.
C4.10 Terminations

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C5.0 HAND TROWEL APPLICATION

parameters:



may be applicable.

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Coatings advised.
C5.4 Material Preparation for Hand Trowel Application

requirement:
• Warm enough to mix, typically 20 to 25oC (68 to 77°F)
C5.5 Mixing
International’s thinner GTA123 or GTA822 is recommended for this purpose.

ID Rev. Date
APP MAN UK 0 01/05/07
gradually.
C5.6 Hand Trowel Application Method

C5.7 Mixing of Partial Kits


ID Rev. Date
APP MAN UK 0 01/05/07
Worked Example
weight:
Measured Weight of Part A ÷ 2.50 (the Chartek 8 weight ratio)
Required Weight of Part B
calculated as follows:
e.g. 8kgs of Part A ÷ 2.50
= 3.20kgs of Part B

and added to the 8kgs of Part A is 3.20kgs.

C5.9 Surface Finish

C5.10 Terminations

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

ID Rev. Date
APP MAN UK 0 01/05/07
APPENDIX A – HK-1TM Meshing Detail

ID Rev. Date
APP MAN UK 0 01/05/07
APPENDIX B – Not Applicable
THIS APPENDIX HAS BEEN DELIBERATELY LEFT BLANK.

ID Rev. Date
APP MAN UK 0 01/05/07
APPENDIX C – Certified Thicknesses - Bulkheads and Decks

Chartek® 8
Certified Reinforcement and Thickness Arrangements
for Bulkhead and Decks
TABLE 1: BULKHEADS
Chartek 8 Thickness
(mm)
Design
American Bureau of
Shipping
A-60 class
NC NC NC
4.0 4.0
H-0 class (400°C) NC
No mesh No mesh
H-30 class NC NC NC
H-60 class 5.0

NC NC
(Insulated backface) No mesh
H-60 class NC NC NC
H-120 class 6.0 6.0

NC
(Insulated backface) No mesh No mesh
H-120 class NC NC NC

TABLE 2: DECKS
Chartek® 8 Thickness
(mm)
Design
American Bureau of
Shipping
A-60 class NC NC NC
4.5 4.5
H-0 class (400°C) NC
No mesh No mesh
H-30 class NC NC NC
H-60 class 5.0 5.0

NC
H-60 class NC NC NC
H-120 class 6.0 6.0

NC
H-120 class NC NC NC
NC = Not Certified

ADDITIONAL THICKNESS FOR JET FIRES:
Notes:
The thickness of coating Chartek® for jet fire exposure may determined by adding a “jet fire erosion
thickness” as shown in Tables 3 or 4 (dependent on mesh type used) to the thickness required by
hydrocarbon testing as shown in Tables 1 and 2. In all instances the mesh type, position and
overlaps shall be strictly in accordance with the Chartek Application Manual and relevant
certification.
Table 3: Jet Fire Erosion Thickness – HK-1 Mesh
Additional Chartek 8 Thickness

Jet Fire Duration (mm)
American Bureau of
Shipping
No Jet Fire NC NC NC
Up to 20 minutes jet
NC NC NC
fire
21 to 30 minutes jet
NC NC NC
fire
NC NC NC
fire
NC NC NC
fire
NC NC NC
fire

NC NC NC
fire
NC = Not Certified

Table 4: Jet Fire Erosion Thickness – Stainless Steel Mesh
Additional Chartek 8
Jet Fire Duration Thickness
American Bureau of
Shipping
No Jet Fire NC NC NC
Up to 20 minutes jet fire NC NC NC
21 to 30 minutes jet fire NC NC NC
NC = Not Certified

ID Rev. Date
APP MAN UK


edge terminations


Mesh Overlaps

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

Chartek 8 - Basic Installation Checklist
1. Clean surface 2. Prime surface* 3. Inspect
Clean and degrease to

SSPC-SP1, blast surface
to SSPC-SP10 or ISO Record QA details.
8501-1 Sa 2½, profile 50- Apply 50-75 microns (2-3 mils) i.e. weather, blast profile,
75 microns (2-3 mils) of qualified primer* type of primer, etc.
4. Wetting coat of Chartek 5. If HK-1 mesh required, build up to

mesh depth (mid film thickness)
Apply typically 2-3mm (75-115 mils). HK-1 mesh required where specified
Ensure surface is fully wetted, thickness is greater than 7.2mm (283 mils)
trowel if required. Installed at approximate mid film
6. Inspect for thickness and uniformity 7. Install HK-1 mesh, if required,

in wet Chartek
Wet gauge Ensure correct mesh overlaps,

minimum 50mm (2”), in accordance
with Chartek Application Manual
10. Final inspection for 11. Document 12. Finish with recommended
uniformity of thickness topcoat as required. Record
measurements
type and QA details
Wet gauge or drill
For full details refer to the current * For qualified primers and alternative
Chartek Application Manual. topcoats, please contact International Paint
20 March 2006_Rev.1
This document and its contents are the copyright of International Paint Limited and may not be reproduced in whole or in part without the express permission of
International Paint Limited
ID Rev. Date
APP MAN UK 0 01/05/07


Technical Note
TN/F/077_Rev.0_130203

(PITR)
Introduction
implemented.

critical items.
1. Material Removal

commencing.

1
Technical Note
TN/F/077_Rev.0_130203
• The primer system is of known origin and approved by International Paint

for use under Chartek fireproofing. The primer system must be a
recognised primer in accordance with the current acceptable primers list for
use with Chartek fireproofing, obtainable from International Paint, Fire &
Insulation Products.
table.




(3–4.4 mils) (5 mils)
accordance with the Chartek 7 Fireproofing Application Manual.

2
Technical Note
TN/F/077_Rev.0_130203



Required
present
application

3
Technical Note
TN/F/077_Rev.0_130203

3.5 Chartek fireproofing must be installed in strict accordance with the Chartek 7
Fireproofing Application Manual. Particular attention should be paid to the
environmental conditions during application of material.
required this will include acceptance by the Chartek fireproofing Field Service
Engineer as part of the fire protection installation audit procedure conducted by

to carry out an audit of the installation process. He is not responsible for the daily
inspection activities, which should be carried out by the Chartek fireproofing

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

Application Manual in a timely fashion.

4
ID Rev. Date
APP MAN UK

zinc primers”

Technical Note
TN/F/083_Rev.1_040205

Background
edition.
Aged Primers

Technical Note
TN/F/083_Rev.1_040205
Zinc Primers

• Zinc Rich Epoxy
Epoxy Primers
Summary

Technical Note
TN/F/083_Rev.1_040205

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

Technical Note
TN/F/101_121104
site.
disposal.

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

a bcdefg
® ®
Protective Coatings
periods.
Matt 0-15
Eggshell 16-30
Semi-Gloss 31-60
Gloss 61-85
High Gloss >85
(DFT)
(WFT)
Minimum


Maximum
achieved.
Extended





a bcdefg
® ®
Protective Coatings
(ISO 3679:1983).
CONTENT (VOC)
test methods:-

Disclaimer
ID Rev. Date Chartek® Application Manual Page 1 of 53
APP MAN UK 0 01/05/07
SECTION D – CHARTEK 1709

APP MAN UK 0 01/05/07
D1.0 CHARTEK PACKAGING AND STORAGE

D1.1 50kg (110 lb) Kit
For plural component spray equipment, Chartek is supplied in a 50kg (110 lb) kit
50kg (110 lb) Kit Size

Part A 35.70kg (78.7 lb)
(2 Drums)
Part B 14.30kg (31.5 lb)
(1 Drum)
Total 50.00kg (110.2 lb)
NOTE: 50kg (110 lb) kits are only suitable for use with plural spray equipment.
D1.2 20kg (44.1 lb) Kit

(44.1 lb) kit comprising of one part filled drum of grey coloured resin (Part A) and one
20kg (44.1 lb) Kit Size

Part A 14.3kg (31.5 lb)
Part B 5.7kg (12.6 lb)
Total 20.0kg (44.1 lb)
NOTE: 20kg (44.1 lb) kits can also be used with plural spray equipment.
D1.3 Cast Grade

D1.4 General Storage Conditions for Chartek

D1.4.1 Storage Conditions
Chartek should be stored dry, indoors and out of direct sunlight. The material should be protected
from frost and excessive temperatures.
Drums should be stored unopened and damage to drums avoided.
Stock should be rotated to ensure oldest material is used first.
D1.4.2 Storage Temperature

Ideally the material should be stored at room temperature 20°C (68°F) and should in all
circumstances be stored within the following storage temperature ranges:

APP MAN UK 0 01/05/07
• Minimum 1°C (34°F)

• Maximum 30°C (86°F)
Storage temperatures should be monitored and recorded as part of the QA/QC procedures. This is
achieved by the use of a minimum/maximum thermometer (see photos below).
Figure D1: Example Minimum/Maximum Thermometers

APP MAN UK 0 01/05/07
D2.0 HK-1TM CARBON FIBRE MESH REINFORCEMENT

D2.1 Meshing Designs
and thickness, and fire type. Refer to Appendix A for HK-1 mesh design drawings.
Table D1: HK-1 Mesh Requirements

Structural Steel Tested and certified in accordance with ANSI/UL1709 Not suitable for Jet Fire designs,
standard without the use of mesh reinforcement on fire use Chartek 7.
ratings up to and including 1 hour and with HK-1 mesh
reinforcement only on the flanges, around tips, for fire
ratings greater than 1 hour and up to 3½ hours.
D2.2 HK-1 and HK-1 (M) Carbon Fibre Mesh Reinforcement

D2.3 Packaging of HK-1TM and HK-1 (M)TM Carbon Fibre Mesh Reinforcement
D2.4 General Rules for HK-1 Meshing (where required*)

solvent.
hollow sections.
*NOTE: Chartek 1709 is tested and certified in accordance with ANSI/UL1709

standard without the use of mesh reinforcement on fire ratings up to and
including 1 hour and with HK-1 mesh reinforcement only on the flanges, around
tips, for fire ratings greater than 1 hour and up to 3½ hours.

APP MAN UK 0 01/05/07
D3.0 METAL MESH REINFORCEMENT

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

APP MAN UK 0 01/05/07
D4.0 APPLICATION WITH SINGLE LEG AIRLESS SPRAY

EQUIPMENT
D4.1 Ambient Conditions
parameters:

dispensing method.
D4.2 Surface Cleanliness

D4.3 Primer and Surface Preparation

may be applicable.

APP MAN UK 0 01/05/07
Coatings advised.
D4.4 Kit Size

D4.5 Material Preparation for Single Leg Airless Spray Figure D1: 20kg (44.1 lb) Kit
Application

APP MAN UK 0 01/05/07
25°C (77°F) 30°C (86°F)



Optimum mixed temperature Figure D2: Digital

o
C thermometer and
25 to 30 probe.
D4.6 Heated Storage Units

ventilated.

APP MAN UK 0 01/05/07
Figure D3: Typical storage container, showing insulation on inside
Figure D4: Example fin tube heaters (heater type dependent on local regulations)
advice.
D4.7 Mixing Equipment


APP MAN UK 0 01/05/07
mixing operation.
Figure D5: Suitable Chartek mixing equipment
D4.8 Use of Solvent

refilled.

APP MAN UK 0 01/05/07
kit of Chartek.
D4.9 Mixing Procedure

D4.10 Single Leg Airless Spray Equipment

used.

Ratio
Figure D6: Modified Airless Spray Unit

APP MAN UK 0 01/05/07
if required.

spray tips.
For smaller structural steel a narrow spray fan pattern Figure D7: High Pressure Spray Gun

Notes on Spraying:
time and material.

APP MAN UK 0 01/05/07
D4.11 Single Leg Spray Application Method

temperatures.
surface.

APP MAN UK 0 01/05/07
D4.12 Water Contamination

D4.13 Surface Finish

acceptable.

APP MAN UK 0 01/05/07
D4.14 Terminations

APP MAN UK 0 01/05/07
D5.0 CHARTEK APPLICATION WITH PLURAL SPRAY EQUIPMENT

parameters:



may be applicable.

APP MAN UK 0 01/05/07
Coatings advised.
D5.4 Material Preparation for Plural Component Spray Application

WARNING:
D5.5 Plural Component Spray Equipment


APP MAN UK 0 01/05/07
temperatures.
of the team.
conventional spray
Table D2: Operating Parameters for Plural Component Spray Machines
Storage tank temperatures Part A: max. 60°C (140°F)
Part B: max. 50°C (122°F)
In-line heater temperatures Part A: 55 to 65°C (131 to 149°F)
Part B: 45 to 55°C (113 to 131°F)
Gun exit temperature 50 to 55°C (122 to 131°F)
Storage tank pressures Part A: 5.5 bar (80 psi)
Part B: 2.72 bar (40 psi)
Fluid lines:
Spray tips:

APP MAN UK 0 01/05/07
D5.6 Ratio Checks

weight:
respectively.
Example Calculation
Part B full container weight 4.05kg (8.91lb
2.61:1 Maximum
(Total combined = 100%)
Part B – 30% to 28%
D5.7 Plural Spray Application Method

and spray pump.

APP MAN UK 0 01/05/07

APP MAN UK 0 01/05/07

D5.9 Surface Finish

acceptable.
D5.10 Terminations

APP MAN UK 0 01/05/07
D6.0 HAND TROWEL APPLICATION

parameters:



may be applicable.

APP MAN UK 0 01/05/07
Coatings advised.
D6.4 Material Preparation for Hand Trowel Application

requirement:
• Warm enough to mix, typically 20 to 25°C (68 to 77°F)
D6.5 Mixing
International’s thinner GTA123 is recommended for this purpose.

APP MAN UK 0 01/05/07
gradually.
D6.6 Hand Trowel Application Method

D6.7 Mixing of Partial Kits


APP MAN UK 0 01/05/07
Worked Example
weight:
Measured Weight of Part A ÷ 2.50 (the Chartek 1709 weight
Required Weight of Part B
calculated as follows:
ratio)
e.g. 8kg of Part A ÷ 2.50

= 3.20kg of Part B

and added to the 8kg of Part A is 3.20kg.

D6.9 Surface Finish

D6.10 Terminations

APP MAN UK 0 01/05/07
APPENDICES

APP MAN UK 0 01/05/07
APPENDIX A – HK-1TM Meshing Details

U n d erw rite rs L ab o rato ries In c .
A N S I/U L 1709 F ire R e sistan ce R atin g s
C h arte k 1709 - D esig n N o .X R 6 25
R a tin g C h a rte k 17 0 9 C h a rte k 17 0 9 M esh
(h o u rs ) T h ic k n e ss (m m ) T h ic k n e ss (m ils ) R e in fo rc e m e n t
½ 2 .7 4 108
N o m e sh re info rcem e nt
¾ 4 .5 5 179
re qu ire d .
1 5 .7 8 228
1½ 8 .2 4 324
2 1 0 .70 421 H K -1 ca rb on fib re
co m po site m e sh ap p lied
2½ 1 3 .16 518
in m id film o ve r th e
3 1 5 .62 615 flan ge a nd a ro u nd tip s.
3½ 1 8 .08 712
APP MAN UK 0 01/05/07
APPENDIX B – Not Applicable
THIS PAGE HAS DELIBERATELY BEEN LEFT BLANK.

APP MAN UK 0 01/05/07
APPENDIX C – Not Applicable
THIS PAGE HAS DELIBERATELY BEEN LEFT BLANK.

APP MAN UK 0 01/05/07


edge terminations


Mesh Overlaps

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

Chartek 1709
Basic Installation Checklist
1. Clean surface 2. Prime surface* 3. Inspect
Clean and degrease to

SSPC-SP1, blast surface
to SSPC-SP10 or ISO Record QA details.
8501-1 Sa 2½, profile 50-
Apply 50-75 microns (2-3 mils) i.e. weather, blast profile,
75 microns (2-3 mils) of qualified primer* type of primer, etc.
4. Wetting coat of Chartek 1709 5. Build up to mesh depth
Apply typically 2-3mm (75-115 mils). Where mesh

Ensure surface is fully wetted, reinforcement is required,
trowel if required. install HK-1 at mid film.
6. Inspect for thickness and uniformity 7. Install HK-1 mesh into wet Chartek
Where mesh reinforcement is
required, mesh applied across
flanges and around flange tips.
Wet gauge Ensure correct mesh overlaps,

minimum 50mm (2”)
Where mesh
reinforcement is
required.
10. Final inspection for 11. Document 12. Finish with Interthane 990
uniformity of thickness topcoat*, 50 microns (2 mils).
measurements
Record QA details
Wet gauge or drill
For full details refer to the current * For qualified primers and alternative
Chartek 1709 Application Manual. topcoats, please contact International Paint
1 October 2005 – Rev.1
This document and its contents are the copyright of International Paint Limited and may not be reproduced in whole or in part without the express permission of
International Paint Limited
APP MAN UK


Technical Note
TN/F/077_Rev.0_130203

(PITR)
Introduction
implemented.

critical items.
1. Material Removal

commencing.

1
Technical Note
TN/F/077_Rev.0_130203
• The primer system is of known origin and qualified by International Paint for
use under Chartek fireproofing. The primer system must be a recognised
primer in accordance with the current acceptable primers list for use with
Chartek fireproofing, obtainable from International Paint.
table.




(3–4.4 mils) (5 mils)
accordance with the Chartek Application Manual.

2
Technical Note
TN/F/077_Rev.0_130203



Required
present
application

3
Technical Note
TN/F/077_Rev.0_130203

3.5 Chartek fireproofing must be installed in strict accordance with the Chartek
Application Manual. Particular attention should be paid to the environmental
conditions during application of material.
required this will include acceptance by the Chartek fireproofing Technical
Service Engineer as part of the fire protection installation audit procedure
conducted by International Paint.

to carry out an audit of the installation process. He is not responsible for the
daily inspection activities, which should be carried out by the Chartek fireproofing

4.2 Topcoating should be applied in accordance with the Chartek Application Manual
in a timely fashion.

4
APP MAN UK

zinc primers”

Technical Note
TN/F/083_Rev.1_040205

Background
edition.
Aged Primers

Technical Note
TN/F/083_Rev.1_040205
Zinc Primers

• Zinc Rich Epoxy
Epoxy Primers
Summary

Technical Note
TN/F/083_Rev.1_040205

APP MAN UK 0 01/05/07

Technical Note
TN/F/101_121104
site.
disposal.

APP MAN UK 0 01/05/07

a bcdefg
® ®
Protective Coatings
periods.
Matt 0-15
Eggshell 16-30
Semi-Gloss 31-60
Gloss 61-85
High Gloss >85
(DFT)
(WFT)
Minimum


Maximum
achieved.
Extended





a bcdefg
® ®
Protective Coatings
(ISO 3679:1983).
CONTENT (VOC)
test methods:-

Disclaimer

Chartek 7 8+1709 Application Manual Rev0 010507

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ID Rev.

©International Paint Limited, 2007

SECTION A – GENERAL (ALL PRODUCTS) .......................................................................... 10

©International Paint Limited, 2007

SECTION B – CHARTEK 7......................................................................................................... 1

©International Paint Limited, 2007

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

©International Paint Limited, 2007

©International Paint Limited, 2007

SECTION C – CHARTEK 8......................................................................................................... 1

©International Paint Limited, 2007

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

©International Paint Limited, 2007

SECTION D – CHARTEK 1709 ................................................................................................... 1

©International Paint Limited, 2007

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

©International Paint Limited, 2007

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

©International Paint Limited, 2007

©International Paint Limited, 2007

SECTION A – GENERAL (ALL

©International Paint Limited, 2007

The Americas 6001 Antoine Drive Tel: +1 713 684 1223

Korea 17th Floor Tel: +82 51 5806150

Australasia 115 Hyde Road Tel: +61 738928887

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

©International Paint Limited, 2007

Chartek Application Manual Revisions

©International Paint Limited, 2007

A1.2 System Description

A1.3 Quality Control Requirements

©International Paint Limited, 2007

A2.0 SURFACE PREPARATION

The primary objectives of surface preparation include:

For a range of definitions and abbreviations refer to Appendix I.

©International Paint Limited, 2007

Acceptable methods of degreasing include:

A2.3 Blast Cleaning

Definition of degrees of cleanliness:

Near white blast cleaning

Sweep (Brush-off) blast

©International Paint Limited, 2007

Wet abrasive blasting

Hydro-blasting (high pressure water jetting)

A2.4 Power Tool Cleaning

©International Paint Limited, 2007

Table A1: Chartek Surface Preparation Requirements

©International Paint Limited, 2007

Table A2: Primer System Maximum Dry Film Thicknesses

Primer System Dry Film Thickness

©International Paint Limited, 2007

Reduction of Excessive Primer Thickness

The primer manufacturer’s application instructions should be followed.

©International Paint Limited, 2007

A4.0 QUALIFIED CHARTEK APPLICATION CONTRACTORS

©International Paint Limited, 2007

A5.0 CHARTEK THICKNESS MEASUREMENT

The following procedure for thickness measurement must be followed.

A. Method for measuring wet Chartek thickness:

B. Method of measuring dry Chartek thickness:

©International Paint Limited, 2007

As a guidance, it is recommended that readings are taken as follows:

• ‘I’ sections, tee sections and channels: