CHARTEK 1709 FIREPROOFING INSTALLATION PROCEDURE

CHARTEK INSTALLATION OVERVIEW

Overview:

Chartek Description

Equipment & Materials

Warehouse Space

Manpower

Surface Preparation

Staging Steel

Masking Block-outs

Primer (Intergard 251)

Chartek Spray Application Process

Thickness Measurement

Topcoat

Quality Control

WHAT IS CHARTEK?

• Chartek is a passive fireproofing system which consists of an epoxy intumescent coating designed to protect substrates from fire and corrosion.

• In a fire, Chartek fireproofing will intumesce (expand) to form an insulating layer of char. It is this char and its formation the protects the substrate from the effects of the fire.

EQUIPMENT & MATERIALS

Equipment

(XM PFP Plural Pump) Materials

Chartek 1709 110lb Kits (Part A & Part B)

Intergard 251 Primer

GTA123 Thinner – Used to wet nap when rolling material

HK-1 Carbon Fiber Mesh – Used at flanges * No Mesh in webs

Interthane 990HS Topcoat – (2-3 mils)

MEK Solvent – Used to clean pump equipment & Craft tools

WAREHOUSE

Square Foot Spacing

Calculate available sqft floor space needed to estimate quantity of pieces to be staged at one point.

Staging is critical –The layout should be determined prior to receiving steel .The steel should be staged keeping in mind continuous and sequential flow to minimize pump shut downs.

*Avoid moving material twice

The beams/columns are staged on horses, know the beam & column lengths and what areas of the steel receive fire proofing. Keep in mind that beams can be staged with top flanges facing downward (as it does not receive FP). Allow sufficient space between pieces of steel to allow for efficiency. Staging pieces on four (4) ft. – five (5) ft. centers is optimal.

There should be sufficient area available to spray and enough manpower to keep up with the gun.

Entries and Exits – Know the door sizes to determine how the steel will be moved in and out of the warehouse.

SETTING UP THE JOB (MANPOWER)

Crew Size: It is recommended that a crew size of nine (9) is used to perform the tasks needed to complete the project effectively. *Note: The Crew size (9) was determined as the work scope

did not include Shell prep, priming, or topcoat.

Tasks include: (1) Pump Operator – Responsibilities include: Feeding material into the pump Disposing of empty drums

(2) Nozzle men (1 for spraying & 1 to gauging material depth) – Responsibilities include: Spraying Chartek Confirming application is applied correctly (not too thick, thin and

confirm no mesh is visible following final coat) Cleaning Static mixer assembly (Changing out with replacement) Cleaning spray gun

(4) Pre-cutting HK-1 mesh and Rolling material – Responsibilities include: Cutting mesh for flanges Rolling material to uniform thickness Removing masking Tape

(2) Masking block-outs & wiping down steel with MEK.

SURFACE PREPARATION (IMPORTANCE OF SURFACE PREP)

Surface preparation is vital to the success of any fireproofing system. Failure in properly prepping the substrate can lead to insufficient adhesion of the coating and can also lead to rapid failure of the entire system. To ensure the installation conforms to quality standards, the following measures should be performed: Degreasing (SP1): Remove any visible dirt, oil or grease from the

surface prior to installing primer or Chartek. Sweep Abrasive Blast Cleaning (SP7): Only if additional profile is needed

STAGING

Staging is Critical

• The steel should be staged at a minimum of 4ft on center.

• Keep in mind that Beams can be staged with the non-fireproofed (top) flange facing downward.

• Columns should be staged with column base directly on staging horse, and opposite end should be sitting on section that does not receive intumescent coating so that all fireproofed areas can be achieved without having to re-move column.

• Prioritize sequences by tagging them with ribbon (As indicated in photo).

• Colors should determine what sequences are to be shipped according to schedule.

• Ex: “White” = Highest Priority (Shipping in 1 week)

• “Orange” = 2nd Priority (Shipping in 2 weeks)

• Sequences should remain grouped and be in continuous flow to avoid any disruption to production.

4ft. 4ft.

STAGING COLUMNS

• Columns Staged so that surface area that does not receive fireproofing (Galvanized Only) is laying on horse (As indicated in red).

• This ensures that all sides of column can be sprayed with intumescent without additional moves.

• Prior to applying Intergard and/or Chartek be sure to properly mask Galvanized Only surface.

• This can be achieved quickly by utilizing stretch wrap or Visqueen.

4ft. 4ft.

STAGING BEAMS

• Beams staged with non-fireproof (Prime Only) flanges facing downward.

• Keeping this in mind, notice that the distance between staging horses are not as critical, however be sure to space them closer to the end of beams.

• Prior to applying Intergard and/or Chartek be sure to properly mask block-outs.

4ft. 4ft.

MASKING BLOCK-OUTS

It is good practice that Quality Control properly marks the primed substrate with an “X” to determine what areas of the steel are designated as “block-outs” and therefore should be masked. Properly marking the steel will reduce confusion surrounding block-outs and

ensure that non-fireproofed areas do not receive Chartek.

MASKING BLOCK-OUTS (APPROVED METHOD)

• Ensure that the proper method is being used:

• Masking tape should only be used to secure the masking paper to the steel.

• This method ensures easy removal following 2nd coat of Chartek.

MASKING BLOCK-OUTS (INCORRECT METHOD)

• Masking an entire block-out surface using only masking tape should not be used due to the following reasons

1. It is counterproductive as it takes twice the time as the masking paper method.

2. This method of masking makes the removal process following the final coat of Chartek extremely cumbersome as there will be multiple strips of tape to remove

• Subsequently, the substrate will be covered in material and additional steps such as re-priming the surface will have to be performed.

3. It will rapidly consume your masking tape inventory.

CHARTEK – 1ST COAT PRE-CHECKLIST

• Pre-installation QC checklist: Block-outs properly masked

Substrate properly wiped down with MEK

Ambient Conditions Air Temperature: min. (41F) – max (122F)

Relative Humidity: max 85%

Surface Temperature: 5F above dew point

HK-1 mesh pre-cut and ready for install

Bridge gauges in hand

Ratio checked performed and accurate ratio achieved

Floor properly covered with visqueen

CHARTEK 1ST COAT & HK-1 INSTALLATION - CONTINUED

Application:

• When spraying, the nozzle man should keep in mind that the thickness of each individual coat should be no less than an 1/8”

• One coat alone cannot achieve full thickness of 421 mils as sagging and/or slumping will occur

• The nozzleman should ensure that the block-outs are clearly visible when spraying to ensure easy identification once the masking paper is to be removed (Do not cover masking areas).

1ST COAT & HK-1 CARBON FIBRE MESH INSTALLATION - CONTINUED

Rules for Meshing:

1. Mesh is to be installed into wet Chartek at mid-thickness.

2. Mesh should be rolled thoroughly into the wet material using short nap rollers dampened with GTA 123 solvent.

3. Overlap pieces of mesh by at least 2”

4. After installing HK-1 spray a light coat of Chartek over the mesh

5. The webs do not receive HK-1 (Chartek 1709)

Rules for Rolling:

1. If the Chartek has not gelled (started to cure) sufficiently, it may sag or slump

2. Too much solvent on the roller can retard the cure rate

2ND COAT - FULL THICKNESS (421 MILS)

• The final coat of Chartek should be applied to a firm enough undercoat.

• The final coat should be applied when the previous coat is still tacky (1 hr.)

• Be sure to consistently monitor thickness using bridge gauges

• Properly roll material to achieve consistent and uniform thickness throughout the substrate

FULL THICKNESS (421 MILS)

LOADING PIECES FOR DELIVERY

MATERIAL PROCEDURE

JTT has material specified procedures applicable for each job we obtain. (Pyrocrete 241, Chartek 1709, Fendolite MII/P, Concrete, Etc)

*each procedure is subject to modification according to job specifics

Procedure Bullet Points

1.0 – Scope/Objective

2.0 – Materials & Storage

3.0 – Equipment & Cleaning

4.0 – Preparation & Priming

5.0 – Mixing

6.0 – Intumescent Installation

7.0 – Topcoat Installation

8.0 – Quality Control & Assurance

9.0 – References

QUALITY ASSURANCE / QUALITY CONTROL PROGRAM

JTT has detailed fireproofing quality control program for intumescent Structural Steel Fireproofing.

JTT will submit for approval the following:

Hold points Inspection and testing requirements Reports required Traceability Submittals per project requirements

J.T. Thorpe & Son, Inc. recognizes the

responsibility of producing a quality final product and providing evidence and documentation of this quality to the customer.

*Example of quality control report

CONTACTS – PROJECT SOURCES

International - Akzonobel

Todd Weigel – National Rep. assigned to JTT Each regional can additionally leverage

Regional Sales Rep relationships for business

Steel Fabricators • Determine regional players • Sell our services • Get on bid list

End Users • Make customers aware of service • Demand of a specific applicator can be driven

through end user