Carboline Thermo-lag 3000 Instructions for use

THERMO-LAG 3000

Fire Barrier System

Application Manual

Commercial / Light Industrial Market

ASTM E119 (UL 263 / NFPA 251)

January, 2016

Rev. 4

Notices and Statements

NOTICE

CARBOLINE PROPRIETARY RIGHTS ARE INCLUDED IN THE INFORMATION DISCLOSED HEREIN.

RECIPIENT AGREES THAT NEITHER THIS DOCUMENT NOR THE INFORMATION DISCLOSED HEREIN NOR

ANY PART THEREOF SHALL BE REPRODUCED OR TRANSFERRED TO OTHER DOCUMENTS OR USED OR

DISCLOSED TO OTHERS FOR MANUFACTURING OR FOR ANY OTHER PURPOSE EXCEPT AS

SPECIFICALLY AUTHORIZED IN WRITING BY CARBOLINE

THE INFORMATION AND TECHNICAL DATA CONTAINED IN THIS DOCUMENT IS ACCURATE AND

COMPLETE TO THE BEST OF OUR KNOWLEDGE AS OF THE DATE PRINTED.

THE INFORMATION IN THIS DOCUMENT IS SUBJECT TO CHANGE WITHOUT NOTICE.

CARBOLINE MAKES NO WARRANTY,EXPRESSED OR IMPLIED,OF ANY KIND WITH REGARD TO THIS

PRINTED MATERIAL.CARBOLINE ASSUMES NO RESPONSIBILITY FOR ERRORS OR OMISSIONS THAT

MAY OCCUR IN THIS DOCUMENT.CARBOLINE DOES NOT MAKE A COMMITMENT TO KEEP THIS

DOCUMENT CURRENT AND UP TO DATE.

CARBOLINE,ITS EMPLOYEES AND AGENTS SHALL HAVE NO OBLIGATION OR LIABILITY FOR DAMAGES,

INCLUDING BUT NOT LIMITED TO CONSEQUENTIAL DAMAGES ARISING OUT OF OR IN CONNECTION WITH

THE USE,OR INABILITY TO USE,THE INFORMATION INCLUDED IN THIS GUIDE.

Table of Contents

Page No.

NOTICES AND STATEMENTS i

TABLE OF CONTENTS ii

PREFACE v

AUDIENCE v

LOCATING INFORMATION v

NUMBERING SYSTEM v

BREAKDOWN OF INFORMATION v

Related Publications and Documents

This document occasionally refers to other Guides, data sheets, or specifications that

may be helpful. Copies are available from CARBOLINE. Related information can be

accessed at www.Carboline.com.

Other documents that may be helpful include:

• OSHA - Occupational Safety and Health Administration Safety Rules

• National Spray Equipment Manufacturer’s Association Precautions for Spraying

• Power tools, hand tools or other mechanical equipment operating procedures

Safety Precautions

THERMO-LAG 3000 Bulk Grade Material weighs approximately 10.5 - 11.5 pounds per gallon.

Caution should be taken when lifting and moving the material to prevent injury

Observe the National Spray Equipment Manufacturers Association precautions for spraying.

DO NOT point spray gun at any part of the human body.

Notes on Installation

Basis for Installation Procedures in This Guide

The installation steps and procedures in this guide were prepared with the best available data.

All of the steps and procedures presented in this guide are based upon tests. As additional test

and installation data becomes available, including revised installation procedures, CARBOLINE

may update and modify this guide.

NOTE:

This is a general Application Manual and cannot cover all possible situations which may

arise in the field. For technical assistance, contact CARBOLINE’s Fireproofing Technical

Service Group at: 1-800-848-4645.

Page 1of 35

1.0 GENERAL CONDITIONS

1.1 SCOPE

This Application Manual describes the requirements for the application of the THERMO-LAG

3000 Fire Barrier System to steel surfaces for the commercial / light industrial market, based

on the requirements of ASTM E119. For the application of THERMO-LAG 3000 to any other

substrates, markets or specifications, contact CARBOLINE Technical Service or your local

CARBOLINE Sales Representative.

1.2 QUALITY CONTROL MANUAL

1.2.1 QUALIFICATIONS OF APPLICATORS/RESPONSIBILITIES OF PERSONNEL

The application shall be performed by a Qualified Applicator having CARBOLINE training

with proper equipment and experience.

1.2.2 REQUIREMENTS

In order to qualify, an Applicator shall:

(a) Undergo specific training by CARBOLINE

(b) Be experienced in the application of thick film coatings, preferably epoxy based.

quality control instrumentation.

(d) Have in place an acceptable QA/QC system and be prepared to permit

CARBOLINE audits.

(e) Understand and recognize their statutory obligations with regard to health and

Safety.

1.3 SAFETY PRECAUTIONS

The Applicator shall follow standard industrial hygiene practices for the handling of chemical

coatings and shall conform to applicable codes of practice, regulations, and Owner Safety

rules in all respects. Reference THERMO-LAG 3000 MSDS and Health and Safety Data

Sheets for additional information and instruction.

Where power tools hand tools, spray equipment or other mechanical equipment are being

used, the proper operating procedures for each tool or piece of equipment, as well as eye,

hearing and respiratory protection should be followed. Equipment used to apply THERMO-

LAG 3000 is under high pressure. Any injury caused by high pressure liquids can be

serious and immediate medical attention should be sought.

1.4 DELIVERY

THERMO-LAG 3000 shall be delivered to the site in original, unopened containers, bearing

clearly visible product names, batch number, name of manufacturer, expiration date, and

storage instructions.

1.5 STORAGE

THERMO-LAG 3000 not in immediate use shall be stored off the ground in a covered area

assigned for that purpose. The materials in storage shall be protected from temperatures

above 100˚F (38˚C) and below 32˚F (0˚C).

Page 2of 35

Prior to use with plural component equipment, THERMO-LAG 3000 A shall be heated to a

minimum of 100˚F (38˚C).

Prior to use with plural or single component equipment, THERMO-LAG 3000 SA shall be

heated to a minimum of 70˚F (21˚C) and a maximum of 110˚F (43˚C).

1.6 PROTECTION OF ADJACENT SURFACES

The applicator shall mask off all adjacent areas and equipment from material overspray

during the application. Overspray shall be removed promptly before material has cured.

When applying these coating in windy conditions, additional precautions to control overspray

should be undertaken.

2.0 MATERIALS

The THERMO-LAG 3000 Fire Barrier System consists of the following materials:

2.1 PRIMERS

Prior to use, all primer systems must be accepted by CARBOLINE prior to use under

THERMO-LAG 3000. The acceptable primer system shall be applied to properly prepared

surfaces in accordance with the manufacturer's and project specifications in a range of 3 – 5

mils (75 – 125 microns) DFT per SSPC PA2. Refer to Appendix A, Carboline’s Approved

Primer List.

All steel surfaces shall be blasted to a 1.5 – 2.0 mils (37 – 50 microns) angular profile, to a

minimum of a SSPC SP6 (Sa2). (For galvanized steel surfaces see Section 4.3 –

Galvanized Surface Preparation)

Final dry film thickness in excess of this value shall be agreed upon by CARBOLINE in

writing.

2.2 THERMO-LAG 3000

THERMO-LAG 3000 is a two component, thermally activated, intumescent epoxy coating.

When exposed to flame, the material volatilizes at fixed temperatures, exhibits a volume

increase through formation of a multicellular matrix and absorbs and blocks heat to protect

the substrate material.

THERMO-LAG 3000 A (100% Solids)

THERMO-LAG 3000 SA (95% Solids)

2.3 TOPCOATS

Topcoat systems must be acceptable to Carboline prior to use over THERMO-LAG 3000.

Refer to Appendix B, Carboline’s Approved Topcoat List for various topcoat options.

2.4 FP-FIBERGLASS MESH

The FP-Fiberglass Mesh is 5.3 oz/yd2(180 grams/m2), Type "E", and must be purchased

from CARBOLINE. The application details of the FP-Fiberglass Mesh are dependent upon

the design, size of steel, project requirements, etc. and can be found in the appendices of

this manual.

FP-Fiberglass Mesh is utilized for Intertek Design Nos. CC/BA 180-01 and CC/CA 180-02

and UL Design No. N608.

Page 3of 35

2.5 HIGH TEMP MESH

The High Temp Mesh is an open weave carbon mesh and must be obtained from

CARBOLINE. The application details of the High Temp Mesh are dependent upon the

design, size of steel, project requirements, etc. and can be found in the appendices of

this manual.

High Temp Mesh is utilized for Intertek Design No. CC/CA 180-03.

3.0 EQUIPMENT (Minimum)

3.1 APPROVED PLURAL COMPONENT EQUIPMENT FOR THERMO-LAG 3000 A AND

THERMO-LAG 3000 SA

The following approved plural component units (without holding tanks) are suitable for the

application of THERMO-LAG 3000 shall be purchased from:

AirTech Spray Systems, Inc. CoverCat Spray Systems Ltd.

4303 Piedmont Dr. 35A Northfield Way, Newton Aycliffe

Houston, TX 77018 County Durham, DL5 6UF UK

Tel: 713-681-0013 Tel: 44-1325-314120

MODEL NO: MODEL NO:

AT2.3/4000 (Bucket Pump) 352 F (Tank Mounted Pump)

452 F (Tank Mounted Pump)

Spray-Quip, Inc.

1754 Des Jardines Covercat U.S.A.

Houston, TX 77023 40 Austin Boulevard

Tel: 713-923-2771 Commack, NY 11725

MODEL NO 631-462-2952:

397-884 SQ/GRACO H.D. Fixed Ratio

(Tank Mounted Pump)

We recommend the use of tank mounted pumps.

It is essential that all the equipment used by the Applicator is properly maintained. It is

necessary to regularly change items such as seals, gun tips, packing and hoses.

Every Applicator shall obtain a parts list and/or manual from the manufacturer for the proper

operation of the equipment and its maintenance.

Any company which has not utilized the specific pump prior to applying THERMO-LAG 3000

shall be trained in the proper operation of the pump by the pump manufacturer.

CARBOLINE takes no responsibility for the lack of proper instruction on the use of the

pump.

Poorly maintained equipment will not function properly and may cause the ratio of

components A and B, (set at 1:1), to vary. The permitted ratio tolerance of components A

and B is +/- 5% (by volume). The Applicator shall perform at least 2 ratio checks (by

volume) per shift collecting a minimum of 2.5 gallons (10 liters) of components A and B

during each check.

Ratio checks shall only be performed by pumping both components into separate pails

simultaneously.

Page 4of 35

3.1.1 EQUIPMENT STARTUP PROCEDURE

A. The pump and all lines shall be clean and free from any contamination.

B. Turn off air to main pump. Be sure all pressure is removed from lines.

Prior to loading heated material under follower plates, premix Parts A and B for 2 – 3

minutes.

Load heated material under follower plates. Lower follower plates on to buckets and

bleed off trapped air and then close bleed valves.

NOTE: If using pump with holding tanks, use transfer pumps and begin filling unit with

material.

Turn on the main pump air to assist in the movement of material into the material lines.

Continue pumping Part A and Part B until a steady flow of material is present at the end

of each fluid delivery hose. Turn off all air.

C. Turn on fluid and line heaters, and adjust temperature of the heaters to 140-160˚F (60˚C

- 71˚C). Wait at least 30 minutes for material to heat thoroughly or recirculate the

material until the temperature of the material reaches the temperatures stated above.

D. The pump shall be set for a 1:1 ratio and it is important to check this ratio before

beginning any work.

Hose Bundle: ¾” (100’ maximum) Whip Hose: ½” (20’ maximum).

E. The air pressures needed for properly delivering material may vary from pump to pump,

and adjustments may vary from the stated pressures herein.

F. The use of other plural component equipment (with holding tanks), shall be approved by

CARBOLINE prior to use.

With the air still turned off to the main pump,

Adjust the air pressure to the "A" component transfer pump to 40 psi. Adjust the air

pressure to the "B" component transfer pump to 40 psi. While directing the discharge

into separate, clean and equally sized containers, turn the air on to the main pump.

Keep pumping until both or one of the containers is full. Insure that the transfer pumps

are not continuously cycling. If this is so, turn up the main pump to increase the back

pressure or reduce the pressure on the transfer pumps (see note below).

G. If containers contain equal volumes, the 1:1 ratio has been achieved. If not, check for

restrictions in the air or material flow and material temperature. Repeat above

procedure. If ratio is still not correct, inspect equipment and pump packings and replace

if needed. Repeat the above procedure until a 1:1 ratio is achieved.

CARBOLINE requires that when using plural component pumps, which have

holding tanks and recirculation capabilities, the material shall not be recirculated

more than one time, and the temperature of the holding tanks shall not exceed

140˚F(60˚C). Tank mixers should be used at minimum revolutions.

Material shall be pre-heated to a minimum of 100˚F (37.8˚C) prior to introduction to

the pumping units. Thoroughly mix Parts A and B well - separately - before using.

Page 5of 35

NOTE:

If the transfer pump pressure is adjusted too high, it will over pressure the proportioning

unit, and affect the ratio.

H. Apply enough pressure to the main pump to achieve a proper fan pattern. Apply material

in accordance with the procedures recommended herein.

A minimum of two ratio checks per shift is required. An additional ratio check is required

before starting a pump which has been repaired, or after a continuous down time of

more than one hour. Static mixers shall be examined and changed after every 2 hours

of continuous spraying, and the mixing block and valves leading to it shall be inspected

and cleaned after the days work is completed. All other maintenance procedures

specified by the pump supplier shall be followed.

3.2 SINGLE COMPONENT EQUIPMENT FOR THERMO-LAG 3000 SA

Airless Spray Pump: Fluid to Air Ratio of 45:1 or greater.

Hopper Feed required with a minimum ¾” outlet on high pressure

side with an output of 3.3 gallons/minute (minimum)

Gun: Binks lM Mastic Gun with Graco Tip Adapter

Tip Size: 0.035" - 0.045" Graco Heavy duty RAC non- diffuser tips)

Fan Size: 6" - 10"

Material Hose: Solvent Resistant:

3/4" I.D. 50’ Max

1/2" I.D. Whip hose 25’ Max

Pressure at Gun: 2500 - 3000 psi

Air Requirements: 40 -100 cfm @ 100 psi per unit. Use moisture and oil traps.

Static Mixer Standard 12 turn ¾” mixer

Refer to CARBOLINE‘s application instructions for complete requirements, which can be

found in this manual.

Note: THERMO-LAG 3000-SP must be thinned up to 3% with Toluene or Plasite Thinner

#19 only. Thinning the material will increase the pot life of the material, however it will slow

the curing process. CARBOLINE must approve the use of other thinners prior to start up.

3.2.1 EQUIPMENT STARTUP PROCEDURE

Material shall be pre-heated to a minimum of 70˚F (21˚C)

It is important that the pump and all lines are clean and free from any contamination.

If half filled containers have been supplied, add thinner into part B and mix thoroughly.

Stage Part B onto Part A and mix thoroughly. Thinning will decrease the amount of material

which can be applied in one coat and decrease the rate of cure.

If full containers are supplied, it is required to mix Parts A and B before splitting containers in

half. Make sure that there are equal volumes of each. Follow instructions listed above.

Page 6of 35

Pour mixed material into hopper. Remove spray gun from the end of the hose. Turn pump

pressure up only high enough to move material to the end of the delivery line. Turn off air

and replace spray gun. Increase air pressure until appropriate fan pattern is achieved. Apply

material in accordance with the procedures detailed herein.

4.0 PREPARATIONS PRIOR TO THERMO-LAG APPLICATION

4.1 DEGREASING, BLASTING AND PRIMING

4.1.1 DEGREASING

All surfaces shall be cleaned and degreased prior to grit blasting the steel per SSPC SP1.

When selecting a cleaning method the primer manufacturer’s and project recommendations

must be adhered to.

When it is necessary to clean the surface of THERMO-LAG 3000 before applying a further

coat or top coating, solvent wiping with Toluene or Plasite Thinner #19 is recommended.

4.1.2 BLASTING

All blasting abrasive shall be dry, clean and free from contaminants. Where grit is used,

contact primer manufacturer for specific details on acceptable blast abrasive and other

industry standards.

4.1.2.2 SURFACE PREPARATION

All steel surfaces shall be blasted with an angular anchor profile of 1.5 – 2.0 mils (37 – 50

microns) to a minimum of a SSPC SP6 (Sa 2).

4.1.3 PRIMING

Only primer systems acceptable by CARBOLINE shall be used under THERMO-LAG 3000.

The primer shall be applied in accordance with the manufacturer's and project’s

specification. Refer to Appendix C, CARBOLINE’s Approved Primer List.

The primer system thickness range shall be between 3 – 5 mils (75 – 125 microns) (DFT)

per SSPC PA2. Any other final dry film thickness in excess of this value shall be agreed

upon by CARBOLINE in writing.

4.1.3.1 PRIMER THICKNESS AND ADHESION MEASUREMENTS

As previously stated, controlling the thickness of applied primers is very important. The

following method will be the only one accepted by CARBOLINE:

(a) Use a flat polished steel plate to calibrate the measuring device to zero.

(b) Use the measuring device to measure individual primer coats and multi-coat

thicknesses.

(d) Thickness of primer must be sufficient to fully cover blast profile.

4.1.3.2 PRIMER REACTIVATING

If multiple primer coats are required, care must be taken to ensure that the manufacturers

recommended maximum overcoating time has not been exceeded.

4.1.4 PRIMER ADHESION

The coating inspector for the project must be satisfied that the adhesion values of the primer

system meet the project specification.

Page 7of 35

4.2 SURFACE PREPARATION WHERE AN EXISTING / NON-APPROVED PRIMER WAS

INSTALLED

This SECTION applies to areas where an existing / non-approved primer system has been

installed and the existing surface was prepared to SSPC SP6 (Sa 2) with a minimum of 1.5

– 2 mils (37 – 50 microns) profile.

Ultra high pressure water jetting may be employed to remove a primer or other coating

where no dry blast surface preparation is permitted. Note: Ultra high pressure water jetting

will not generate an accepted profile on steel that has not been previously profiled.

Thoroughly water jet the surface until the original blasted surface has been revealed. The

cleaned surface should be blown dry with clean, dry compressed air to remove water

residues. Immediately after, the clean surface shall be primed with an approved wet blast

type primer, in accordance with the manufacturer's and project specification. Contact

CARBOLINE for the current list of acceptable wet blast type primers.

No wet blast system shall be used without first consulting with CARBOLINE prior to start up

of the project.

4.3 GALVANIZED SURFACE PREPARATION

Galvanizing requires a roughened surface for optimum adhesion/performance of high build

epoxies. Remove any contaminants per SSPC SP1; ensure there are no chemical

treatments that may interfere with adhesion; and abrade the surface to establish a suitable

roughness per SSPC-SP7 (Sa1) with a minimum angular anchor profile of 1.5 – 2 mils (37 –

50 microns). Prime with Carboguard 893 SG Primer @ 3 – 5 mils (75 – 125 microns) (DFT)

per SSPC PA2.

4.4 STAINLESS STEEL SURFACE PREPARATION

All steel surfaces shall be blasted to a SSPC-SP7 (Sa 1) with a minimum angular anchor

profile of 1.5 – 2 mils (37 – 50 microns). Prime with Carboguard 893 SG Primer @ 3 – 5

mils (75 – 125 microns) (DFT) per SSPC PA2.

4.5 WELD CUT BACK

It is often necessary to mask off areas on the structure before the application of THERMO-

LAG 3000 to allow for future welding.

As heat is generated during the welding process, either during a preheating stage and/or

during the welding itself, it is important that a suitable distance is left around the weld area to

prevent damage to the adjacent THERMO-LAG 3000.

For small weld attachments such as the addition of clips and hangers, a cutback distance of

2” (50mm) on each side of the weld areas should be sufficient. When carrying out welding

close to THERMO-LAG 3000, a discoloration may be noted.

This discoloration denotes that the THERMO-LAG 3000 has received too much heat and the

bond to the steel is likely to have been affected. When this happens, the discolored

THERMO-LAG 3000 must be removed as described in 7.0 Removal and Repair Procedures.

For larger welds, i.e. full girth, a cutback of 12” (300 mm) each side of the weld area may be

sufficient.

The cutback distances given below assume that the weld will be made at the center and are

given as recommendations only. The precise nature of the weld, including the mass of steel

and the method of preheating used, will determine the precise distance. As indicated above,

discoloration of the THERMO-LAG 3000 will denote that an insufficient cutback distance has

been used.

Page 8of 35

Weld Preheat Total Cutback

Temp °F (°C) Time (hr) Inches (mm)

212 100 4 - 8 30 750

212 100 8 - 12 40 1000

302 150 4 - 8 30 – 40 750 - 1000

302 150 8 - 12 40 – 50 1000 – 1250

5.0 THERMO-LAG 3000 APPLICATION PROCEDURES

THERMO-LAG 3000 shall be applied in good weather, following good painting practices. In

general, the substrate and ambient temperature shall be no less than 41°F (5°C), and 5°F

(3°C) above dew point. Humidity shall not exceed 85%.Any deviation shall be subject to

approval by CARBOLINE. All attempts shall be made to maintain dry conditions throughout

the application process, through the topcoat application.

The Applicator shall apply THERMO-LAG 3000 over a properly cured approved primer. The

material shall be applied in 40 – 120 mil (1mm – 3mm) passes. Apply as many passes

required to provide the desired film thickness. Lighter coats will provide an improved surface

appearance. Allow applied material to cure sufficiently to support the weight of subsequent

coats. The thickness which can be applied in a single coat will depend on the temperature,

humidity, applicator technique, etc. The time between coats is largely dependent upon

ambient temperatures and in general the following table should be used:

Typical Overcoating Times Between

THERMO-LAG 3000 A (100% Solids) Coats

Temperature (°F/°C) Min. Time (Mins.) Max. Time (Hrs.)

50°F (10°C) 60 72

77°F (25°C) 30 72

85°F (29°C) 30 48

95°F (35°C) 30 48

110°F (43°C) 30 24

If the overcoat time has been exceeded, the surface of the THERMO-LAG 3000 must be

reactivated as described below:

The actual production work must follow, and conform to the approved finish / surface quality

established by the site sample. The site sample is a mandatory requirement and should be

kept available for all parties to have access to throughout completion of the project.

If required, contact Carboline’s Fireproofing Technical Service Group for further assistance

with finishing techniques.

Greater than 72 hours but less than 7 days

THERMO-LAG 3000 must be solvent wiped with Toluene or Plasite Thinner #19 to

reactivate the surface and remove contaminants.

Page 9of 35

7 Days or beyond

The surface of the THERMO-LAG 3000 must be "Sweep Blasted" or mechanically abraded

to remove any contamination or particulate. The freshly blasted surface must then be

solvent wiped (Toluene or Thinner 19) to reactivate the THERMO-LAG 3000 and to remove

contaminants.

THERMO-LAG 3000 must be protected from direct rain until it has reached sufficient cure. If

water contamination occurs to uncured THERMO-LAG 3000, any uncured material must be

removed and reapplied. The material must be clean and dry prior to applying subsequent

coats of THERMO-LAG 3000 or topcoating.

Topcoating shall be applied in accordance with the project specification and manufacturer's

recommendations. The maximum allowable time to topcoat the THERMO-LAG 3000 is 7

days at 70˚F (21˚C). If this time is exceeded, the area should be sweep blasted or

mechanically abraded with 40 grit paper (or approved equal), then solvent wiped, prior to

topcoating. A topcoat is always required. The minimum topcoating time for THERMO-LAG

3000 A is 10 hours, and for THERMO-LAG 3000 SA is 48 hours.

The Applicator shall take frequent thickness measurements during application, using a

penetrating measuring device to ensure that the coating is uniformly applied at the required

film thickness. The thickness checks shall be made as required by the project based on

AWCI Technical Manual 12-B.

Care shall be taken to keep the fan pattern at an angle of 90 degrees to the surface and at

12" (305mm) to 18" (457mm) away from the surface.A brush and/or roller can be used to

improve the surface quality. Please read the THERMO-LAG 3000 product data sheet before

application commences.

Excessive build-up of THERMO-LAG 3000 in angle areas can be removed or leveled by

rolling the surface with a solvent resistant foam or short napped mohair roller. Use Toluene

or Plasite Thinner #19 to keep roller moist which will prevent roller from sticking to the

material. CARBOLINE recommends the use of solvent resistant spray bottles to minimize

the use of solvents.

Do not use excessive solvent during rolling, as this will retard the surface cure of the

material.

Special care should be taken when spraying flange edges on structural steel members to

ensure complete coverage and a consistent thickness. The normal spray pattern on the

outside and the inside surfaces of the flanges should cause the material to flow and wrap

around the edge of the flange. If the coating on the flange edge is uneven after application,

the edge shall be rolled lightly in order to provide an even surface.

5.1 INSTALLATION OF MESH ON STRUCTURAL STEEL I & H SECTIONS

After the first coat of THERMO-LAG 3000 has been applied, the mesh is placed in position

as detailed in certification or approval documentation. See Appendix C. Ensure that the

proper mesh reinforcement is utilized based on the project specific UL or Intertek Design i.e.

Design No. UL N608 (Restrained/Unrestrained Beams): FP-Fiberglass Mesh

Design No. CC/BA 180-01 (Restrained/Unrestrained Beams): FP-Fiberglass Mesh

Design No. CC/CA 180-02 (Wide Flange Columns): FP-Fiberglass Mesh

Design No. CC/CA 180-03 (Tubular Columns): High Temp Mesh

Wide Flange Section

The mesh shall be overlapped 1” (25mm) on all longitudinal seams running down the wide

flange member.

Page 10 of 35

Rolled Hollow Section (RHS)

Tubular and other hollow steel sections are reinforced in a similar manner except that the

entire surface is reinforced by using one or two pieces of mesh. The mesh shall be

overlapped 1” (25mm) on all seams.

5.2 FINAL THERMO-LAG 3000 APPLICATION

After the mesh has been installed, apply THERMO-LAG 3000 to the final required thickness

in as many coats as is necessary. Any overcoating shall be done within 72 hours of the

prior coat. If the time is exceeded, the surface must be prepared as stated in Section 5.0.

It is mandatory that imbedded mesh is covered with 40 mils (1 mm) of THERMO-LAG

3000 prior to daily shutdown.

5.2.1 TERMINATION ONTO NON-FIREPROOFED STEEL

Where the THERMO-LAG 3000 terminates to non-fire protected steel, the THERMO-LAG

3000 shall be sprayed to the specified thickness for the given length and beveled on a 45°

angle down to the substrate. The top coat system shall continue down onto the no-

fireproofed substrate (minimum 1” or 50mm) to insure a proper seal.

5.3 FINAL THICKNESS

The final thickness shall be specified in project drawings and Owner specifications.

Thicknesses for THERMO-LAG 3000 are outlined in Intertek Design Nos. CC/BA 180-01,

CC/CA 180-02, CC/CA 180-03 and UL Design No. N608. All are based on average

thicknesses. However, on some projects, a minimum thickness may be specified from the

owner or specific engineering firm. When an average thickness is specified, the minimum

acceptable thickness for any one point shall not be less than 80% of the specified thickness.

The overall average thickness must be equal to or greater than the specified thickness. The

number of thickness checks and other issues regarding this topic are found in Technical

Manual 12-B and SSPC PA2. All matters relating to the thickness(es) shall be decided

between the owner and the applicator prior to the startup of the job.

After THERMO-LAG 3000 has cured, an approved thickness gauge shall be used to ensure

the thickness requirements have been met. Thicknesses below specification shall be built

up to specified thickness by the application of additional THERMO-LAG 3000. An alternate

method of thickness measurement can be performed by drilling a pilot hole and using a

penetrating measuring device. It is required to fill all probe holes with THERMO-LAG 3000

after measurements have been taken.

5.4 SAMPLE INSTALLATION

Prior to actual production work, a sample test area shall be prepared following all specified

procedures and approved finish / surface quality. This sample must then be approved by

representatives of the owner, applicator, architect and any others having a vested interest in

the installation. The actual production work must follow, and conform to, the standards and

approved finish / surface quality of the site sample.

The site sample is a mandatory requirement and shall be made available to all parties

throughout the completion of the project.

5.5 EQUIPMENT CLEANUP / FLUSHING

Plural component equipment with hot water flush components must be flushed using 150˚F

(66˚C) water, minimum.

Plural component equipment with solvent flush components must be flushed with Toluene or

Plasite Thinner #19.

Page 11 of 35

The spray gun, static mixer and block assembly must be hand cleaned at the end of each

spray period using Toluene or Plasite Thinner #19.

5.6 TOPCOATING (Refer to 2.3 Topcoats)

Topcoating shall be applied in accordance with the project specification and manufacturer's

recommendations. The maximum allowable time to topcoat the THERMO-LAG 3000 is 7

days at 70˚F (21˚C). If this time is exceeded, the area should be sweep blasted or

mechanically abraded with 40 grit paper (or approved equal), then solvent wiped, prior to

topcoating. A topcoat is always required. The minimum topcoating times for THERMO-

LAG 3000 A is 10 hours, and for THERMO-LAG 3000 SA 48 hours.

5.7 RECORD KEEPING

The maintaining of proper records is an essential requirement for all THERMO-LAG 3000

projects. The minimum requirements will be established by the project. Refer to Appendix D

for typical application logs.

6.0 CLEAN-UP

The application area shall be maintained in a clean and orderly condition. Following the

application, all overspray, debris, and equipment shall be removed and the area left in a

condition acceptable to the Owner and Main Contractor.

7.0 REMOVAL AND REPAIR PROCEDURES

7.1 REMOVAL

The preferred method is to cut through the THERMO-LAG 3000 at right angles to the

substrate with a disc saw around the area to be removed. Make sure that the steel

substrate is not damaged. A power chisel can then be used to “chip” away the THERMO-

LAG 3000 from the substrate.

It is essential that proper safety precautions are taken during this operation. Reference shall

be made to the THERMO-LAG 3000 Material Safety Data Sheets (MSDS) and all site safety

requirements.

7.2 REPAIRS - GENERAL

In instances when THERMO-LAG 3000 has been damaged or is in need of repair the

following procedures shall be followed:

The primer system shall be reinstated to its original specification.

Remove all damaged material back to solidly adhered material. All edges can be left as butt

joints to a 90 degree angle or beveled to a 45 degree angle. All edges must be solvent

cleaned and allowed to dry before commencing application of THERMO-LAG 3000. It is

important that the newly applied THERMO-LAG 3000 blends into the existing material to

achieve a uniform appearance. The THERMO-LAG 3000 shall be troweled or spray applied

to the appropriate thickness for mesh placement. The specified mesh type shall be butted

up to the existing mesh (no overlaps required). The final specified thickness of THERMO-

LAG 3000 can then be applied, based on the project specification and fire test certification.

The specified topcoat system shall be applied, based on the original specification, in strict

accordance with Carboline’s written instructions.

8.0 IN SHOP APPLICATION – PRE-ERECTION

Page 12 of 35

8.1 INTRODUCTION

THERMO-LAG 3000 lends itself to being a material which can be applied off site and later

shipped to the job site. This allows for a more consistent application of the material off site

and elimination of interference with other trades which may affect application flow. When

this type of application is performed, contact CARBOLINE for advice. In general, the

application of THERMO-LAG 3000 follows the guidelines in this manual. The following

additional requirements are necessary:

8.2 BLOCK OUT AREAS

Prior to application of the shop fireproofing, define all areas of the steel structures that do

not receive THERMO-LAG 3000 until after the erection phase of the construction. These

areas which are not to receive THERMO-LAG 3000 shall be masked off in the proper

dimensions, prior to application. The size of the block out shall be determined by the

applicator, owner or engineering firm. THERMO-LAG 3000 has high bond strength, and

cannot be easily removed. For in shop application, the specified topcoat system shall be

applied to all THERMO-LAG 3000 surfaces.After steel is erected, the topcoat shall be

mechanically removed from the edges and back approximately 1” from the edge of the block

out.

Application to the block out areas may now continue, utilizing spray or trowel methods. The

THERMO-LAG 3000 finish appearance must be approved by the owner.

The specified mesh type shall be installed and butted up to the existing mesh (no overlap

required). The final specified thickness of THERMO-LAG 3000 can then be applied.

The blocked out edges can be left as butt joints to a 90 degree angle or beveled to a 45

degree angle.

The specified topcoat system shall be applied, based on the original specification, in strict

accordance with Carboline’s written instructions.

8.3 HANDLING, STORAGE AND ERECTION

8.3.1 UNLOADING

Generally the fireproofed steel is loaded and unloaded with a crane to permit maximum

loading of each truck. It is not advisable to unload fireproofed steel with forklifts, as the steel

is nested in ways that forklifts do not easily accommodate and damage to fireproofing may

occur.

8.3.2 RIGGING

Wherever possible, steel should not be rigged to the fireproofed portion of the member.

Shackles at end holes are a generally acceptable practice and provide the best method for

unloading members. Follow all site specific safety standards for handling structural steel.

8.4 DUNNAGE

Members should be stored on proper dunnage (on the block out areas) to avoid exposure to

the ground and moisture.

8.4.1 ORIENTATION OF MEMBERS

Members should be stacked with webs vertical to avoid ponding of water and snow. Elevate

one end of the steel member to provide water run off.

8.4.2 STACKING

Where members must be double stacked, avoid placing dunnage on the fireproofed

surfaces.

8.5 RIGGING

Page 13 of 35

Avoid using chokers against fireproofed surfaces. Wherever possible, add erection tabs or

bolt holes at the beam ends to allow top rigging without using chokers around the

fireproofing. Follow all site specific safety standards for handling structural steel.

8.5.1 SWING RADIUS

Where infill beams use framing angles, the erector must be aware of the swing radius of the

member impacting the fireproofing. This type of connection has a blockout on each side of

the holes on the primary member. When the block out dimension is insufficient, the erector

is advised to chip out a minimal amount of fireproofing on ONE SIDE ONLY. It is better to

chip a minimal amount of fireproofing than to make all the connections unnecessarily large.

Follow all site specific safety standards.

8.5.2 CONSIDER GROUND ASSEMBLY

On repetitive structures like pipe racks, by pre-assembling the bents it will minimize the

damage to the fireproofing.

8.6 LIFTING

All pre-erection projects will require the steel to be lifted onto trucks or into place on the

jobsite. All lifting shall be done utilizing the block out areas for strapping, shackling to

erection tabs or bolt holes. Lifting should be performed from a 2 point lift so to insure the

straps are flat against the steel, so that no slipping and tearing can occur.

8.7 DAMAGE

Any damage to the coating system shall be repaired as per section 7.0 of this

guide

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