Pyrocrete 40 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 40 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 further information and approved primers

Generally not required. In severely corrosive atmospheres, topcoats may be used for added durability and chemical resistance. consult Carboline Fireproofing Technical Service for selection of the coating most suitable for the operating environment

Seal Coat – In corrosive environments, use an appropriate topcoat. If topcoating is required, apply Carboguard 1340 as a seal coat. Carboguard 1340 shall be thinned 25% with Carboline Thinner 2. Carboguard 1340 may be applied after 24 hours of final application of Pyrocrete 40. Consult the Carboguard 1340 Product Data Sheet for minimum and maximum cure times

Topcoat – Surface hardness should be a minimum Shore DO 64 as measured with a durometer prior to application of the topcoat.

Normally, this minimum dry time is 10 days at 21°C and 40 days at 4°C, for thickness of 25.4 mm or less

Caulking – For exterior installations, Acrilast caulk should be applied at all termination joints between Pyrocrete 40 and the substrate. Contact Rawlins on Tech - 0113 2455450 (option 2) or [email protected] for full information

1.66 m² at 25.4 mm thick @ 640 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 taken into account 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

Pyrocrete 40 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 – XR705, XR706, XR707 (lath free)

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 - X760, X761, X762, X763, X784, X785, Y707, Y708

Roof Assembly – P927, P928, P734, P735, P736, P737, P738, P739, P926, P929

Beams – N737, N738, N739, N740, N771, N772, N773, N774, N775, S717, S719, S731, S732, S733

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

Walls – U704

Precast Concrete and Steel Joists – G706, G707, G708, J713, J714, J715, J716

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 galvanised 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 galvanised 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 galvanised 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 3m centres, both horizontally and vertically. Please refer to design details or contact Rawlins

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 40 typically requires a mixer volume of 227L minimum

Do not use pan type mixers

Target water level: 18 litres

Add clean, potable water to a mortar mixer with rubber tipped blades. With mixer running slowly, add powder and mix for 2 minutes until a homogeneous mortar-like consistency is achieved. Longer mixing times may result in lower densities. Total water must not exceed 20 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

Target wet density: 897 - 961 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

Contact Rawlins on Tech - 0113 2455450 (option 2) or [email protected] for additional details

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

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

Speedflow - 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

Pyrocrete 40 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 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° 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 40 be applied at a thickness less than 6.4 mm or “skim” coated