Read Hempel Book PC-MC June 2007.pdf text version

Application Instructions


For product description refer to product data sheet


BASE 05509 with CURING AGENT 98500


These Application Instructions cover surface preparation, application equipment, and application details for HEMPEL'S EPOXY RESIN 05500, in combination with glassfibre matting. Steel: Abrasive blasting to Sa 2½ or Sa 3 depending on area of use. Surface profile corresponding to Rugotest No. 3 BN11, Keane-Tator Comparator 5.5 G/S, or ISO Comparator, Coarse (G). Oil and grease must be removed with suitable detergent, salt and other contaminants by (high pressure) fresh water cleaning prior to blasting. After blasting clean the surface carefully from abrasives and dust. The blasted and cleaned surface may advantageously be primed with HEMPADUR 15590, at a dry film thickness of 30 to 50 micron. Avoid a higher dry film thickness of the primer. On old steel surfaces having been exposed to salt water, excessive amounts of salt residues in pittings may call for dry abrasive blasting, high pressure fresh water hosing, drying, and finally, dry abrasive blasting again. In case of extensively pit-corroded surfaces (tank bottoms): Remove oil and grease with suitable detergent. Blasting to Sa 2, ISO 8501-1: 1988. Pittings on tank bottoms are often omega-shaped (typically in the case of chloride-induced corrosion) for which reason the following procedure is recommended: After rough cleaning for dust and abrasives, the tank surfaces are to be thoroughly high pressure fresh water hosed. Let the water remain in the tank so that all pit corroded areas are covered by approx. 5 cm/2" of water. After 24 hours the water is removed by wet vacuum cleaning and the tank is dried. If needed, i.e. if there is still salt contamination to be found in the pits, the washing treatment has to be repeated. After cleaning, the surfaces are blasted to min. Sa 2½ with a surface roughness profile as described above. After blasting clean the surface carefully for abrasives and dust. Special care must be taken when cleaning the tank bottom. Concrete: The concrete must be of good quality and fully cured, e.g. 28 days for normal Portland cement, and completely dry with a humidity content in the surface below 4%. The concrete must also be controlled for absence of capillary water action or for subsoil water. Minimum pull-off value should normally be 20 kilopond/cm² measured after surface preparation. Any cracks, crevices and voids must be repaired. All possible slip agent, oil, grease and other contaminants must be removed by e.g. abrasive blasting, volatilising by flame cleaning or treatment with suitable detergent. The last mentioned in the following way: Saturation of the surface with fresh water. Washing with suitable detergent followed by fresh water hosing. Depending on construction and purpose, abrasive blast, high pressure water jet or treat the concrete with power tools to obtain a rough and firm surface free of scum layer and other contamination. Remove dust and loose material. If mechanical treatment is impossible, the surface may be treated with acid etching. For this purpose an approx. 5% w/w nitric or phosphoric acid solution is recommended. Note: Strong acids, take necessary precautions, make sure that safety regulations are obeyed!

Surface preparation:

Issued: January 2005

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HEMPEL Application Instructions


HEMPEL'S EPOXY RESIN 05500 Prior to etching, the concrete should be saturated with fresh water to prevent acid corrosion of the reinforcement bars. Leave the acid to act for 3-4 minutes and hose down the surface with fresh water - preferably first a 5% w/w sodium hydroxide solution and scrub carefully. After that the surface must dry homogeneously and appear as an even, rough surface free of a loose outer layer. The surface must have a pH reaction of between 6.5-8.0. If any of these conditions are not fulfilled, the process must be repeated. The surface must be dried with good ventilation for at least 2 days at 65% relative humidity and 20°C/68°F. The pre-treatment is controlled by scraping with a strong knife. The surface must feel solid and hard, and the knife must only leave a clear scratch mark. Seal the surface with HEMPADUR SEALER 05990 in such a way that the surface is just saturated. Surplus must be removed (do also see the Product Data sheet for HEMPADUR SEALER 05990). Filling/repairs: Cracks, crevices, damages, pittings and other irregularities in the concrete or steel surface (e.g. blowholes in welding seams) should be repaired prior to application of the first coat with HEMPEL'S EPOXY RESIN 05500. Depending on the type of substrate and size of irregularities, repair can be carried out by filling with HEMPADUR MULTI-MIL 85490, HEMPEL'S EPOXY KNIFING FILLER 355SA, HEMPEL'S EPOXY GROUT 353SA or similar. In case the irregularities or damages are of such extent that filling will not provide a sound repair method, more efficient repairs may be required ( e.g. grinding, welding, or steel renewals). Before application of the first full coat of HEMPEL'S EPOXY RESIN 05500, a mixture of HEMPEL'S EPOXY RESIN 05500 and silica sand (like HEMPEL'S ANTI-SLINT 67500) should be applied on areas where the risk of creating air pockets/voids during the glassfibre matting is present. This includes, but is not limited to, overlap welding seams, welding seams on supports, double plates and the "chime area" (where the shell joins the tank bottom). The mixture should be applied in such a manner that a smooth, concave surface is obtained and "bridging" of the glassfibre mats is avoided. The silica sand used for this mixture must be washed, dried and sieved. The mixing ration of silica sand and resin is depending on the area of use, but as a general guideline, an amount of 2.0-2.5 kg silicate sand should be added to 750 ml of mixed resin. An increased amount of silica sand may be desired for the chime area, while less silica sand may be required on other areas. Application equipment/ Materials needed: Materials needed: HEMPEL'S EPOXY RESIN 05500 Glassfibre mat - 450 g/m² (e.g. HEMPEL'S GLASSFIBRE MAT 690SA) Surface tissue - 30 g/m² (e.g. HEMPEL'S GLASSFIBRE SURFACING TISSUE 691SA) Silica sand (e.g. HEMPEL'S ANTI-SLINT 67500) Application equipment: Medium pile (mohair) rollers 8 to 10" and brushes (2" width) of good quality. Aluminium or stainless steel serrated and split-washer rollers, ranging from 0,5 to 1,5" in diameter and a width of 3 to 6". Stainless steel trowels or spatulas Mixing: Stir the base thoroughly with a powerful, mechanical mixer. Add the CURING AGENT to the base and stir again thoroughly for several minutes. Minimise the residues in the curing agent can. It is not recommended to add thinner to the product before, during or after mixing; the mixed product should be applied undiluted. If the in-can temperature is below approximately 15°C/59°F, the viscosity will be too high for proper application. The ideal paint temperature for application is 20-25°C/68-77°F. Note that a higher paint temperature may result in a shortened pot life and curing in can/spray equipment.

Paint temperature/ Pot life:

Issued: January 2005

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Application Instructions


HEMPEL'S EPOXY RESIN 05500 Application: Application of resin and glassfibre mat: Apply HEMPEL'S EPOXY RESIN 05500 by means of medium pile (mohair) rollers in a wet film thickness of 500-600 micron. Ensure a homogeneous wet film distribution and proper film formation during application. Roll out the full glassfibre mat (e.g. HEMPEL'S GLASSFIBRE MAT 690SA), straighten the mat by pulling gently at both ends simultaneously and lay the mat on the wet resin. In case working with the full length of the mat is difficult and shows a high density of wrinkles, cutting the mat in lengths of 6 to 8 meters is recommended. For application on the side shell, lengths of 3 to 4 meters may be considered in order to prevent sagging of the coating systems at longer lengths. Press the glassfibre mat into the resin, using serrated/split-washer rollers. It is important that this process is maintained for a sufficient period of time, using an adequate pressure, in order to flatten and saturate the mat and expel all (entrapped) air from the coating system. Apply additional resin and repeat the rolling procedure in order to ensure a proper saturation. This process should be completed before HEMPEL'S EPOXY RESIN 05500 has reached the end of its pot life. Small serrated/split-washer rollers are recommended for usage on areas like corners and joints. The overlap of the glassfibre mat from side shell on the tank bottom should be at least 30 cm. A minimum overlap of 10 cm between adjacent mats is recommended. Do not allow overlaps of mats to be positioned on the same location as welding seams or areas that have been treated with a filler or epoxy resin-silica sand mixture. Wrinkles in the mat must be avoided at all times. If they are not removed by the process described above, they should be eliminated while the epoxy resin is still wet, by making an incision in the centre of the wrinkle with a sharp knife, followed by pressing with a serrated roller. Stripe Coating: Edges corners, manual welds and placed difficult to cover properly, should be stripe coated (touched up) with HEMPEL'S EPOXY RESIN 05500 either before or after application of the first coat of epoxy resin and glassfibre mat. Normally, a minimum of two stripe coats is recommended in order to achieve the specified dry film thickness. Application of surface tissue: It is recommended to apply a layer of surface tissue (e.g. HEMPEL'S GLASSFIBRE SURFACING TISSUE 691SA), shortly after application of the first coat of epoxy resin and glassfibre mat. This surface tissue has the purpose to imbed fibres from the glassfibre mat which are protruding through the epoxy resin and is applied in accordance with the same procedure as for the application of the glassfibre mat (apply epoxy resin, lay out mat, saturate). If rectified by the given condition of the first coat of epoxy resin and glassfibre mat, it may be considered to apply the second coat of epoxy resin without surface tissue. When this stage is completed, the glassfibre system will have a typical (total) dry film thickness of approximately 1000-1200 micron. Application of sealer coat: When the full glassfibre-epoxy resin system is through dry (after approximately 24 hours at 20°C/68°C), the surface should be sanded down with emery paper (grit 240-320) to remove any protruding glass fibres and imbedded or fairly adhering contamination. After sanding, clean the surface thoroughly (for dust) by means of an industrial vacuum cleaner. Apply one seal coat of HEMPEL'S EPOXY RESIN 05500 at a wet film thickness of 300 micron.

Issued: January 2005

Page 3 of 4

Application Instructions


HEMPEL'S EPOXY RESIN 05500 Ventilation during application: Recoating intervals: Ventilation is not specifically required for drying/curing of the coating, but some ventilation is recommended in order to remove e.g. spray dust from application. Provided that a maximum relative humidity of 85% and the specified wet/dry film thickness are kept, the following recoating intervals apply:

Steel temperature Minimum Maximum 10°C/50°F 60 hours 8 days 20°C/68°F 24 hours 3 days 30°C/86°F 12 hours 36 hours 40°C/104°F 7 hours 22 hours

Curing time:

HEMPEL'S EPOXY RESIN 05500 is fully cured after 7 days at 20°C/68°F. Tanks or pipelines should generally not be taken into service before HEMPEL'S EPOXY RESIN 05500 is fully cured. Full curing is mandatory in case of potable water service. Handle with care. Before and during use, observe all safety labels on packaging and paint containers, consult HEMPEL Material Safety Data Sheets and follow all local or national safety regulations. Avoid inhalation, avoid contact with skin and eyes, and do not swallow. Take precautions against possible risks of fire or explosions as well as protection of the environment. Apply only in well ventilated areas. HEMPEL PAINTS (SAUDI ARABIA W.L.L.) - 0550000000CO01



This Product Data Sheet supersedes those previously issued. For explanations, definitions and scope, see "Explanatory Notes" in the HEMPEL Book. Data, specifications, directions and recommendations given in this data sheet represent only test results or experience obtained under controlled or specially defined circumstances. Their accuracy, completeness or appropriateness under the actual conditions of any intended use of the Products herein must be determined exclusively by the Buyer and/or User. The Products are supplied and all technical assistance is given subject to HEMPEL's GENERAL CONDITIONS OF SALES, DELIVERY AND SERVICE, unless otherwise expressly agreed in writing. The Manufacturer and Seller disclaim, and Buyer and/or User waive all claims involving, any liability, including but not limited to negligence, except as expressed in said GENERAL CONDITIONS for all results, injury or direct or consequential losses or damages arising from the use of the Products as recommended above, on the overleaf or otherwise. Product data are subject to change without notice and become void five years from the date of issue. Issued: January 2005 Page 4 of 4

Application Instructions


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Hempel Book PC-MC June 2007.pdf