ITW DEVCON ENGINEERED COATINGS - ITW Futura Coatings

1.0 GENERAL.
SPECIFICATION AND APPLICATION GUIDELINE FOR
COATING STEEL SURFACES WITH
IRATHANE 155
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Revised Date: 06/2012
Replaces Date: 04/2010
1.1. This specification guideline establishes the minimum technical requirements and describes the
work to be performed for the application of Irathane 155 and related systems on to steel surfaces.
This work is to include total responsibility for surface preparation, cleaning, environmental control
of the work area, abrasive cleanup and the application of the elastomeric polyurethane system.
1.2. The contractor is to supply suitable equipment of all manner required to prepare specified
surfaces for application of lining system and apply same.
1.3. Insure that all Product Data Sheets and Material Safety Data Sheets are the current versions.
1.4. Operations shall comply to all company, state, local and federal safety codes and regulations.
1.5. Materials shall be delivered to the jobsite in the manufacturer's original unopened containers. The
containers shall include the following information on the label: supplier, name or number of the
material, manufacture date or batch code. All materials shall be carefully handled and stored to
prevent inclusion of foreign materials or exposure to temperatures below 55°F or exceeding 90°F.
Components outdated as indicated by shelf life shall not be used.
1.6. Applicator training is required and spray equipment must be approved by ITW Futura Coatings
prior to the application of any coating materials.
2.0 JOB CONDITIONS AND SAFETY REQUIREMENTS.
2.1. Conditions which may be detrimental to start up, completion or performance of the specified work
shall be reported in writing to the on-site inspector, plant manager, or project engineer in charge
of the program, prior to commencing work. Work shall not be started until defects are corrected or
specific approval has been given in writing.
2.2. All coating materials shall be stored, mixed and applied at 55-90°F material temperature.
2.3. Ambient temperatures must be between 55°F and 90°F during application of coating materials.
Relative humidity must be below 85%.
06/12 Irathane 155 Steel

2.4. Substrate surface temperature shall be above 55°F and lower than 100°F, and must be at least
5°F above the dewpoint.
2.4.1. Substrate temperature must be steady or increasing.
2.4.2. Avoid direct sunlight on the substrate during all phases of coating work.
2.5. Adequate ventilation is to be maintained at all times in the work area. Open fires and spark
producing equipment shall not be used in or near work areas during the application of all coating
materials.
2.6. Post "No Smoking", “Fire Hazard” and other warning signs as required in work areas during and
for at least forty-eight (48) hours following the application of all coating materials.
2.7. All personnel shall wear and utilize all safety equipment as recommended in the Material Safety
Data Sheets when handling, mixing and applying coating materials.
2.7.1. Fresh air respirators are required during the application of Irathane 155.
2.8. Adequate lighting shall be provided to sufficiently light up all areas to be worked on without
Inclusion of shadow areas.
2.9. All coating materials should be handled in accordance with all precautions recommended in their
Material Safety Data Sheets and Product Data Sheets.
2.10. All cured and uncured coating materials, solvents and other chemicals shall be disposed of in
accordance with all local, state and federal regulations.
3.0 INSPECTION.
3.1. All work including rigging of staging, lighting, ventilation, surface preparation, application and
curing of the coating system shall be carried out to the satisfaction and approval of the
Inspector(s) and/or Owner.
3.2. Any proposed deviation from the specified procedures as contained herein, that may be deemed
necessary, shall be reported in writing in accordance with Section 2.1.
3.3. A daily log must be maintained by the Inspector(s) to record application conditions.
3.4. A final inspection of the coating system should be performed after installation of equipment to
assure a holiday free lining.
3.5. Specific inspections should be performed for each stage of coating work as specified.
4.0 SURFACE PREPARATION
4.1. Compressed air used for all surface preparation and coating work shall be free of oil, water, or
other contaminants. Oil and water filter/separators shall be installed in the air supply.
4.2. All areas that are not to be coated should be properly protected prior to the commencement of
surface preparation procedures.
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4.3. Prior to abrasive blast cleaning remove all deposits of dirt, oil, grease, or other contaminants in
accordance with SSPC-SP1.
4.4. All immersion-service steel surfaces shall be prepared in accordance with SSPC-SP5, White
Metal Blast Cleaning.
4.4.1. All non-immersion areas can be prepared in accordance with SSPC-SP10, Near White Metal
Blast Cleaning.
4.5. All steel surfaces shall have a surface profile (anchor pattern) of 3 to 4 mils.
4.5.1. Heavily corroded steel, containing grooving or pinholes shall be opened up and sharp edges
removed through the use of an appropriate mixture of non-metallic, abrasive blast media.
4.5.2. The surface profile (anchor pattern) shall be verified through the use of replica tape in
accordance with ASTM D4417, “Standard Test Methods for Field Measurement of Surface
Profile of Blast Cleaned Steel”.
4.6. All welds must be continuous. Skip or intermittent welds must be made continuous by welding.
4.7. All welds must be clean and free of spatter or sharp projections.
4.8. All welds must be ground to remove sharp edges, undercutting, pinholes or any other
irregularities. Relative smooth, ripple finish welds are acceptable.
4.9. All welds must meet NACE RP0178 Designation “C” as a minimum.
4.10. All lap joints must receive a continuous fillet weld.
4.11. All corners and sharp edges must be ground to a minimum 1/8” radius.
4.12. All inlet and outlet ports must be welded pads or flanges, not threaded.
4.13. All internal bracing or reinforcement with open ends must be capped and seal welded.
4.14. Prior to coating application, all prepared surfaces shall be vacuumed or blown down with clean,
dry compressed air to remove dust, grit, or abrasives.
4.15. Surfaces to be coated shall be tested for soluble salts contamination. Salt contamination levels in
excess of 40 micrograms per square centimeter shall be rejected, and additional cleaning with
steam or fresh water to flush away the soluble salts will be required.
4.16. Simultaneous coating application and abrasive blasting operations shall not be conducted where
possible contamination of the coating can occur.
4.17. If surface preparation is conducted in sections, no coating may be applied within six (6) inches of
the temporary boundary of a cleaned area.
4.18. Abrasive blasted surfaces shall be coated within eight (8) hours maximum and prior to any rust
bloom occurring. No metal shall be coated that exhibits visible rust bloom.
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5.0 APPLICATION - GENERAL
5.1. Coatings shall be applied in accordance with the requirements of this specification guideline, to
clean, dry surfaces during periods of favorable temperature and humidity conditions.
5.1.1. Surface temperature of the substrate should be at least 5°F above the dew point and rising,
before any coating work is attempted.
5.1.2. No coating work shall be done at a relative humidity above 85%.
5.1.3. Coating application shall be restricted to ambient temperatures in the 55 to 90°F range.
5.1.4. Coating application shall be restricted to substrate temperatures in the 55 to 90°F range.
5.2. Surfaces to be coated shall have the specified surface preparation at the time of coating
application. If surfaces have degraded or become contaminated subsequent to surface
preparation and prior to coating, they shall be restored to the specified degree before coating
application.
5.3. Stripe coat, using a brush, all welds, edges, corners, bolt heads, rivets. This operation shall be
done before the application of the initial Futura-Bond 610HS coat.
5.4. Observe recommended recoat intervals between the initial application and subsequent overcoats.
6.0 PRIMER APPLICATION
6.1. Futura-Bond 610HS is a two component urethane primer that can be spray or roller applied over
properly prepared metal surfaces at a dry film thickness of 2 - 4 mils and should be applied to all
properly prepared surfaces. All Futura-Bond 610HS primed surfaces must be inspected prior to
the application of Irathane 155.
6.2. Recommended application equipment: 30:1 ratio or larger airless spray unit with a minimum
output of 2 ½ gallons per minute, Teflon packings and either nylon or Teflon lined material hoses.
Spray tip sizes can range from 0.015 to 0.031inches.
6.2.1. Purge all lines and equipment with clean Xylene or Toluene thinner prior to and after
spraying Irathane 155 to prevent a build up of material inside the spray unit and material
hoses. Do not use Ketones, such as MEK, MIBK or Acetone. The use of Ketones will
severely affect the cure of the Irathane 155.
6.3. Do not mix Futura-Bond 610HS until all surfaces are properly prepared and accepted for coating
application.
6.4. Futura-Bond 610HS has a one and a half (1 1/2) hour pot life at 75°F, do not mix more material
than can be applied in this period of time.
6.5. Futura-Bond 610HS may be thinned with acetone up to 15% by volume. N. Butyl Acetate may be
added up to that allowable by local regulations.
6.6. Futura-Bond 610HS should not be applied in direct sunlight.
6.7. Refer to the current Futura-Bond 610HS Product Data Sheet for mixing and application
instructions.
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6.8. Futura-Bond 610HS shall be applied within eight (8) hours of the completion of abrasive blast
cleaning and before any flash rusting occurs.
6.9. Futura-Bond 610HS has a minimum drying time of ten (10) hours and a maximum of twenty-four
(24) hours, at 75°F for application of the Irabond UU 96.
6.9.1. If more than twenty-four (24) hours and less than forty-eight (48) hours drying time, at 75°F
occurs with any Futura-Bond 610HS coat, an additional coat of Futura-Bond 610HS must be
applied prior to the application of Irabond UU 96.
6.10. All of the above recoat times are temperature sensitive. Temperatures below 70°F will lengthen
the recommended recoat times while temperatures above 70°F will shorten the recommended
recoat times.
6.11. Uncured Futura-Bond 610HS shall be protected against damage from dust, detrimental foreign
matter, and rain.
6.12. Before proceeding with the coating application it is necessary to generally inspect the substrate.
There must be no sharp corners and all edges should be rounded. Surface tension of the coating
will cause reduced thickness in these locations and acceptable coating gauge may not be
obtained. Acceptable rounded edges will be approximately 0.090 inches radius or larger.
7.0 ADHESIVE APPLICATION
7.1. Irabond UU96 should be used with Futura-Bond 610HS or if Irathane 155 recoat has
exceeded as indicated in Section 8.
7.2. Irabond UU 96 is a one component adhesive system that can be spray or roller applied over
Futura-Bond 610HS surfaces and should be applied at a 2-3 mil wet film thickness.
7.2.1. Power-mix the Irabond UU 96 to a smooth uniform consistency.
7.2.2. Do not thin or cut Irabond UU 96.
7.3. Irabond UU 96 must be applied to the Futura-Bond 610HS within the recoat parameters.
7.4. The minimum recoat window for Irabond UU 96 is fifty (50) minutes and the maximum recoat
window is five (5) hours at 75°F. TO AVOID ADDITIONAL WORK, DO NOT SURPASS THIS
RECOAT WINDOW.
7.5. If the Irabond UU 96 recoat window is surpassed, by less than twenty-four (24) hours at 75°F, an
additional coat of Irabond UU 96 must be applied. If it is more than twenty-four (24) hours, the
surface must be abrasive blasted back to the original surface preparation requirements in
accordance with Section 4.0 and primed with Futura-Bond 610HS.
8.0 TOPCOAT APPLICATION
8.1. Irathane 155 is a 65% solids by volume, two-component (1:1 mix ratio by volume) elastomeric
polyurethane coating that must be sprayed over Irabond UU 96 or 610HS coated surfaces.
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8.2. Recommended application equipment: 30:1 ratio or larger airless spray unit with a minimum
output of 2 ½ gallons per minute, Teflon packings and either nylon or Teflon lined material hoses.
Spray tip sizes can range from 0.015 to 0.031inches.
8.2.1. Purge all lines and equipment with clean Xylene or Toluene thinner prior to and after
spraying Irathane 155 to prevent a build up of material inside the spray unit and material
hoses. Do not use Ketones, such as MEK, MIBK or Acetone. The use of Ketones will
severely affect the cure of the Irathane 155.
8.3. Refer to the current Irathane 155 Product Data Sheet for mixing and application instructions.
8.3.1. Power-mix the "B" component for a minimum of three (3) minutes before combining with the
"A" component in a single container.
8.3.1.1. The “A” component (ISO) does not require mixing.
8.3.2. After combining the components, power mix for a minimum of five (5) minutes, scraping the
sides and bottom of the mixing container to blend any unmixed materials, and then "box" to
ensure a good mix.
8.3.2.1. “Boxing” is a method of mixing Irathane products. Following the initial mix in a large
mixing container, pour the mixed material back into the original “A” and “B” component
pails and power mix each for a minimum of one (1) minute. Re-pour these containers
back into the large mixing container and power mix for an additional two (2) minutes.
8.3.2.2. Box mixing assures proper mixing and proportioning of all components as well as
reduces hazardous waste since mixed and cured material can typically be disposed of
as non-hazardous waste.
8.3.2.3. All waste must be handled in accordance with all local, state and federal regulations.
8.3.3. Only full kits of Irathane 155 should be mixed. Do not mix partial kits.
8.3.4. Do not thin or cut the Irathane 155.
8.4. All coating work shall be preceded by a brush-applied, “stripe coat” application to welds, seams,
and edges of difficult to coat surfaces.
8.5. Irathane 155 shall be applied in two (2) or more build passes, using a cross-hatch spray
technique.
8.5.1. The first coat of Irathane 155 shall be applied utilizing a “tack coat” or “mist coat” technique
allowing a dry time of 5 – 15 minutes, followed by a multi-pass build coat of 20-40 mils wet film
thickness.
8.5.2. The second and/or subsequent coats of Irathane 155 shall be applied utilizing the procedure
shown in Section 8.5.1 but the tack coat may be omitted and the Irathane 155 applied up to
20-40 mils wet film thickness per multi-pass coat.
8.6. Allow a minimum recoat time between Irathane 155 applications of fifteen (15) minutes at 75°F
and a maximum of eight (8) hours. The preferred recoat time is from thirty (30) minutes to four (4)
hours. If the recoat time exceeds eight (8) hours, but is less than sixteen (16) hours, a coat of
Irabond UU 96 must be applied over the semi-cured Irathane 155 prior to additional build coats of
Irathane 155 being applied. TO AVOID ADDITIONAL WORK, DO NOT SURPASS THIS
RECOAT WINDOW.
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8.7. If the recoat time exceeds sixteen (16) hours, the cured surface must be roughened or abraded,
cleaned, and Irabond UU 96 applied prior to any additional Irathane 155 applications.
8.8. Good painting practice shall be used to produce a high-quality application that has uniform dry
film thickness and is free of excessive runs, sags, surface contaminants, overspray, or dry spray.
8.9. Uncured Irathane 155 shall be protected against damage from dust, detrimental foreign matter,
and rain.
8.10. Observe all recommended minimum curing times. Curing should not be attempted below 55°F
without the addition of external, supplemental heat, corresponding adjustments to lengthen curing
time, or both.
8.11. Cure time is also contingent upon the maintenance of sufficient ventilation in the area(s) coated to
carry off solvents released during the curing process. Such ventilation, where necessary, shall be
provided and maintained around the clock.
9.0 REPAIR
8.11.1. A Durometer hardness test shall be used to determine an acceptable level of Irathane 155
cure. ASTM D2240, “Durometer Hardness”, used in conjunction with a Type "Shore A"
Durometer, shall be used to determine these values. A Durometer reading of eighty (80) after
two days of cure at 75°F is considered an acceptable value. The Irathane 155 system should
produce a Durometer reading of ninety-two (92) after 30 days of curing at 75°F.
9.1. In the event the cured Irathane 155 coating becomes damaged, or the application recoat time of
the Irathane 155 exceeds sixteen (16) hours, the following procedures shall be employed:
9.1.1. Thoroughly abrade or roughen the surface of the coating around the damaged area, or region
to be re-coated, using air powered grinders with No.16 or 24 Carborundum pads or equal.
Areas of large repairs may be abrasive blasted to obtain the desired roughness and should
extend at least six (6) inches on each side.
9.1.1.1. Do not abrade Irathane 155 too rapidly or too long in one spot so as to cause heat
build-up and melting of the Irathane 155. A melted Irathane 155 surface will not
develop adhesion with subsequent coats.
9.1.2. Wipe down the abraded areas with a clean cotton cloth that has been saturated with clean
Xylene.
9.1.3. Areas of bare metal shall receive a coat of Futura-Bond 610HS in accordance with Section
6.0.
9.1.4. Brush or spray apply Irabond UU 96 to primed and abraded areas only, at a wet film thickness
of 2-3 Mils Allow a fifty (50) minute drying time and a maximum drying time of five (5) hours at
75°F.
9.1.5. Brush or spray apply Irathane 155 over the properly prepared areas to the recommended dry
film thickness.
9.1.6. Do not apply Irathane 155 to surfaces that have not been properly prepared or primed.
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9.2. The repair of small surface areas, such as those damaged during coating operations, shall be
accomplished with power tools to remove all damaged coating(s), provide a surface roughness,
and return exposed metal to a bright and roughened condition.
9.3. Adjacent, sound areas of coating shall be feathered, tapered, or roughened by hand or power
tools for a minimum overlap distance of two (2) inches in all directions.
9.4. Prepared surfaces shall be re-coated in accordance with Section 5.0 and other applicable
Sections.
9.4.1. Irathane 155 repairs are permitted using less than the standard unit quantities provided that
the Irathane 155 is mixed at a 1:1 by volume ratio of the component “A” to component “B”.
10.0 INSPECTION
10.1. All work and materials supplied under this specification guideline shall be subject to competent
and timely inspection by the contractor or his authorized representative.
10.2. The contractor shall, throughout the course of the coating work described in this specification
guideline, impose a program of inspection and quality surveillance to ensure that the coating
system is installed in a manner that complies with the requirements of this specification guideline
and the Project/Job Specification.
10.3. Mandatory inspections shall be conducted to determine compliance with the "hold points" detailed
in the Project/Job Specification, and "signed off" in the areas provided.
10.4. Inspections shall be conducted, a minimum of four (4) times per shift, or more frequently when
coating work operations or changing environmental conditions require particular surveillance.
10.5. Cured coating shall be tested for holidays (pin holes) using a high-voltage DC holiday detector or
equivalent instrument adjusted and operated in accordance with ASTM D5162-91(B),
Discontinuity (Holiday) Testing of Non-conductive Protective Coating on Metallic Substrates.
Irathane 155 can be tested at a rate of 100 volts/mil. All holidays should be repaired in
accordance with Section 9.0 of this specification guideline.
10.6. Timely and daily completion of inspection documents by the inspector(s), contractor, or his
designate, is highly recommended throughout the course of the job. These documents should
record the following inspections: Surface preparation, surface temperature, dew point of
substrate, temperature and humidity of ventilating air, batch numbers and identification of mixed
coating components, wet film thickness or application rate of individual coats, dry film thickness of
individual coats, recoat intervals, Location and repair of pinholes and determination of degree of
cure.
10.7. All coating inspection instruments, inspection standards, calibration standards, and testing
materials shall be in good working order, appropriate for the use intended, and where required,
shall have been calibrated within twelve (12) months of their use. The owner shall have access to
all required calibration certificates.
10.8. Coating dry film thickness shall be determined by the use of magnetic thickness instruments used
and calibrated in accordance with SSPC, Paint Application Standard PA2.
10.9. Coating areas that fail to meet the minimum dry film thickness requirements of the SSPC-PA2
survey method shall be repaired in accordance with the guidelines presented in Section 9.0.
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