Petrochemical Application

In order to obtain optimal results, the following spray equipment setup for CAFCO^® FENDOLITE^® M-II / ISOLATEK^® TYPE M-II on Industrial, Chemical and Petrochemical processing sites is required:

• A rotor stator type, open throat, screw feed pump with minimum “No. 4” soft rubber stators.
• Compressed air is required and must be delivered to the spray nozzle at a minimum volume of 420 L/min (15 cfm) and a minimum pressure of 4.92-7.03 kg/cm² (70-100 psi).
• A paddle or ribbon-type mortar mixer with a safety cover, rubber tipped blades and provision for quick dumping of mix directly into the pump hopper is recommended. Mixers with an 227 liters (8 cu. ft.) capacity or larger, capable of operating speeds of 35 to 40 RPM.
• Screw-on type quick connect/disconnect couplings that do not restrict product flow are required.
• The spray nozzle assembly must consist of a minimum 25 mm (1 in.) ID aluminum pole with a blow-off type nozzle cap, a nozzle orifice and valves for product and air control. Nozzle orifice must be nominal 13 mm diameter (1/2 in.).

CAFCO FENDOLITE TG / ISOLATEK TYPE TG is mixed and then hand applied using common masonry tools.

Careful preparation of substrates is important. Correct preparation ensures that the durability of the fire protection system is maintained and the required level of adhesion is achieved. Poorly prepared substrates may compromise the long term corrosion protection to the structure. Where mechanical fixings are attached to the substrate, careful attention is required in order to reinstate the corrosion system after the fixings have been attached. It is required that the substrates are prepared in accordance with Isolatek’s written instructions.

CAFCO^® FENDOLITE^® M-II / ISOLATEK^® TYPE M-II does not cause corrosion to steel. However, for petrochemical environments, the steelwork must be suitably primed, painted or galvanized prior to the application of the CAFCO FENDOLITE M-II / ISOLATEK TYPE M-II System. All primer/paint systems must be fully cured in accordance with the manufacturers’ application instructions.

The substrate to be protected with the CAFCO FENDOLITE M-II / ISOLATEK Type M-II system must be prepared such that it is free from dirt, dust, oil or other contamination that would impair the adhesion of the CAFCO FENDOLITE M-II / ISOLATEK Type M-II system. Pre-existing protective primers and coatings must be sealed prior to the installation of the CAFCO FENDOLITE M-II / ISOLATEK Type M-II system with ISOLATEK® SBK-113 sealer / keycoat. As an alternate, a galvanized diamond lath may be installed as a substrate for the system.

The reinforcement system for steel structures is galvanized or plastic coated galvanized woven wire or hexagonal mesh. The mesh is secured to the steel by use of stud welded, helical or powder actuated fasteners. The reinforcing mesh is held to the substrate at the fixing points, and then pulled away from the substrate to the middle third of the total thickness of the CAFCO FENDOLITE M-II / ISOLATEK TYPE M-II or CAFCO FENDOLITE TG / ISOLATEK TYPE TG product as it is being applied.

For certain applications, galvanized diamond lath may be used. The lath is secured to the substrate in either a contour or boxed configuration in accordance with Isolatek’s application Instructions and design guidelines.

For storage vessels and spheres, the mesh retention system is installed such that no mechanical fixings are required to be attached to the substrate. The method of installation depends on the type and size of the vessel to be protected.

The CAFCO FENDOLITE M-II or TG / ISOLATEK TYPE M-II or TG is then applied to the surface of the mechanical reinforced substrate in accordance with our written application instructions. Refer to our Application Techniques section for more details regarding the step by step processes used.

CAFCO^® FENDOLITE^® M-II & TG / ISOLATEK^® Type M-II & TG

Maintenance and Repair Procedures of the CAFCO FENDOLITE M-II  / ISOLATEK Type M-II and CAFCO FENDOLITE TG / ISOLATEK Type TG System for Petrochemical Facilities – Short Form.

Routine maintenance performed through testing and inspection of Spray-Applied Fire Resistive Materials (SFRMs) ensures that the product will be in-place for its intended life cycle.

Petrochemical structures are continually exposed to severe environments. As a result, the fireproofing system is susceptible to damage caused by items such as impact and weathering.

A Maintenance program is essential to maintain the integrity of a completely installed fireproofing system. The complete system consists of the steel substrate (i.e. galvanized or primed/coated), metal lath or mesh, anchoring system (i.e. shots, pins, studs and/or wire ties), the fireproofing material, along with the sealer/top coat (if required) and caulking system.

A complete survey of the fireproofing is needed in order to maintain the system and project future cost of the Maintenance Program.

The survey must be conducted by a N.A.C.E. Inspector with knowledge of the fireproofing system, and recommended and approved by Isolatek International.

The procedures outlined below are intended as a guide for conducting your maintenance program. The N.A.C.E. inspector will need a complete copy of the drawings (steel, equipment and support) for mark up, along with access to the project site. The drawings are to remain with owner and/or owner’s rep upon completion of survey.

The N.A.C.E. Inspector will divide the survey in segments (i.e. pipe rack, equipment, HCU unit, Alkyd unit, Diesel unit, etc.) so that all areas and units have their own cost / breakdown for tracking purposes.

Download Maintenance and Repair Procedures PDF

1.0 INSPECTION

1.1 The N.A.C.E. Inspector will inspect and record on the drawings all areas of concern including but not limited to locations where:

1. Fireproofing system is damaged
2. Corner bead is damaged (if used)
3. Previous repaired areas
4. Delamination areas
5. Cracking
6. Mildew
7. Chemical stain/damage areas
8. Wet areas
9. Top coat/sealer failure
10. No caulk or improperly applied caulk
11. Areas that may have steam discharge onto the system

1.2 The N.A.C.E. Inspector shall submit to the owner and/or owners representative all of the drawings with the mark ups, along with a written procedure to complete all of the necessary repairs of the fireproofing system in accordance with Isolatek International’s guidelines.

2.0 Decision

2.1 Inspector must ascertain which observed items require attention within the current maintenance cycle, based on one or both of the following criteria:

1. A repair (i.e. fissure or crack) which may allow moisture and chemical ingress / accumulation behind the fireproofing material.
2. Aesthetic appeal.

3.0 REPAIR

3.1 Termination Seal Delamination and/or Cracking.

1. Strip away the old caulk to reveal the original surfaces. This must occur a minimum of 6 inches (150 mm) beyond the problem area in both directions.
2. Re-apply an approved compatible caulk in its place.

3.2 Topcoat Failure

1. Remove all peeling topcoat by adhering to SSPC-SP 2 (hand tool cleaning).
2. Ensure surface is free from dust and other contaminants.
3. Apply new approved topcoat.

3.3 Prior Repair or Patch Failure

1. Remove existing/damaged patching material down to steel substrate/reinforcement, chamfering sharp edges to leave only sound material
   in place.
2. Attach a new piece of 3.4 lb/yd² (1.84 kg/m2) expanded metal lath or mesh reinforcement into the void by either attaching to existing reinforcement via No. 18 SWG tie wire, or by attaching to the substrate via powder actuated fastener or studwelder. If hexagonal mesh is used in the original application, attach a new piece of plastic coated hexagonal mesh or mesh of 50mm x 50mm x 1.4mm – 1.6mm
   galvanized hexagonal mesh to the existing mesh using 18 SWG wire ties (or twist cut ends together) and maintain a 2 inch (50 mm) overlap at all joints.
3. Position the new reinforcement within the middle third of fireproofing thickness.
4. Pre-wet the existing CAFCO FENDOLITE M-II / ISOLATEK Type M-II fireproofing material.
5. Apply freshly mixed CAFCO® FENDOLITE® M-II / ISOLATEK Type M-II or CAFCO® FENDOLITE® TG / ISOLATEK Type TG(Trowel Grade) material into the void, taking care to push the material behind the reinforcement and completely filling the void.
6. Wait approximately 7 to 10 days before re-applying the approved topcoat (if necessary).

3.4 DAMAGE TO CORNER BEAD AND/OR OTHER REINFORCEMENT

1. Cut away bent or broken corner bead, lath or mesh and strip away adjacent fireproofing a minimum of 6 inches (150 mm) beyond the repair area in all directions down to steel substrate / reinforcement and chamfer all sharp edges leaving only sound material in place.
2. Attach a new piece of corner bead to the existing 3.4 lb/yd² (1.84 kg/m2 ) expanded metal lath using No. 18 SWG steel tie wire. If hexagonal mesh was used in the original application, attach a new piece as previously described in 3.3.2 above and ensure that it will lie in the mid third of the freshly applied repair thickness.
3. Pre-wet the existing CAFCO FENDOLITE M-II / ISOLATEK Type M-II fireproofing material surrounding the repair area.
4. Apply freshly mixed CAFCO FENDOLITE M-II / ISOLATEK Type M-II or CAFCO FENDOLITE TG / ISOLATEK Type TG, flush with surrounding/existing material.
5. Wait approximately 7 to 10 days before re-applying approved topcoat (if necessary).

3.5 SIGNS OF RUSTING BEHIND FIREPROOFING (BLEED-THROUGH)

1. Remove all CAFCO FENDOLITE M-II / ISOLATEK Type M-II material to a minimum of a 12 inch (300 mm) radius around the problem area, down to the steel substrate/reinforcement.
2. Observe rusting of surface of steel. In the case that the project inspector feels that the rusting goes beyond the exposed area, strip away the CAFCO FENDOLITE M-II / ISOLATEK Type M-II until the rusting has ceased.
3. Strip away existing reinforcement.
4. Remove loose rust from the steel surface as per SSPC-SP 2/3 Hand and/or Power tool cleaning.
5. Ensure that the area is free from loose mill scale, oils, dust, or other contaminants.
6. Apply Epoxy Mastic/DTR or other approved surface tolerant epoxy to the surface. The coating must be compatible with the existing coating and the fireproofing material.
7. Apply new reinforcement. Attached with powder actuated fastener or studwelder. Studwelds will require additional surface preparation (i.e. grinding down areas to bare metal, pinning, and final touch-up with Mastic/DTR or approved surface tolerant epoxy).
8. Pre-wet the existing CAFCO FENDOLITE M-II / ISOLATEK Type M-II fireproofing material surrounding the repair area.
9. Apply freshly mixed CAFCO FENDOLITE M-II / ISOLATEK Type M-II or CAFCO FENDOLITE TG / ISOLATEK Type TG, flush with surrounding/existing material.

The above-mentioned application procedure is applicable to structural steelwork in petrochemical and hydrocarbon processing facilities and shall be read in conjunction with the specific requirements of the client as detailed in any specification prepared for the project.

Unless directed to the contrary in the procedure, CAFCO FENDOLITE M-II / ISOLATEK Type M-II must be stored, mixed, applied, controlled and repaired in accordance with Isolatek International’s latest CAFCO FENDOLITE M-II / ISOLATEK Type M-II, CAFCO FENDOLITE TG / ISOLATEK Type TG, CAFCO FENDOLITE M-II/P / ISOLATEK Type M-II/P Application and Installation Manual.

Should you have further questions pertaining to this matter, please contact the Isolatek International Technical Service Department at 800-631-9600, extension 269.

CAFCO^® FENDOLITE^® M-II/P / ISOLATEK^® Type M-II/P

Maintenance and Repair Procedures of the CAFCO FENDOLITE M-II/P / ISOLATEK Typ M-II/P System for Petrochemical Facilities – Short Form

Routine maintenance performed Routine maintenance performed through testing and inspection of Spray-Applied Fire Resistive Materials (SFRMs) ensures that the product will be in-place for its intended life cycle.

Petrochemical structures are continually exposed to severe environments. As a result, the fireproofing system is susceptible to damage caused by items such as impact and weathering.

A Maintenance program is essential to maintain the integrity of a completely installed fireproofing system. The complete system consists of the steel substrate (i.e. galvanized or primed/coated), metal lath or mesh, anchoring system (i.e. shots, pins, studs and/or wire ties), the fireproofing material, along with the sealer/top coat (if required) and caulking system.

A complete survey of the fireproofing is needed in order to maintain the system and project future cost of the Maintenance Program.

The survey must be conducted by a N.A.C.E. Inspector with knowledge of the fireproofing system, and recommended and approved by Isolatek International.

The procedures outlined below are intended as a guide for conducting your maintenance program. The N.A.C.E. inspector will need a complete copy of the drawings (steel, equipment and support) for mark up, along with access to the project site. The drawings are to remain with owner and/or owner’s rep upon completion of survey.

The N.A.C.E. Inspector will divide the survey in segments (i.e. pipe rack, equipment, HCU unit, Alkyd unit, Diesel unit, etc.) so that all areas and units have their own cost / breakdown for tracking purposes.

Download Maintenance and Repair Procedures PDF 

1.0 INSPECTION

1.1 The N.A.C.E. Inspector will inspect and record on the drawings all areas of concern including but not limited to locations where:

1. Fireproofing system is damaged
2. Corner bead is damaged (if used)
3. Previous repaired areas
4. Delamination areas
5. Cracking
6. Mildew
7. Chemical stain/damage areas
8. Wet areas
9. Top coat/sealer failure
10. No caulk or improperly applied caulk
11. Areas that may have steam discharge onto the system

1.2 The N.A.C.E. Inspector shall submit to the owner and/or owners representative all of the drawings with the mark ups, along with a written procedure to complete all of the necessary repairs of the fireproofing system in accordance with Isolatek International’s guidelines.

2.0 DECISION

2.1 Inspector must ascertain which observed items require attention within the current maintenance cycle, based on one or both of the following criteria:

1. A repair (i.e. fissure or crack) which may allow moisture and chemical ingress / accumulation behind the fireproofing material.
2. Aesthetic appeal.

3.0 REPAIR

3.1 Termination Seal Delamination and/or Cracking.

1. Strip away the old caulk to reveal the original surfaces. This must occur a minimum of 6 inches (150 mm) beyond the problem area in both directions.
2. Re-apply an approved compatible caulk in its place.

3.2 Topcoat Failure

1. Remove all peeling topcoat by adhering to SSPC-SP 2 (hand tool cleaning).
2. Ensure surface is free from dust and other contaminants.
3. Apply new approved topcoat.

3.3 Prior Repair or Patch Failure

1. Remove existing/damaged patching material down to steel substrate/reinforcement, chamfering sharp edges to leave only sound material
   in place.
2. Attach a new piece of 3.4 lb/yd² (1.84 kg/m2) expanded metal lath or mesh reinforcement into the void by either attaching to existing reinforcement via No. 18 SWG tie wire, or by attaching to the substrate via powder actuated fastener or studwelder. If hexagonal mesh is used in the original application, attach a new piece of plastic coated hexagonal mesh or mesh of 50mm x 50mm x 1.4mm – 1.6mm galvanized hexagonal mesh to the existing mesh using 18 SWG wire ties (or twist cut ends together) and maintain a 2 inch (50 mm) overlap at all joints.
3. Position the new reinforcement within the middle third of fireproofing thickness.
4. Pre-wet the existing CAFCO FENDOLITE M-II/P / ISOLATEK Type M-II/P fireproofing material.
5. Apply freshly mixed CAFCO FENDOLITE M-II/P / ISOLATEK Type M-II/P material into the void, taking care to push the material behind the reinforcement and completely filling the void.
6. Wait approximately 7 to 10 days before re-applying the approved topcoat (if necessary).

3.4 DAMAGE TO CORNER BEAD (IF USED) AND/OR OTHER REINFORCEMENT

1. Cut away bent or broken corner bead, lath or mesh and strip away adjacent fireproofing a minimum of 6 inches (150 mm) beyond the repair area in all directions down to steel substrate / reinforcement and chamfer all sharp edges leaving only sound material in place.
2. Attach a new piece of corner bead to the existing 3.4 lb/yd² (1.84 kg/m2) expanded metal lath using No. 18 SWG steel tie wire. If hexagonal mesh was used in the original application, attach a new piece as previously described in 3.3.2 above and ensure that it will lie in the mid third of the freshly applied repair thickness.
3. Pre-wet the existing CAFCO FENDOLITE M-II/P / ISOLATEK Type M-II/P fireproofing material surrounding the repair area.
4. Apply freshly mixed CAFCO FENDOLITE M-II/P / ISOLATEK Type M-II/P, flush with surrounding/existing material.
5. Wait approximately 7 to 10 days before re-applying approved topcoat (if necessary).

3.5 SIGNS OF RUSTING BEHIND FIREPROOFING (BLEED-THROUGH)

1. Remove all CAFCO FENDOLITE M-II/P / ISOLATEK Type M-II/P material to a minimum of a 12 inch (300 mm) radius around the problem area, down to the steel substrate/reinforcement.
2. Observe rusting of surface of steel. In the case that the project inspector feels that the rusting goes beyond the exposed area, strip away the CAFCO FENDOLITE M-II/P / ISOLATEK Type M-II/Puntil the rusting has ceased.
3. Strip away existing reinforcement.
4. Remove loose rust from the steel surface as per SSPC-SP 2/3 Hand and/or Power tool cleaning.
5. Ensure that the area is free from loose mill scale, oils, dust, or other contaminants.
6. Apply Epoxy Mastic/DTR or other approved surface tolerant epoxy to the surface. The coating must be compatible with the existing coating and the fireproofing material.
7. Apply new reinforcement. Attached with powder actuated fastener or studwelder. Studwelds will require additional surface preparation (i.e. grinding down areas to bare metal, pinning, and final touch-up with Mastic/DTR or approved surface tolerant epoxy).
8. Pre-wet the existing CAFCO FENDOLITE M-II/P / ISOLATEK Type M-II/P fireproofing material surrounding the repair area.
9. Apply freshly mixed CAFCO FENDOLITE M-II/P / ISOLATEK Type M-II/P, flush with surrounding/existing material.

The above-mentioned application procedure is applicable to structural steelwork in petrochemical and hydrocarbon processing facilities and shall be read in conjunction with the specific requirements of the client as detailed in any specification prepared for the project.

Unless directed to the contrary in the procedure, CAFCO FENDOLITE M-II/P / ISOLATEK Type M-II/P must be stored, mixed, applied, controlled and repaired in accordance with Isolatek International’s latest CAFCO FENDOLITE M-II / ISOLATEK Type M-II, CAFCO FENDOLITE TG / ISOLATEK Type TG, CAFCO FENDOLITE M-II/P / ISOLATEK Type M-II/P Application and Installation Manual.

Should you have further questions pertaining to this matter, please contact the Isolatek International Technical Service Department at 800-631-9600, extension 269.

Quality Control Test Data Report (Form # C01A)

In order to provide a method for our customers to monitor and maintain product quality during installation, we have developed the Quality Control Test Data Report (Form # C01A). This method provides a summary of quality as the product is installed and allows means to address non-conformities. At the end of the project there is a record that the product and the installation have met all performance standards and fulfills the Quality Control in Application (Section 9.4) of the API 2218; Fireproofing Practices in Petroleum and Petrochemical Processing Plants. This minimizes future risk and gives applicators, engineers and architects the highest degree of confidence in their fire resistive system.

View Quality Control Test Data Report PDF