Carboline Pyrocrete 241

    PY00241

    We no longer stock this product; please contact our technical team on 0113 2455450 (option 2) or send a message to [email protected] where we will be happy to find an alternative product.

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    Description

    Carboline Pyrocrete 241 is a high-density cementitious fireproofing designed for the fire protection of exterior and interior structural steel.

    A 55 lb./ft³ (881 kg/m³) density, Portland cement based, cementitious fireproofing. It provides both hydrocarbon and cellulosic fire protection for structural steel and can also be used to upgrade the fire resistance of existing concrete. Recommended areas of application include refineries, petrochemical, pharmaceutical facilities, pulp and paper mills, offshore platforms, nuclear and conventional power plants, factories, warehouses, institutional and biomedical facilities.

    Pyrocrete 241 neither promotes nor prevents corrosion. The fireproofing should not be considered as part of the corrosion protection system. For applications where primers are required, use a Carboline approved, alkaline resistant primer. Pyrocrete 241 must meet minimum UL bond strength criteria for contour applications where primers are used. Contact the Rawlins on Tech - 0113 2455450 (option 2) or [email protected] for approved primers.

    Not recommended for use as a refractory cement or where continuous operating temperatures exceed 93°C.



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    Features and Benefits


    • Over 39 years of proven performance
    • Exceptional durability and toughness
    • UL 1709 hydrocarbon fire rated up to 4 hours
    • BS 476 hydrocarbon fire rated up to 4 hours
    • ISO 22899-1 jet fire rated up to 2 hours
    • ASTM E119 cellulosic fire rated up to 4 hours
    • Cryogenic protection against LNG spills and immersion exposures
    • Resistant to 3 bar blast overpressure
    • Hose stream resistant
    • Tolerant to wide range of climates
    • Lightweight – one-fifth the weight of concrete for equal fire protection
    • Ideal for onsite and offsite application
    • Easy application by spray or trowel
    • Non-flammable – during or after application
    • Chloride and sulphide free – no special priming required
    • Asbestos-free – complies with EPA and OSHA regulations
    • Non-friable – high impact strength



    Product Specification


    Technical Data
    Carboline Pyrocrete 241
    Primer:

    Pyrocrete 241 neither promotes nor prevents corrosion. The fireproofing should not be considered as part of the corrosion protection system

    For applications where primers are required, use a Carboline approved, alkaline resistant primer. Pyrocrete 241 must meet minimum UL bond strength criteria for contour applications where primers are used

    Contact Rawlins on Tech - 0113 2455450 (option 2) or [email protected] for further information and approved primers

    Finish:Textured If a smooth finish is required, this may be done by trowel, roller or brush typically within 1 to 2 hours after final application of Pyrocrete 241
    Theoretical Coverage Rate:

    1.23 m² @ 25.4 mm thick @ 881 kg/m³

    Field results will vary depending upon application parameters. Coverage based on theoretical gross yield without loss

    Material losses during mixing and application must be considered when estimating project requirements.

    Coverage based on 22.7 kg bags (one board ft = one ft² of material at one inch thick or 0.9 m² of material at 25.4 mm thick

    Application Thickness:12.7 - 15.9 mm on initial pass
    Limitations:Not recommended for use as a refractory cement or where continuous operating temperatures exceed 93°C
    Shelf Life:24 months (minimum) when kept at recommended storage conditions.



    Performance Data
    Test MethodResults
    ASTM D2240 Durometer Hardness (Shore DO)83
    ASTM D2794 Impact ResistancePass (No cracking at 20 foot pounds)
    ASTM E605 Density155 lb./ft³ (881 kg/m³) (minimum average)
    ASTM E736 Bond Strength (Unprimed Steel)222,026 psf (1,054 kPa)
    ASTM E759 DeflectionPass
    ASTM E760 Bond ImpactPass
    ASTM E761 Compressive Strength1,111 psi (7.6 MPa)
    ASTM E84 Flame Spread0
    ASTM E84 Smoke Development0
    ASTM E937 Corrosion0.00 gm/mm²
    Coverage 22.7 kg bag1.23 m² @ 25 mm
    Explosion Resistance3 bar
    Hose Stream ResistancePass
    Shrinkage<0.5%



    • Air dry at ambient conditions until constant weight is achieved. Do not force dry
    • Bond strength testing performed utilizing ASTM E736 with AWCI Technical Manual 12-A modifications.
    • All test data above was generated under laboratory conditions. Field testing results may vary. Physical property data was derived using 4.5 gallons of water per 22.7 kg bag
    • Material shall reach a hardness of Shore DO 64 prior to handling and topcoating
    • Test reports and additional data available upon written request





    Testing/Certification
    Underwriters Laboratories, Inc.

    Pyrocrete 241 has been tested by Underwriters Laboratories, Inc. and is classified for exterior or interior use by UL in the following designs:

    UL 1709

    Rapid temperature rise hydrocarbon fire exposure

    Columns – XR701, XR702, XR734, XR738

    BS 476: Part 20: Appendix D

    hydrocarbon fire exposure

    Columns Report No. R11193

    Cryogenic Testing

    Tested in accordance to “Specification for Cryogenic Protection and Passive Fire Protection of Structural Members", dated March 2006 from South Hook LNG Terminal Company Ltd. Additional splash and spill testing perform at varying flow rates. All testing has been witnessed by UL.

    ASTM E119 (UL 263, NFPA 251)

    Cellulosic fire exposure

    Columns - X732, X733, X735, X736, X743, X744, Y707, Y708

    Roof Assembly – P734, P735, P736, P737, P738, P739, P926, P927, P928, P929, G706, G707, G708, J713, J714, J715, J716

    Beams – N715, N716, N717, N718, N771, N772, N773, N774, N775, S706, S713, S731, S732, S733

    Floor Ceiling Assembly – D744, D767, D768, D769, D770, D771, D772, D773, D774, D775, D776, D777, D927, D928

    Walls – U704

    City of New York

    MEA No. 172-80-M (Columns)

    MEA No. 173-80-M (Columns W14x233)

    MEA No. 174-80-M (Beams)

    City of Los AngelesRR24763
    FM GlobalTested and listed by FM Global for structural Test and LPG vessels at 3/8” (10mm) thickness from face of metal lath for 2 hour rating, including hose stream endurance test.
    City of San Francisco164 C57.7A
    Det Norske Veritas3 bar overblast protection
    Lloyd's RegisterJ-120 jet fire protection - certificate No. SAS F180103



    Drying Times


    Curing Schedule
    Surface TempDry to Recoat
    21°C2 Hours



    Fresh Pyrocrete 241 must be protected from rain or running water for 24 hours at 21°C. In low humidity, high temperature, direct sun or wind, the Pyrocrete surface should be kept damp for at least 12 hours by applying a water mist or wrapping in plastic sheets to reduce rapid water loss

    Caution: Do not start work if ambient temperatures are expected to drop below 2°C for 24 hours after application. Material shall reach a hardness of Shore DO 64 prior to handling and topcoating. For shipping and handling instructions of shop applied Pyrocrete 241 Series materials to individual steel members or modular steel sections, please contact Rawlins.



    Surface Preparation


    Preparation
    General:Before applying Pyrocrete 241, the substrate coating must be free of all oil, grease, condensation, or other contamination
    Steel:

    If primer is required, steel preparation before priming should be done in accordance with the recommended primer’s product data sheet

    Contact Carboline Fireproofing Technical Service for approved primers

    Galvanised Steel:

    Pyrocrete 241 is usually applied directly over galvanized surface

    If priming is required, contact Rawlins on Tech - 0113 2455450 (option 2) or [email protected] for recommendations

    Concrete:The recommended primer to seal concrete prior to applying Pyrocrete 241 is Carboguard 1340
    Non-Ferrous Metals:Aluminum, copper and other non-ferrous metals shall be primed with one coat of Carboline's Rustbond Penetrating Sealer
    Lathing and Attachments:

    1.85 kg/m² galvanised metal lath, may be pre-bent and tie-wired into place for appropriate design. Optionally, beam furring clips or electrically welded, pneumatic or self-tapping screws or studs, may be used.

    Contour Design - 1.85 kg/m² galvanized metal lath wrapped around the flange edges toward the web approximately 38 mm. Contour column designs allow the use of 50.8 mm x 50.8 mm galvanized or PVC coated hexagonal metal mesh with beam furring clips as an alternate to the 1.85 kg/m² galvanised metal lath. Plastic-nosed corner beads may also be used for better thickness control and aesthetics on flange edges of steel. Please refer to design details. For contour applications on structural members with web span greater than 406 mm or flange widths greater than 304 mm refer to the UL Fire Resistance Directory under “Coating Materials” section.

    Boxed Design - 1.85 kg/m² galvanized metal lath wrapped around member spanning the web, overlapped 25.4 mm and tie-wired on the flange face 304 mm on centre. For large webbed members, additional support for lath may be needed for ease of installation. Plasticnosed corner beads may also be used for better thickness control and aesthetics.

    Tower Skirts and Flat Surfaces - Require that 1.85 kg/m² galvanised metal lath be anchored on 304 mm to 610 mm centres depending upon requirements. The lath should overlap and be tie-wired. On tower skirts only, PVC coated mesh can be used in lieu of 1.85 kg/m² galvanised lath. Mesh shall be 50.8 mm x 50.8 mm 20 gauge wire coated with PVC as furnished by Carboline. When ram set or welding is prohibited; a pneumatic fastener may be used. On very large areas, control joints are made by scoring halfway through the thickness of Pyrocrete. This is achieved by using the trowel blade edge or an appropriate scoring tool. A preferred option would be the use of plastic-nosed corner beads. Spacing should be on 3 m centres, both horizontally and vertically. Please refer to design details or contact Rawlins for further information.



    Application Methods


    Product Information
    Mixer:

    Use a heavy-duty mortar mixer rotating at 40 rpm with rubber tipped blades that will scrape the sides and bottom of the mixer. A 22.7 kg bag of Pyrocrete 241 typically requires a mixer volume of 227 L minimum and mixer.

    Do not use pan type mixers.

    Mixing:Target water level: 17 litres, Add +/- 0.5 gallons of clean, potable water to a mortar mixer with rubber tipped blades. With mixer running slowly, add powder and mix for 5 minutes (10 minutes maximum) until a homogeneous mortar-like consistency is achieved. Longer mixing times may result in lower densities. Total water must not exceed 19 litres per 22.7 kg bag. In cool weather, warm water may be used to enhance application. In hot weather, cold water may be used.
    Pot Life:

    2 hours at 21°C and less at higher temperatures. Pot life ends when the material thickens and becomes unusable.

    Do not re-temper material

    Density:

    Target wet density: 1,217-1,313 kg/m³. Wet density measurements are critical to obtaining correct dry densities. When checking wet densities, use the following procedures:

    Equipment needed:

    • 1 litre (1000 cc) polyethylene cup
    • Small metal spatula
    • Scale accurate to 1 gram

    Determination of Pyrocrete wet density:

    • Weigh the empty cup to the nearest gram, then tare the scale.
    • Use the spatula to fill the cup completely with mixed material (do not tamp cup).
    • Remove the excess material on top by placing the vertical edge of the spatula on the top edge of the cup.
    • Use a sawing motion to level the mixed Pyrocrete material flush with the top of the cup.
    • Weigh the filled cup to the nearest gram.
    • Record the weight of material in grams. This value equals the wet density in grams/litre and kg/m³
    • To calculate the wet density of the material in lb./ft³, multiply the value in grams/litre by 0.0624.
    Pump:

    This material can be pumped with a wide range of piston, rotor stator and squeeze pumps designed to pump cement and plaster materials 

    Trowel:Standard plasterers’ hawk and trowel may be used. A rubber float may also aid in finishing.
    Material Hose:Minimum 25.4 mm I.D. hose with 300 psi minimum bursting pressure. For lengths over 15 m use 38 mm I.D. hose. Do not reduce hose diameter by more than 6.4 mm per 7.6 m unless a tapered conical reducer equipped with swivel fitting is used. A 3m length of 25.4 mm I.D. hose may be added at the gun for use as a whip
    Nozzle/Gun:

    Binks - part# 7E2 (47-49 fluid tip / 3/8"-1/2" air cap)

    Graco - part# 204000(3/8" - 1/2" fluid tip / air cap)

    Speeflow - part# 701(3/8" - 1/2" fluid tip / air cap)

    Airtech - Internal mix with 3/8" - 1/2" fluid tip

    Standard plasterers gun with 3/8" - 1/2" fluid tip

    Compressor:Be certain that the air supply is a minimum 22 cfm at 100 psi (689 kPa) and higher when distances longer than 22 m are required
    Air Line:Use 12.7 mm I.D. line, with a minimum bursting pressure of 100 psi (689 kPa)
    General:

    Pyrocrete 241 may be applied by spray and/or trowel. Material build will depend on application method, weather conditions and equipment used. For application overhead, a scratch coat of up to ½” (12.7 mm) is recommended to key into the lath. Allow to set for approximately 1 to 2 hours at 21°C before applying the subsequent coats. It is recommended that the total required thickness be applied within a 24-hour period. If this is not possible, the preceding coats should be left as sprayed or scored after application. Product must be dampened with water before application of additional coats.

    • Maximum time to achieve the full thickness is 3 days at 21°C and 50% relative humidity. This would be less at higher temperatures
    • All additional coats are applied monolithically to the entire perimeter of the member
    • At no time shall Pyrocrete 241 be applied at a thickness less than 6.4 mm or “skim” coated
    Finishing:Material can be left as sprayed or finished with a trowel for better aesthetics



    Application Conditions


    Conditions
    ConditionMaterialSurfaceAmbientHumidity
    Minimum4°C4°C4°C0%
    Maximum38°C52°C43°C95%



    Health and Safety


    Clean Up

    • Pump, mixer, and hose should be cleaned with clean, potable water at least once every 4 hours at 21°C, and more often at higher temperatures
    • Sponges should be run through the hoses to remove residual material
    • Wet Pyrocrete 241 overspray must be cleaned up with soapy or clean, potable water
    • Cured overspray may require chipping and/or scraping to remove

    Safety

    • Observe the precautionary notices on the container label, and read the Material Safety Data Sheet before use
    • Employ normal workmanlike safety precautions
    • Use adequate ventilation
    • Keep container closed when not in use

    Overspray

    • Adjacent surfaces shall be protected from damage and overspray
    • Sprayed fireproofing materials may be difficult to remove from surfaces and may cause damage to architectural finishes
    • Cured overspray may require chipping and/or scraping to remove

    Ventilation

    • When used in enclosed areas, thorough air circulation must be used during and after application until the product is dry
    Product Details
    PY00241

    Data sheet

    Manufacturer
    Carboline
    For Use On
    Steel, Galvanized Steel, Concrete, Aluminum, copper
    Application Method
    Spray, trowel
    Sheen
    Textured
    Single, Two or Three Pack
    Single
    Product Certifications
    UL 1709, BS 476, ISO 22899-1, ASTM E119
    Pack Size
    22.7KG
    Maximum Applied Thickness
    12.7 - 15.9 mm on initial pass
    Coverage
    1.23 m² @ 25.4 mm thick @ 881 kg/m³
    Max. Application Temperature
    Material: 38°C, Surface: 52°C, Ambient: 43°C, Humidity: 95%
    Min. Application Temperature
    Material: 4°C, Surface: 4°C, Ambient: Humidity:
    Density
    Target wet density: 1,217-1,313 kg/m³
    Shelf Life (from date of manufacture)
    24 months
    Attachments
    Download


    Customer agrees that before placing an Order, Customer has read and understood the most up to date Product Data Sheet for the Product. Where we have access to the Product Data Sheet from the manufacturer, we will either provide a copy on request, or include a link to the Product Data Sheet available on the manufacturer’s website. Customer further agrees that we have no liability for any errors or omissions contained within the Product Data Sheets. For more information, please see our Terms & Conditions of Sale.


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    IMPORTANT SHIPPING & DELIVERY INFORMATION

    Carboline Pyrocrete 241 is only available with the shipping and delivery timescales listed below - please do not contact our Customer Support Team with enquiries about alternative or earlier shipping and delivery times.

    Saturdays and Sundays, as well as Bank Holidays, are not classed as working days.

    Orders placed after the cut-off for this product will not be processed for earliest dispatch until 9am the next working day.

    All delivery costs below are excluding VAT


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