Plasite® 9570
APPLICATION GUIDE
PART I GENERAL
1.01 SCOPE
A. This guide details the procedures recommended by the Carboline Company for
the application of Plasite 9570 protective coating system to the interior of process
and storage vessels.
B. In cases where there is a procedure difference between this specification and
any other specification or standard referred to, the other specification’s author
and the Carboline Company Technical Service Group shall be consulted.
C. The applicator shall review this specification and consult the Carboline Company
Technical Service Group regarding its interpretation, disapproval or request for
procedure changes. Deviations from this specification should be discussed and
agreed to by the Carboline Company Technical Service Group.
D. The coating material manufacturer’s current product data sheets are to be used
in conjunction with and become a part of this specification. The applicator shall
adhere to all accommodations of product shelf life, mixing ratios and acceptable
thinners.
E. The applicator shall use industry standard inspection equipment, quality control
and inspection policies in regards to the application of this product.
F. It is the responsibility of the applicator to adhere to industry standard application
and inspection procedures for record keeping purposes.
G. The coating system is to be applied in two coats, using alternate colors, to a
nominal film thickness required for the intended service. The typical service
would require a nominal 14 mils (350 microns). The acceptable minimum is 12
mils (300 microns) and the maximum is 15 mils (375 microns) with acceptable
spots at 18 mils (450 microns).
H. It is the applicator’s responsibility to compute and supply adequate ventilation to
prevent explosion and toxicity hazard conditions as prescribed by standards of
good safety practices, local and state regulations, OSHA and other federal
regulations.
1.02 SUBMITTALS
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Plasite® 9570
APPLICATION GUIDE
A. Product Data: Submit manufacturer's technical data, installation instructions, and
chemical resistance data for the lining. Include certification indicating compliance
of materials with requirements.
PART II PRODUCTS
2.01 COATING MATERIALS
A. Lining material shall be Plasite 9570 consisting of two coats. Reference: The
Carboline Company product data sheet Plasite 9570.
2.02 COLOR
A. Iron oxide yellow and olive oxide
PART III EXECUTION
3.01 PRELIMINARY INSPECTION
Before any coating is begun, the interior surfaces of the vessel shall be inspected to
see that the following has been done.
A. All weld splatter, sharp projections, slivers and pits shall be removed.
1. Weld metal shall be used to fill repairs. Putty shall not be used without
consulting the Carboline Company Technical Service Department.
B. Welds that are rough, irregular and not well formed shall be corrected by grinding
smooth.
C. All sharp corners and edges shall be rounded to at least a 1/8" radius.
D. No other conditions exist which would shorten the expected life of the applied
coatings.
E. Used vessels. (Based on the previous service environment, decontamination
may be required.)
1. Decontamination shall be performed by one or a combination of the following
methods.
(a) Prebaking at 300°F(149C) or a minimum of 50°F above final cure
temperature for 4 hours.
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Plasite® 9570
APPLICATION GUIDE
(b) Steaming for 24 hours with 15 psi steam.
(c) Ultra high pressure (30,000 psi) washing.
(d) High pressure washing with cleaning or neutralizing chemicals.
2. Decontamination shall be verified by the use of a chloride test kit, pH test or
black light, whatever is dictated by the previous service conditions.
3.02 SURFACE PREPARATION
A. Oil and grease shall be removed from the surfaces to be coated with a suitable
safety solvent prior to abrasive blasting.
1. Vessel design and fabrication details shall be in accordance with NACE
SP0178. All sharp edges and welds shall be ground smooth to a rounded
contour in accordance with NACE Weld Preparation Designation "C" and all
weld splatter shall be removed prior to abrasive blasting.
2. Non-carbon steel parts that will not be coated shall be removed and/or
protected prior to blasting, including but not limited to hatch covers, hatch
rings, outlet valves and vents. The lining shall be terminated on the non-
carbon steel approximately 1" past the interface.
3. The compressed air used for blasting shall be free of water and oil. In order to
determine cleanliness, blast without abrasive onto a collector surface (eg.
white cloth or rigid transparent plastic) in accordance with ASTM D4285. The
compressed air system shall be blown down to allow reaching operating
conditions prior to test on collector surface. Acceptable result is no oil or
water contamination on collector surface.
4. All weld seams shall be individually blasted prior to blasting other areas of the
vessel. Weld seams are the areas of early coating failure. Removal of
contaminants and achieving the proper anchor pattern in the heat affected
zone at the welds is critical to the service life of the lining.
B. Surfaces shall be abrasive blasted to "near-white metal" cleanliness in
accordance with SSPC-SP 10/NACE No. 2 Joint Surface Preparation Standard.
1. The anchor pattern or "tooth" in the metal shall be a minimum of 2.0 mils (50
microns) with an average representing 20 to 25% of the total dry film
thickness of the coating system. Proper abrasive shall be a sharp natural
abrasive, slag grit or steel grit similar to or equal to G40 or other abrasives
having a sharp, hard-cutting surface, properly graded, dry, of best quality and
of proper size to produce the specified anchor pattern.
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Plasite® 9570
APPLICATION GUIDE
C. All internal surfaces shall be vacuum cleaned to remove all blast media and dust
after blasting is completed. External surfaces may be air blown clean using dry,
oil-free air.
1. No visible oxidation shall be permitted between the time of blasting and
priming the blasted surface.
2. The interior of the vessel shall be protected from moisture formation from the
time of commencing abrasive blasting to the time that application and curing
are completed.
3. Protect all tank bottom area surfaces from overspray or off spray with
temporary masking such as clean plastic sheeting, tarps or drop cloths.
Ensure tank bottom surfaces are clean following removal of temporary
masking and proceeding with coating applications
3.03 COATING APPLICATION
A. Before starting coating application, it is recommended that the applicator read all
available safety data including, but not limited to, GHS-compliant safety data
sheet, product data sheet, and backup label.
B. Plasite 9570 consists of two pre-measured parts in 4A:1B mix ratio which must
be separately pre-mixed and then thoroughly power mixed together. After the
epoxy base and curing agent have been combined and power mixed together,
the mixed coating shall be allowed 30-minute “sweat-in” or induction period prior
to adding any thinning and usage. After power mixing the combined components,
Plasite 9570 has a pot life of 3 to 4 hours at 70°F (21°C). A decrease in film build
and spray properties will be noted at the end of usable pot life. Reference: the
Carboline Company Product Data Sheet Plasite 9570.
1. It will always be necessary to thin the coating. Normal application
temperatures will require the addition of approximately 10 to 20% by volume
Plasite Thinner 71. Above the normal application temperature range of 65 to
85°F (18-29°C) will require additional thinning at the rate of approximately
2.5-3.0% per every 5°F (3°C) of increased temperature.
C. The lining application must not proceed until the substrate temperature is a
minimum of 5°F (3°C) above the dew point. Minimum air and/or surface
temperature at the time of application shall be 50°F (10°C) or higher, but
substrate temperature must be increased to at least 70°F (21°C) or higher within
24 hours following coating application for proper polymerization. Maximum air
and surface temperature for application is 105°F (41°C). If forced air ventilation
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Plasite® 9570
APPLICATION GUIDE
cannot maintain required substrate over dew point spread during preparation and
coating operations, then DH (dehumidification) equipment is recommended to
assist forced air ventilation.
D. Weld seams, edges, welded internal attachments, and difficult to coat areas shall
be scrub striped before spray application begins.
Note. Scrub brush stripping of weld seams is not to build film thickness
but to seal the irregular steel area and reduce the surface tension for the
first spray coat.
1. The striping shall be performed with a good quality bristle brush using Plasite
9570 which has been thinned equal parts by volume with Plasite Thinner
71. Thinning shall be added following sweat-in or induction time.
2. Scrub striping is accomplished by moving the brush back and forth in a
scrubbing motion to work the primer into crevices, any lap joints, around nuts
& bolts and undercut areas of the welds; result is a shading or partial hiding
wet film thickness only. Allow at least 15-30 minutes of ventilated solvent
flash off prior to full spray application of coating.
3. Bristles left on the surface shall be removed before the stripe coating dries.
E. All areas subject to overspray and drips (such as lower tank shell, floor level
piping and bottom) shall be protected by a suitable covering while spraying other
areas in the tank.
F. Compressed air supply shall be uncontaminated.
G. Conventional Air Spray: Use a dual-regulated conventional air spray pot with
minimum ⅜” (9.5 mm) I.D. fluid hose and minimum 5/16” (8 mm) I.D. atomization
air hose by maximum 50 ft (15 m) long from spray pot to spray gun. Load the
spray pot, adjust pot/fluid pressure to 10-15 psi (0.6-1.0 bar) and then adjust
atomization air pressure to approximately 45-50 psi (3.1-3.4 bar). Recommend
use of standard industrial-type conventional air spray guns such as Binks 2001 or
2100 or DeVilbiss JGA-510 or MBC-510 with 0.070” I.D. fluid tip and appropriate
needle and air cap.
H. Airless Spray: When airless spray equipment is used, the pump shall be 30:1
ratio or greater with a minimum volume output of 2.3 gallons/minute (8.7
liters/minute) with airless fluid hose minimum diameter of ⅜” (9.5 mm) I.D. The
recommended fluid spray pressure is 1800-2200 psi (124-151 bars) with tip size
from 0.017-0.021.” Adjust spray tip orifice size and material fluid pressure to
obtain a spray pattern with the best possible atomization
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Plasite® 9570
APPLICATION GUIDE
I. Apply a mist bonding pass of Plasite 9570 to a workable area of steel surface.
Allow to dry approximately one minute but not long enough to allow film to dry
completely.
J. Then spray apply Plasite 9570 to mist coated area using multi-pass technique
with cross hatching and 50% overlap between passes moving gun at a fairly
rapid rate (while maintaining perpendicular orientation and consistent distance to
the substrate) to effect a continuous, even, wet-appearing film at approximately
8.0-10.0 wet mils (200-250 microns) as measured using a wet film thickness
gage in accordance with ASTM D4414. Application equipment required to apply
the Plasite 9060 coating will dictate gun application speed. Wet mil gage
readings of 8.0-10.0 wet mils (200–250 microns) will yield 6.0-7.0 mils (150-175
microns) of dry film thickness at 10% thinning.
K. Venting of the vessel is recommended during the application and curing process.
Ventilation air supplied at sufficient volume rate to tank interior spaces shall
ensure at least 3-5 or more air volume changes per hour to tank interior space is
recommended. Air movement to all interior surfaces – especially at tank bottom
areas - is essential for curing of the lining.
L. Minimum dry to recoat time will vary with the temperature and ventilation and will
require at least 24 hours at 70°F (21°C) or 16 hours at 90°F (32°C) for enclosed
spaces.
1. Force curing between coats is optional and may be used to expedite the
between coats curing process. After a minimum 1 hour forced ventilation
period, raise substrate temperatures slowly and evenly, not to exceed 30°F
every 30 minutes. Raise substrate temperature to a maximum of 150°F
(65.5°C). *Normally, the following curing schedule may be used for the
coating to reach a set (physically workable) condition. If force curing
between coats is used to expedite the application process, substrate
temperatures representing the high and low temperature areas of the
subject tank shall be monitored. Temperature monitoring equipment
such as an adequate number of thermal couplings attached to the
external of the tank in positions representing the potential high and low
temperature areas shall be used to assure good temperature control.
SUBSTRATE CURING SUBSTRATE CURING
TEMP TIME TEMP TIME
100F/37.6C 8-10 Hours 140°F/60C 2 ½ Hours
120°F/48.9C 6 Hours 150°F/65.5C 1 Hour
130°F/54.4C 3 Hours
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APPLICATION GUIDE
*Note: Varying film thicknesses and forced ventilation procedures and
capabilities may alter results noted in the above between coats force curing
schedule.
CAUTION! Force curing between coats above 150°F(65.5°C) substrate
temperature and/or exceeding 12 hours at the above temperatures will
result in poor intercoat bonding.
M. Prior to applying the topcoat, all runs, drips and rough areas shall be removed
from the primer by light sanding and recoating.
NOTE: Be sure to remove any dust from sanding before applying topcoat.
N. Topcoat - By repeating Steps I-J, using Plasite 9570, a homogenous film of 12 to
15 mils (300-375 microns) is obtained.
1. Topcoat shall be smooth in appearance and holiday-free as determined with a
holiday tester.
M. Defects shall be sanded smooth and recoated for retest for film thickness and
holidays.
3.04 CURING
A. Following the second/topcoat application of Plasite 9570 it is commonly
recommended to perform all inspection hold points (ie. visual, DFT verification,
and holiday detection with any required spot repair and spot retest for continuity)
prior to low baking of the lining. Allow a ventilated curing time of at least 24
hours at 70°F (21°C) substrate temperature for the final coat before low voltage
wet sponge holiday testing is performed. Spot repair as necessary and spot re-
test for continuity after allowing a minimum cure of 24 hours at 70°F (21°C)
substrate temperature. Force curing procedure entails raising the substrate
temperature approximately 30°F (17°C) in increments of 30 minutes until the
desired temperature is reached. Curing time begins when the specific substrate
temperature is reached (Temperature monitoring equipment such as an
adequate number of thermal couplings attached to the external of the tank in
positions representing the potential high and low temperature areas shall be
used to assure good temperature control):
SUBSTRATE TEMPERATURE CURING TIME
200°F (93°C) 4 Hours
250°F (121°C) 2 Hours
NOTE: A final bake of 250°F (121°C) will increase resistance to certain exposures
and is generally recommended when the exposure is considered to be extremely
severe.
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Plasite® 9570
APPLICATION GUIDE
B. The less favorable option is to low bake the lining prior to performing industry
standard inspection hold points. If that is the chosen option, allow an air dry time
of 1 hour at 70 to 100°F (21-38°C) shall be allowed after the second/topcoat
application before low gake force curing. After air dry period, substrate
temperature shall be raised approximately 30°F in increments of 30 minutes until
the desired temperature is reached. Curing time begins when a substrate
temperature of 200°F (93°C) is reached: force cure at 200°F (93°C) for 4 hours.
Can also force cure at 250°F (121°C) for 2 hours – especially if chemical
exposure is extremely severe. Temperature monitoring equipment such as an
adequate number of thermal couplings attached to the external of the tank in
positions representing the potential high and low temperature areas shall be
used to assure good temperature control.
3.05 INSPECTION
A. Determine degree of blast cleanliness using NACE or SSPC standards.
B. Depth of blast profile should be determined by either by using Press-O-Film
replica tape with micrometer or surface profile depth gauge in accordance with
ASTM D4417.
C. Prior to applications of Plasite 9570, verify that steel temperature is at least 50°F
(10°C) or higher and at least 5°F (3°C) above the dew point temperature. Note
that within 24 hours after each coat is applied, a minimum substrate temperature
of at least 70°F (21°C) or higher is required to be obtained and held for at least
24 hours at 70°F (21°C) or at least 90°F (32°C) for 16 hours for proper
polymerization of the coating (to allow foot traffic, DFT gage readings, as well as
application of the final coat).
D. Ensure wet thickness readings are periodically taken in accordance with ASTM
D4414 during spray applications of Plasite 9570.
C. Dry film thickness of each spray-applied coat shall be determined utilizing a
calibrated and properly-adjusted Type 2 electronic DFT gage as described in
ASTM D7091 and SSPC-PA2. The total dry film thickness shall be a minimum of
12 mils (300 microns), with a maximum of 15 mils (375 microns). A suspect
area, that being in excess of 15 mils (375 microns) and no greater than 18 mils
(450 microns) total DFT, shall be acceptable if an average of 12 to 15 mils (300–
375 microns) is obtained when four additional readings are observed, taken
approximately 12 inches (30.5 cm) away from the suspect reading area at top,
bottom and both sides – and the average of the five readings is within acceptable
range.
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Plasite® 9570
APPLICATION GUIDE
D. After a minimum 24 hour cure at 70 to 90°F (21-32°C), the coating film can be
tested for discontinuities with a low voltage holiday detector such as a Tinker-
Rasor Model M-1 low voltage holiday detector or equivalent in accordance with
NACE SP0188 or ASTM D5162 standard. All discontinuities shall be repaired. A
coating film discontinuity test shall be preferably performed after the final coat
and before the final force cure.
NOTES:
A. Coating film discontinuities found after the final force cure will require force
curing at a minimum of 200°F (93°C) for 4 hours (or when exposure is
extremely severe at a minimum 250°F/121°C for 2 hours).
B. The discontinuity tests shall be performed with a low voltage non-destructive
type holiday detector such as the Tinker Rasor Model M-1 (or equivalent).
3.06 REPAIR
A. Areas which contain visual rust shall be abrasive blasted feathering onto
adjoining sound coating.
B. Where there is no evidence of rust, abrade area by sanding or grinding the
surface of sound, existing coating where touch up or repair material will overlap.
C. Remove all dust and debris from prepared surfaces. Solvent wipe prepared
areas with MEK.
D. Apply coating with brush, roller or spray gun depending on the size of the area to
be patched. The number of coats required may vary depending on the size of
the area to be repaired and the method of application.
E. Any coating film defects or discontinuities found after the final force cure will
require spot repair followed by retest for dry film thickness and continuity and the
spot force cured at a minimum of 200°F (93°C) for 4 hours (or when exposure is
extremely severe at a minimum 250°F/121°C for 2 hours).
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Plasite® 9570
APPLICATION GUIDE
3.07 SAFETY
A. THE SOLVENT IN THIS COATING IS FLAMMABLE AND CARE AS
DEMANDED BY GOOD PRACTICE, OSHA, STATE AND LOCAL SAFETY
CODES, ETC. MUST BE FOLLOWED CLOSELY. Keep material away from
excessive heat, direct sunlight, sparks and open flame and use necessary safety
equipment, such as respiratory, eye and skin protection, explosion-proof
electrical equipment, non-sparking tools and ladders, etc. Avoid contact with skin
and breathing of vapor or spray mist. When working in tanks, rooms and other
enclosed spaces, adequate ventilation with fresh air changes must be provided in
accordance with OSHA standards. Refer to the Carboline Company Bulletin PA-
3 as well as the Carboline Product Data Sheet and Safety Data Sheets for
additional information.
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