Standard Working Procedure

Intergard 251/Interchar 963/Interthane 990 System

L&T,ICICI IT Park Project,Hyderabad
STEELWORK
PREPARATION

To provide a surface which will ensure optimum fire protection performance, preparation is
required to remove surfaces which have a sharp edge. These include, but are not limited
to, plate edges, weld spatter, plate laminations, weld undercuts, or gas cut surfaces.

SURFACE
PREPARATION:

Oil or grease, salts, dirts, chalk marks and similar contaminants shall be removed as
far as possible, prior to surface preparation, using an appropriate method in
accordance with ISO 12944-4.

Sharp Edges, weld spatter, cavities and deformations are to be removed in

accordance with ISO 8501-3, table-3

Assess the steel surface for Rust grades as per ISO 8501-1

Surface shall be cleaned by abrasive blast cleaning (ISO 12944-4 Cl.6.2.3.1.2) in

accordance with ISO 8504-2 (Cl. 5.1.2)

Surface cleanliness shall be as per Sa2.5 in accordance with ISO 8501-1

Surface profile shall be 50-60 microns as per ISO 8503-4

Compressed Air
Air used for blasting must be clean, oil free and dry. Moisture and Oil separators have
to be used to ensure the same.
The pressure should be at least 7kg per cm2 (100lbs per inch2) at the nozzle.
Abrasive
Abrasive used for blasting should be dry and free from dirt, oil, grease or contamination
and have content of water soluble matter not exceeding 0.05%.
The abrasive must be capable of producing the standard of cleanliness and surface
profile specified. (Sa2.5 and profile of 50-60 microns)
Abrasives like copper slag should not be recycled more than once, and should not be
contaminated with soil.
Abrasive like sand should not be recycled.
Cleaning
Before initial blast inspection, the bulk of the spent abrasive should be removed. Any
substandard areas should be identified and repaired. All marking paint, chalk etc.,
must be removed after rectification.
Fabrication repair (if any) should be carried out before application of the primer.
Following inspection of the blast profile and standard, remaining traces of abrasive and
dust should be removed from all areas.

PAINT
APPLICATION

Weather Conditions

Surfaces to be coated must have a temperature at least 3C (5F) above the dew
point, immediately following blasting and priming, intermediate and topcoat
application, and must also remain in this condition during curing of the coatings.

As a guide, relative humidity levels of 25-80% give optimum painting conditions,

although some applications may be carried out up to 85% relative humidity.
Page 1

www.international-pc.com

Release Date:17-Dec-08
Ref: RV/963L&Twp/Rev01

Standard Working Procedure

Intergard 251/Interchar 963/Interthane 990 System
L&T,ICICI IT Park Project,Hyderabad

Primer and finish painting can be carried out on steel temperature up to 45 C.

Interchar 963 may be applied at steel temperatures between+5C and 30+C.

Painting should not be carried out during windy conditions.

The area where Interchar 963 need to be applied must be protected from
condensation and water during application and drying.

General Site Requirements

Prior to any work being carried out there are a number of conditions which must be met.
a) Cleanliness
Any contaminants which may come in contact with the steel (even before surface
preparation comments) can compromise the performance protective coating system,
and as such all effort must be made to keep the working area clean. It is good
working practice to establish a clean area where painting is being done. Cleanliness
must be maintained throughout all stages of the application.
b) Weather Shelters
Weather shelters should be made available to cover application equipment during
mixing and application of material.
c) Paint Storage Facility
All paints should be stored ideally between 10C (50F) and 30C (86F) and facilities
may be needed to store the materials in the correct temperature range prior to mixing
and application.
d) Disposal of empty cans.
All surplus materials and empty containers should be disposed of in accordance with
appropriate regional regulations/legislation.

STRIPE COATING

Stripe coating is an essential part of good working practice, and stripe coats are
highlighted in the detailed product specification sheets.
Stripe coats are applied to areas where it is difficult to get the required coverage,
including but not limited to: Plate edges
Welds
Difficult access areas
Stripe coats are normally applied to a specified film thickness range via a combination of
narrow angle airless spray and brush methods. Over coating intervals for the stripe coats
should be strictly adhered to as per the individual product data sheet.

Page 2

www.international-pc.com

Release Date:17-Dec-08
Ref: RV/963L&Twp/Rev01

Standard Working Procedure

Intergard 251/Interchar 963/Interthane 990 System
L&T,ICICI IT Park Project,Hyderabad
PAINT SPEC
PRIMER COAT

Intergard 251

Application : By Airless Spray.

Mixing Ratio: 4:1 by volume (Base : Hardener)

Mix the base using a power agitator Add C/A slowly during mixing and mix well for 5
minutes. Ensure complete mixing of Base and C/A.

Tip size : 0.38 0.53mm (15-21 thou).

Output fluid Pressure at spray tip : Not less than 155 kg/cm2 (2,200 p.s.i.)

Thinner GTA220 (Use only when required).

Check WFT during application using comb gauge. For 50 dft the WFT shall be 79

Ref. Chart 1 for drying time, Check DFT and record.

(For complete details of the product please refer the product data sheet)

INTERMEDIATE
COAT

Interchar 963

Application : By Airless Spray, 1:68 airless machine would be ideal. For air driven
airless spray pumps the following modifications to the normal set up are
recommended.

All filters should be removed from the pump,lines and gun.A coarse filter(1/2-1mm)can
be fitted over the wet end to prevent contamination from external sources from
entering the spray machine and causing blockages.

Use the minimum length of 9mm bore fluid line.A 2 metre 6.5mm bore whip end with a
swivel connection to the spray gun makes the fluid lines much easier to handle and
more manoeuvrable.

Mixing Ratio: Not applicable.(Single Component)

Mix the using a power agitator for 5 minutes. Ensure complete mixing.

Tip size : 048 0.59 mm (19-23 thou)

Output fluid Pressure at spray tip : Not less than 246 kg/cm2 (3,500 p.s.i.)

Check WFT during application using comb gauge

For 100 microns dft the WFT shall be 133 microns

(For correct film thickness for various areas,refer Hp/A calculation chart provided.

Ref. Chart 3 for drying time, Check DFT and record

Page 3

www.international-pc.com

Release Date:17-Dec-08
Ref: RV/963L&Twp/Rev01

Standard Working Procedure

Intergard 251/Interchar 963/Interthane 990 System
L&T,ICICI IT Park Project,Hyderabad
(For complete details of the product please refer the product data sheet)

Thinning:Thinning of Interchar 963 is not normally required.

Dry film thickness up to 750 Microns:Apply one coat of Interchar 963 as

required,up to a maximum wet film thickness of 1000 microns which will dry back to
750 microns.
If thicker coats are applied,drying and the handling time will be impaired.
Alternatively,if
the coating is built up in thinner coats,the overall drying time will be
reduced.Overcoating times for Interchar 963 with itself is coated on the technical data
sheet for the typical dry film thickness of 750 Microns.Shorter intervals may be
possible for thinner coats.

Dry film thickness greater than750 Microns:Where the required dry film thickness
is greater than 750 Microns the coatings should be built up in two or more applications
up to a maximum wet film thickness of 1000 Microns per coat.Drying times will be
optimised if successive coats are of similar thickness.

Overspray:Where dry overspray falls on primed surfaces before they have been
coated it will affect the adhesion of Interchar 963 and should be dusted off before
proceeding.Where it falls on areas previously coated with Interchar 963,it may give a
rough appearance to the surface.Sometimes this can be dusted off but abrasion may
be required to satisfy the specification for cosmetic appearance.
Overspray can be minimised by work planning and good spray technique.Steel work
should be arranged to allow good access for spraying al surfaces.The sprayer should
be close enough to the work surface at all times to minimise airborne overspray
without leading to excessive ripples or other texture in the coating caused by the
pressure of the spray.

Brush application:Application of Interchar 963 by brush is an accepted method but is

generally recommended for small areas,repairs etc.
Between 250-400 Microns wet film thickness can be achieved per coat.For typical dry
film thickness required for 1 hour fire protection multi coats will be required.
The appearance of brush applied Interchar 963 will be different to that of the spray
applied coating.

Work Stoppages.
Thoroughly flush all equipment with International GTA007 cleaner.All unused material
should be stored in tightly closedcontainers.Partially filled containers may show
surface skinning and/or a viscosity increase of the material after storage.

Page 4

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Release Date:17-Dec-08
Ref: RV/963L&Twp/Rev01

Standard Working Procedure

Intergard 251/Interchar 963/Interthane 990 System
L&T,ICICI IT Park Project,Hyderabad

Clean up:
Clean all equipment immediately after use with International GTA007 cleaner.It is
good working practice to periodically flush out spray equipment during the course of
the working day.Frequency of cleaning will depend up on amount
sprayed,temperature and elapsed time,including any delays.

FINISH COAT

Interthane 990

Application : By Airless Spray

Mixing Ratio: 6 : 1 by volume (Base : Hardner)

Mix the base using a power agitator Add C/A slowly during mixing and mix well for 5
minutes. Ensure complete mixing of Base and C/A. If 20 litres complete mixing is not
possible then proper measuring jars should be employed to ensure accuracy.

Tip size : 0.33 0.45 mm (13-18 thou)

Output fluid Pressure at spray tip : Not less than 155 kg/cm2 (2,500 p.s.i.)

Thinner GTA733 (Use only when required)

Check WFT during application using comb gauge

For 50 dft the WFT shall be 88

Ref. Chart 2 for drying time, Check DFT and record

(For complete details of the product please refer the product data sheet)

INSPECTION

Film thickness control and measurement:

The dry film thickness of Interchar 963 to be applied to individual steel sections will
vary depending on the section size and its intended configuration as well as the
number of sides to be coated,and for beams,the type of decking being supported.To
ensure efficient working the applicator should be in possession of a full list of the
specified dry film thickness and number of sides to be coated,etc and should mark the
sections accordingly.
Any method of marking must not interfere with the application or adhesion of the
coatings.

Wet Film Thickness:

During the application of Interchar 963 frequent checks should be made on the

Page 5

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Release Date:17-Dec-08
Ref: RV/963L&Twp/Rev01

Standard Working Procedure

Intergard 251/Interchar 963/Interthane 990 System
L&T,ICICI IT Park Project,Hyderabad
coating using a wet film comb to ensure that the specified thickness is achieved.Wet
film thickness readings are a guide to the applicator to enable application technique to
be monitored.They should be taken as frequently as necessary to enable a feel for
the coating,and the number of spray gun passes required,to be established.
On second and subsequent coats,wet film readings may be inaccurate due to the
gauge sinking in to the previous coat.
Measurement of Dry Flm Thickness:

After sufficient drying time a survey of the dry film thickness should be carried out
using a suitable calibrated gauge.An electromagnetic induction instrument with a
statistical function to store readings and give an average is most useful.
Where dry film readings include a primer and /or top coat an allowance must be made
for these coatings and subtracted from the total reading.
The following is the recommended procedure for measuring dry film thickness.
Readings should be taken on every steel section as follows
I Sections
Webs

:One reading per metre length on each face.

Outer Flanges

:One reading per metre length on each face.

Inner flanges

:One reading per metre length on each face.

Hollow Sections

:Four readings per metre length spread evenly around the section.

No readings should be taken within 25 mm of any edge or web/flange junction.

Dry film thickness Acceptance criteria:

The average thickness of each section should be equal to ,or greater than,the
specified thickness.
Where any single thickness reading is found to be less than 80% of the specified
thickness,a further three readings should be taken on the same face within a 300 mm
radius of the low reading.If one or more of the additional readings are also less than
80% of the specified thickness,further readings should be taken to establish the extent
of the area of under thickness and the whole area should be brought up to the
specified thickness.
Individual thickness readings of less than 50% of the specified thickness are not

Page 6

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Release Date:17-Dec-08
Ref: RV/963L&Twp/Rev01

Standard Working Procedure

Intergard 251/Interchar 963/Interthane 990 System
L&T,ICICI IT Park Project,Hyderabad
acceptable.
The average measured dry film thickness of any member should not exceed by more
than 10%,the maximum stated thickness for the particular steel shape and orientation
as given in the loading charts.

Dry Film thickness of Top Coat.

The top coat dry film thickness is difficult to measure due to the variation in thickness
of the underlying coats and its own relatively low thickness.It is however,important that
the top coat is applied at the specified thickness to ensure the longevity of the system
without applying excessive thickness.Judging the thickness of the top coat is also
made more difficult as an uneven surface will require more coating to achieve a
uniform appearance.
As a guide,the number of spray gun passes to achieve the required wet film thickness
can be determined by spraying on to a smooth surface.Monitoring of material usage
will also give an indication of the applied thickness.

Standard of cosmetic finish.

The cosmetic finish of Interchar 963 will vary depending on the method of
application.Spray application of the coating is generally considered to give a superior
appearance to brush application.
For non-visible areas,for example,the standard of finish achieved may not be of
concern.
Top coats are relatively thin and will tend to highlight rather than hide surface
defects.It is,therefore,important to ensure that the required finish has been achieved
before application of the top coat.

HANDLING

It is essential that steel work coated with Interchar 963 is stored and handled correctly
to minimise damage and the need for site repair.
Chains are frequently the most effective method for handling the coating when it is not
fully hard,and particularly when turning steelwork in the paintshop.The damage can be
quite deep,but localised and limited.
Straps can strip a large area of soft coating.They may make an impression on a firm
coating but should cause such severe damage as chains when the coating has
hardened.Straps may be more suitable for loading out finish coated steel work.

Page 7

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Release Date:17-Dec-08
Ref: RV/963L&Twp/Rev01

Standard Working Procedure

Intergard 251/Interchar 963/Interthane 990 System
L&T,ICICI IT Park Project,Hyderabad
Once hard enough to handle,coated steel work may be removed to a laydown area
with minimal stacking and sufficient air movement to allow drying to continue.
During storage and transportation the coated steel should wherever possible be kept
in cool,shaded areas to minimise softening in high temperatures.
Erectors should use appropriate handling methods to avoid excessive damage.
After erection all transport and erection damage should be repaired in accordance
with repair procedure.
.

Repair Procedure
REPAIR
PROCEDURE

Repair of Damaged areas,Erection damage etc.

The repair method will depend on the extent of the damage.Repairs should be carried out
at the earliest opportunity using the appropriate procedure from those given below.

1)Damage which exposes Bare Steel

Wherever damages exposing bare steel is observed,any of the below mentioned
procedure to be followed.
Method 1

Remove any oil&grease/dust contamination etc from surface.

Spot blasting to Sa2.5 Standard

Remove unsound and damaged coatings to a neat firm edge.

Apply Intergard 251 at 50 thickness.Follow overcoating interval.

Reinstate the Interchar 963 within the recommended over coating limits of the
repair primer.

Apply Interchar 963 in multiple applications by brush or knife,as appropriate.If

small amounts of the coating are left on a clean surface for a few minutes,solvent
flash-off will give a more knifeable consistency.If a top coat has already been
applied to original system,minimise overlap of fresh Interchar 963 over the top
coat.

Apply top coat as appropriate.

Page 8

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Release Date:17-Dec-08
Ref: RV/963L&Twp/Rev01

Standard Working Procedure

Intergard 251/Interchar 963/Interthane 990 System
L&T,ICICI IT Park Project,Hyderabad
Method 2

Remove any oil&grease/dust contamination etc from surface.

Hand tool/Power tool cleaning to St 2 Standard as per ISO 8501.

Remove unsound and damaged coatings to a neat firm edge.

Feather coating edges by abrading.

Apply Interseal 670HS at 100 thickness.Follow overcoating interval

Reinstate the Interchar 963 within the recommended over coating limits of the
repair primer.

Apply Interchar 963 in multiple applications by brush or knife,as appropriate.If

small amounts of the coating are left on a clean surface for a few minutes,solvent
flash-off will give a more knifeable consistency.If a top coat has already been
applied to original system,minimise overlap of fresh Interchar 963 over the top
coat.

Apply top coat as appropriate.

2)Damage not requiring Primer Repair.

Depending on severity of damage either lightly abrade damaged area to a

feathered edge,or cut out a suitable area of Interchar 963 and feather out the

edges.If cutting out,do not damage the priming system,otherwise repair as per
above will be required.

After the appropriate overcoating Interval,apply an approved top coat in

accordance with original specification.

3)Damage to top coat only

Remove loose or unsound coatings to a firm edge and feather the edges.All
surfaces should be clean,dry and free from all contamination.Reinstate top coat
in accordance with original specification.

Page 9

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Release Date:17-Dec-08
Ref: RV/963L&Twp/Rev01

Standard Working Procedure

Intergard 251/Interchar 963/Interthane 990 System
L&T,ICICI IT Park Project,Hyderabad
Chart 1: Drying Times of Intergard 251

Chart 2: Drying Times of Interthane 990

Page 10

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Release Date:17-Dec-08
Ref: RV/963L&Twp/Rev01