Chemflake Special
Chemflake Special
Chemflake Special
Application Guide
Chemflake Special
Product description
This is a glass flake reinforced vinyl ester coating. It is an ultra high build, extremely chemical resistant and fast
curing barrier coating. Can be used as primer, mid coat or finish coat in atmospheric and immersed
environments. Suitable for properly prepared carbon steel, stainless steel and concrete substrates.
Scope
The Application Guide offers product details and recommended practices for the use of the product.
The data and information provided are not definite requirements. They are guidelines to assist with efficient and
safe use, and optimum service of the product. Adherence to the guidelines does not relieve the applicator of
responsibility for ensuring that the work meets specification requirements.
Jotuns liability is in accordance with general product liability rules.
The Application Guide (AG) must be read in conjunction with the relevant specification, Technical Data Sheet
(TDS) and Safety Data Sheet (SDS) for all the products used as part of the coating system.
Referred standards
Reference is generally made to ISO Standards. When using standards from other regions it is recommended to
reference only one corresponding standard for the substrate being treated.
Surface preparation
The required quality of surface preparation can vary depending on the area of use, expected durability and if
applicable, project specification.
Process sequence
Surface preparation and coating should normally be commenced only after all welding, degreasing, removal of
sharp edges, weld spatter and treatment of welds is complete. It is important that all hot work is completed
before coating commences.
Carbon steel
Initial rust grade
The steel shall be Rust Grade A or B (ISO 8501-1). For steel with Rust Grades C or D, contact your nearest
Jotun office for advice.
Inspect the surface for contaminations and if present, remove with an alkaline detergent. Agitate the surface to
activate the cleaner and before it dries, wash the treated area by Low-Pressure Water Cleaning (LPWC) to Wa 1
(ISO 8501-4) using fresh water.
Non-contaminated areas shall be washed down by Low-Pressure Water Cleaning (LPWC) to Wa 1 (ISO 8501-4)
using fresh water to reduce the concentration of surface chlorides.
Metal finishing
Defective welds shall be replaced and treated to an acceptable finish before painting. Temporary welds and
brackets shall be ground to a flat finish after removal from the parent metal. All edges shall be ground to a
minimum radius of 2.0 mm after a minimum three passes with a mechanical grinder fitted with appropriate
abrasive. All sharp irregularities, burrs, slivers, slag and spatter on welds, whether apparent before or after blast
cleaning, shall be removed before the commencement of coating application. Weld smoke shall be removed by
washing by low-pressure Water Cleaning LP WC method to Wa 1 (ISO 8501-4) using fresh water.
For areas in corrosivity category C5, Im1-3 the requirement are for the steel to conform to grade P2 (ISO
8501-3) Table 1. All edges shall have a rounded radius of minimum 2 mm subjected to three pass grinding or
equally effective method. One may use a mechanical grinder fitted with a suitable abrasive disc. All sharp
irregularities, burrs, slivers, slag and spatter on welds, whether apparent before or after blast cleaning, shall be
removed before coating application. It is recommended that welding smoke should be removed by low-pressure
Water Cleaning LP WC method (ISO 8501-4) Wa 1 using fresh water. Welding smoke residues are water soluble
and could cause blistering if not removed by washing before blasting.
Defective welds shall be replaced and treated to an acceptable finish before painting. Temporary welds and
brackets shall be ground to a flat finish after removal from the parent metal.
Cleanliness
After pre-treatment is complete, the surface shall be dry abrasive blast cleaned to Sa 2½ (ISO 8501-1) using
abrasive media suitable to achieve a sharp and angular surface profile.
Surface profile
The surface shall have a sharp and angular surface profile 55-130 μm, grade Medium to Coarse G (ISO 8503-2).
Measure the achieved profile with surface replication tape (Testex) (ISO 8503-5) or by surface roughness stylus
instrument (ISO 8503-4).
For structures subject to severe mechanical or chemical stress minimum recommended surface profile is 75 µm.
The selected abrasive must be compatible with both the surface to be blast cleaned and the specified coating
system. The abrasive shall meet specifications as per relevant parts of ISO 11124 (Specification for metallic
blast-cleaning abrasives), or ISO 11126 (Specification for non-metallic blast-cleaning abrasives). It should be
sampled and tested as per relevant parts of ISO 11125 (metallic abrasives) or ISO 11127 (non-metallic
abrasives). Dry storage of abrasive and shelter for blasting pots is necessary to prevent equipment becoming
clogged with damp abrasive.
All abrasive blast media used should be new and not recirculated, with the exception of steel grit. If this is
utilized the circulation process must include a cleaning process.
The supply of clean air to blasting pots must be secured to avoid contamination of abrasive and thereby of blast
cleaned surfaces. Compressors must be fitted with sufficient traps for oil and water. It is also recommended to fit
two water separators at the blasting machine to ensure a supply of moisture-free air to the abrasive chamber.
Dust contamination
At the completion of abrasive blasting the prepared surface shall be cleaned to remove residues of corrosion
products and abrasive media, and inspected for surface particulate contamination. Maximum contamination level
is rating 2 (ISO 8502-3) as per Figure 1. Dust size no greater than class 2.
Minor damage of the coating may be prepared to St 3 (ISO 8501-1) using a suitable rotating fiber disc, like 3M
CSD or similar. Leading edges of intact coating around damage shall be feathered to ensure a smooth transition
from the coating to the prepared steel. Consecutive layers of coating shall be feathered to expose each layer and
new coating shall always overlap to an abraded existing layer. Mechanical repairs are only accepted for minor
areas of damage where abrasive blasting is expected to create more damage to the coating system than actual
benefit to the performance of the coating system; i.e. damage/defects found after immersion testing.
Overlapping zones to intact coating shall have all leading edges feathered back by sanding methods to remove
all sharp leading edges and establish a smooth transition from the exposed substrate to the surrounding coating.
Consecutive layers of coating shall be feathered to expose each layer and new coating shall always overlap to an
abraded existing layer. Abrade intact coatings around the damaged areas for a minimum 100 mm to ensure a
mat, rough surface profile, suitable for over coating.
Water jetting
Due to risk of flashrust which is not recommend for these types of coating, water jetting of steel substrates is
not recommended.
Stainless steel
The surface to be coated shall be dry abrasive blast cleaned as required for the specified surface profile using
non-metallic abrasive media which is suitable to achieve a sharp and angular surface profile. As a guide, a
surface profile corresponding to 55-130 µm, grade Medium to Coarse G (ISO 8503-2) should be achieved.
Examples of recommended abrasives are:
• Ferrite free almandite garnet grade 30/60 and 80 grade (US Mesh size)
• Aluminium oxide grade G24
At the completion of abrasive blasting the prepared surface shall be cleaned to remove residues of corrosion
products and abrasive media, and inspected for surface particulate contamination. Maximum contamination level
is corresponding to rating 2 (ISO 8502-3) as per Figure 1 unless otherwise specified.
Finished surfaces shall be dull, profiled and show no areas of shiny metal.
Do not handle the prepared surface with bare hands.
Chlorinated or chlorine containing solvents or detergents must not be used on stainless steel.
Concrete
Concrete should be a minimum of 28 days old, applying any coating before this time will greatly increase the
chance of the coating de-bonding. The moisture content of the concrete should be checked prior to the
application of the coating and should not be greater than 5%. Concrete substrates should be mechanically
prepared to leave a clean, sound and dry base on which a coating system can be applied.
Clean – Free of oils, grease, dust, dirt, chemicals, loose coating, curing compounds, form release oils, sealers or
hardeners.
Sound – Concrete that has unsound areas (voids, hollow spots, and friable surface) may have to be removed,
replaced or repaired with materials that are compatible with the selected coating system.
Dry – It is important to address dryness because most coatings require a dry surface for proper adhesion.
Moisture contained within the concrete that moves towards the surface through the pores of the concrete may
prevent adequate coating adhesion.
Dry abrasive blast cleaning to SSPC-SP 13/NACE No. 6. Where the concrete has become contaminated with oils,
grease, or fuels, water emulsifiable degreasers-cleaners may be used to remove these contaminants. It is
important to only clean an area that can be fully washed down after degreasing before any of the cleaner can
dry on the surface.
Ultra high pressure water jetting can be used to remove laitance and reveal blowholes and imperfections.
Ensure concrete is dry before coating application.
Blast cleaning
Dry abrasive blast cleaning to SSPC-SP 13/NACE No. 6. All prepared surfaces should then have all “blow holes”
and other surface defects filled with suitable filler that is compatible with the primer and finish coat system to
ensure that the coating can be applied over a smooth and regular substrate.
Diamond grind the surface to remove all laitance and expose the aggregates.
Water cleaning
Low pressure water washing to a rough, clean, dry and laitance free surface.
Coated surfaces
Organic primers/intermediates
Shop primers
Prior to application the shop primer shall be completely removed by dry abrasive blast cleaning using abrasive
media suitable to achieve a sharp and angular surface profile. Required surface profile 55-130 μm, grade Medium
to Coarse G; Ry5 (ISO 8503- 2). Measure the achieved profile with surface replication tape (Testex) (ISO
8503-5) or by surface roughness stylus instrument (ISO 8503-4).
Application
Acceptable environmental conditions - before and during application
Before application, test the atmospheric conditions in the vicinity of the substrate for the dew formation
according to ISO 8502-4.
Air temperature 15 - 45 °C
Substrate temperature 15 - 40 °C
Relative Humidity (RH) 10 - 85 %
• Only apply the coating when the substrate temperature is at least 3 °C (5 °F) above the dew point
• Do not apply the coating if the substrate is wet or likely to become wet
• Do not apply the coating if the weather is clearly deteriorating or unfavourable for application or curing
• Do not apply the coating in high wind conditions
Product mixing
Paint temperature
Additive 5-9 °C 10-14 °C 15-19 °C 20-24 °C 25-29 °C 30-34 °C 35-40 °C
WARNING:
Accelerators must never come in direct contact with peroxides.
All peroxides must be stored in a dark and cool storage room (below 25 °C), and kept away from all kind of
combustible materials. Exposure to direct sunlight must be avoided. Use only original or approved containers.
Empty containers should be washed with water and kept in separate storage/containers.
The peroxide may catch fire if exposed to sparks or to hot metal dust from grinding or other mechanical work.
The curing reaction develops heat. For leftovers of mixed paint it is recommended to fill the tin with water to
avoid excessive heat development.
Paint temperature 23 °C
The temperature of base and curing agent is recommended to be 18 °C or higher when the product is mixed.
Thinner/Cleaning solvent
Thinner: Styrene
Thinning max.: 5 %
Thinning is not normally required. Consult the local representative for advice during application in extreme
conditions. Do not thin more than allowed by local environmental legislation.
Note: Korean VOC regulation "Korea Clean Air Conservation Act" and its corresponding thinning limit will prevail
over recommended thinning volumes.
Cleaning solvent: Jotun Thinner No. 17 / Jotun Thinner No. 23 / Jotun Thinner No. 27
Application data
Spray application
Monitor the current drum being used, pushing down any material on the side of the drum and the pick-up pipe
and tilt the drum to use as much of the material as possible.
DO NOT POUR THE NEW MATERIAL INTO THE CURRENT DRUM BEING USED.
When the current drum is exhausted, quickly lift out the paint pick-up pipe and place into the new prepared
drum.
Pumping the paint pick-up pipe up and down in the new material may help to avoid air locks.
Several factors influence, and need to be observed to maintain the recommended pressure at the nozzle. Among
factors causing pressure drop are:
- extended hoses or hose bundles
- extended hose whip-end line
- small internal diameter hoses
- high paint viscosity
- large spray nozzle size
- inadequate air capacity from compressor
- incorrect or clogged filters
All vinyl ester and polyester resin systems are subject to some shrinkage during the curing process. This results
in a practical spreading rate lower than the theoretically calculated. The shrinkage depends on actual dry film
thickness applied and conditions during application.
Can be applied up to 100 % higher than maximum specified film thickness without loss of technical properties.
To ensure correct film thickness, it is recommended to measure the wet film thickness continuously during
application using a painter's wet film comb (ISO 2808 Method 1A). The measurements should be done as soon
as possible after application.
Fast drying paints may give incorrect (too low) readings resulting in excessive dry film thickness. For multi layer
physically drying (resoluble) coating systems the wet film thickness comb may give too high readings resulting
in too low dry film thickness of the intermediate and top coats.
Use a wet-to-dry film calculation table (available on the Jotun Web site) to calculate the required wet film
thickness per coat.
When the coating has cured to hard dry state the dry film thickness can be checked to SSPC PA 2 or equivalent
standard using statistical sampling to verify the actual dry film thickness. Measurement and control of the WFT
and DFT on welds is done by measuring adjacent to and no further than 15 mm from the weld.
Ventilation
Coating loss
The consumption of paint should be controlled carefully, with thorough planning and a practical approach to
reducing loss. Application of liquid coatings will result in some material loss. Understanding the ways that
coating can be lost during the application process, and making appropriate changes, can help reducing material
loss.
Some of the factors that can influence the loss of coating material are:
- type of spray gun/unit used
- air pressure used for airless pump or for atomization
- orifice size of the spray tip or nozzle
- fan width of the spray tip or nozzle
- the amount of thinner added
- the distance between spray gun and substrate
- the profile or surface roughness of the substrate. Higher profiles will lead to a higher "dead volume"
- the shape of the substrate target
- environmental conditions such as wind and air temperature
Drying and curing times are determined under controlled temperatures and relative humidity below 85 %, and
at average of the DFT range for the product.
Surface (touch) dry: The state of drying when slight pressure with a finger does not leave an imprint or reveal
tackiness.
Walk-on-dry: Minimum time before the coating can tolerate normal foot traffic without permanent marks,
imprints or other physical damage.
Dry to over coat, minimum: The recommended shortest time before the next coat can be applied.
Dry to over coat, maximum, immersed: The longest time allowed before the next coat can be applied.
Dried/cured for service: Minimum time before the coating can be permanently exposed to the intended
environment/medium.
If maximum over coating interval is exceeded the surface should in addition be carefully roughened to ensure
good inter coat adhesion.
Itself 48 h 48 h 36 h 24 h 12 h
vinyl ester 48 h 48 h 36 h 24 h 12 h
Itself 48 h 48 h 36 h 24 h 12 h
vinyl ester 48 h 48 h 36 h 24 h 12 h
Too thin areas: Remove contaminants and roughen surface and reapply as soon as possible after surface is
cleaned to prevent contaminants on the surface.
Sags and runs can be caused by too high wet film thickness, too much thinner added or the spray gun used too
close to the surface.
Smoothen the wet film with a paint brush to repair small sags and runs. More extensive sags and runs must be
removed using scrapers or rags depending on severity and accessability.
Sand down to a rough, even surface and re-coat if cured.
Jotun recommends that all coating systems for immersion shall be inspected for film continuity/defects by visual
observation of pin hole rusting through the coating after tank hydro-testing or sea water immersion during sea
trials. Alternatively, full immersion of tanks in combination with tanks fully saturated by tank cleaning
machine(s), soaking all surfaces with sea water and creating a high condensation environment during sea trials.
For onshore storage tanks or for tanks where sea water immersion may not be permitted or practical, coating
shall be tested for film continuity/defects as described in ASTM D 5162, method A or B as appropriate for the
coating thickness.
The recommended voltage is 400 volts per 100 μm DFT. The acceptance criterion is no defects. Defects found
shall be repaired as per coating specification.
Quality assurance
The following information is the minimum required. The specification may have additional requirements.
- Confirm that all welding and other metal work has been completed before commencing pre-treatment and
surface preparation
- Confirm that installed ventilation is balanced and has the capacity to deliver and maintain the RAQ
- Confirm that the required surface preparation standard has been achieved and is held prior to coating
application
- Confirm that the climatic conditions are within recommendations in the AG, and are held during the application
- Confirm that the required number of stripe coats have been applied
- Confirm that each coat meets the DFT requirements in the specification
- Confirm that the coating has not been adversely affected by rain or other factors during curing
- Observe that adequate coverage has been achieved on corners, crevices, edges and surfaces where the spray
gun cannot be positioned so that its spray impinges on the surface at 90° angle
- Observe that the coating is free from defects, discontinuities, insects, abrasive media and other contamination
- Observe that the coating is free from misses, sags, runs, wrinkles, fat edges, mud cracking, blistering, obvious
pinholes, excessive dry spray, heavy brush marks and excessive film build
- Observe that the uniformity and colour are satisfactory
All noted defects shall be fully repaired to conform to the coating specification.
Caution
This product is for professional use only. The applicators and operators shall be trained, experienced and have
the capability and equipment to mix/stir and apply the coatings correctly and according to Jotun's technical
documentation. Applicators and operators shall use appropriate personal protection equipment when using this
product. This guideline is given based on the current knowledge of the product. Any suggested deviation to suit
the site conditions shall be forwarded to the responsible Jotun representative for approval before commencing
the work.
For further advice please contact your local Jotun office.
Health and safety
Please observe the precautionary notices displayed on the container. Use under well ventilated conditions. Do
not inhale spray mist. Avoid skin contact. Spillage on the skin should immediately be removed with suitable
cleanser, soap and water. Eyes should be well flushed with water and medical attention sought immediately.
Accuracy of information
Always refer to and use the current (last issued) version of the TDS, SDS and if available, the AG for this
product. Always refer to and use the current (last issued) version of all International and Local Authority
Standards referred to in the TDS, AG & SDS for this product.
Colour variation
When applicable, products primarily meant for use as primers or antifoulings may have slight colour variations
from batch to batch. Such products and epoxy based products used as a finish coat may chalk when exposed to
sunlight and weathering.
Colour and gloss retention on topcoats/finish coats may vary depending on type of colour, exposure
environment such as temperature, UV intensity etc., application quality and generic type of paint. Contact your
local Jotun office for further information.
Reference to related documents
The Application Guide (AG) must be read in conjunction with the relevant specification, Technical Data Sheet
(TDS) and Safety Data Sheet (SDS) for all the products used as part of the coating system.
When applicable, refer to the separate application procedure for Jotun products that are approved to
classification societies such as PSPC, IMO etc.
Disclaimer
The information in this document is given to the best of Jotun's knowledge, based on laboratory testing and
practical experience. Jotun's products are considered as semi-finished goods and as such, products are often
used under conditions beyond Jotun's control. Jotun cannot guarantee anything but the quality of the product
itself. Minor product variations may be implemented in order to comply with local requirements. Jotun reserves
the right to change the given data without further notice.
Users should always consult Jotun for specific guidance on the general suitability of this product for their needs
and specific application practices.
If there is any inconsistency between different language issues of this document, the English (United Kingdom)
version will prevail.