PCTDS 032 CAFCO Topcoat 200 application onto

Cafco FENDOLITE MII Structural Steel Refurbishment

Topcoat Remedial Specification
Structures protected with the Cafco FENDOLITE MII System
Following the application of the Cafco FENDOLITE MII system in accordance with the
Cafco FENDOLITE MII and Cafco FENDOLITE TG Petrochemical Application Manual,
the following steps are to be followed:

Step 1 Removal of the existing topcoat

Step 2 - Inspection of Cafco FENDOLITE MII
Step 3 - Cleaning the surface of the Cafco FENDOLITE MII
Step 4 - Verification of the moisture content of the Cafco FENDOLITE MII
Step 5 - Final cleaning of the Cafco FENDOLITE MII
Step 6 - Application of 1st coat of CAFCO Topcoat 200
Step 7 - Application of the 2nd coat of CAFCO Topcoat 200

Detailed Description of Remedial works

1. Removal of existing top coat
Remove all existing top coat - aggressive mechanical methods may cause damage to
existing Cafco FENDOLITE MII. Careful removal will be required using coarse sand paper
or hand tools such as scrapers and chisels, as appropriate.
2. Inspection of Cafco FENDOLITE MII
Inspect the Cafco FENDOLITE MII, all areas should be tap tested and any areas found to
be hollow or defective should be removed and made good using Cafco FENDOLITE TG in
accordance with the approved Promat application procedures as detailed in the Cafco
FENDOLITE MII and Cafco FENDOLITE TG Petrochemical Application Manual.
3. Cleaning the surface of the Cafco FENDOLITE MII
Surface lying moisture and any other surface contamination should be removed from areas
to be coated using scrapers and wire brush as appropriate.
Fixed Items: Any fixed item which is not to be included in the coating schedule, including
wires, cables, etc., must either be totally removed or in order to allow access, be
suspended from the surfaces to be coated to allow access. Such items should not be
removed without proper authority. The top coat should be allowed to cure for a minimum
period of seven days before replacement of these fixtures.
Protrusions: Inspect any wall protrusion, ie., vents, pipes, etc., to ensure watertightness.
Repair or replace defective materials as necessary and prepare each protrusion as
required in order to accept the coating.
Previous Repairs: Inspect any previous repair materials, patches, etc., any which are loose
or suspected to be loose should be removed.

AUTHORITY:

Promat Petrochemical Division

Promat UK Limited
Petrochemical
Technical Data
Sheet
PCTDS 032
Page 1 of 6
(April 2010)

Technical Services Department

The Sterling Centre, Eastern Road
Bracknell, Berkshire RG12 2TD
Tel: 01344 381 400
Fax: 01344 381 401
E-mail: technicaluk@promat.co.uk

PCTDS 032 CAFCO Topcoat 200 application onto

Cafco FENDOLITE MII Structural Steel Refurbishment
Cracks/Gaps: Cracks, gaps, holes, etc., in the Cafco FENDOLITE MII should be raked
out, suitably prepared, cleaned and made good using the approved Promat repair
procedure.
Exposed Metal Surfaces: Exposed metal surfaces to be included in the coating schedule
should be wire brushed or mechanically abraded to remove rust/scale or oxidation. Return to
a clean, bright metal wherever possible.
3. Verification of the moisture content of the Cafco FENDOLITE MII
For successful application of the CAFCO Topcoat 200, the Cafco FENDOLITE MII must
be adequately dried and cured.
Determining the moisture content of sprayed cementitious products is difficult but Promat
have developed procedures specifically for the Cafco FENDOLITE MII and recommend
the use of the Protimeter Timbermaster Standard Model BLD5602.
Note: Promat has evaluated the use of moisture meters that provide values for the
through moisture content of the Cafco FENDOLITE MII rather than common moisture
meters which only provide surface moisture content readings.
The supplier contact details for Protimeter Timbermaster Standard Model BLD5602 are:
GE Sensing
Sensing House, Shannon Free Zone East
Shannon, Co. Clare, Ireland
Tel 00 353 61 470200
Promat confirm that this moisture meter has to be used in conjunction with the Protimeter
Calibration Curve which has been developed and is specific to Cafco FENDOLITE MII to
provide the absolute moisture content of the Cafco FENDOLITE MII.
Using the Protimeter Timbermaster Standard - Model no. BLD5602, Promat UK Limited
confirm that the moisture reading should be 45% or less (ie nominal 8% Cafco
FENDOLITE MII moisture content) for successful application of the CAFCO Topcoat 200
on the Cafco FENDOLITE MII.
Protimeter Calibration Curve
16.00%

14.00%

M
oistureContent

12.00%

10.00%

8.00%

6.00%

4.00%

2.00%

0.00%
0.00%

10.00%

20.00%

30.00%

40.00%

50.00%

60.00%

70.00%

80.00%

90.00%

100.00%

Protimeter Reading

AUTHORITY:

Promat Petrochemical Division

Promat UK Limited
Petrochemical
Technical Data
Sheet
PCTDS 032
Page 2 of 6
(April 2010)

Technical Services Department

The Sterling Centre, Eastern Road
Bracknell, Berkshire RG12 2TD
Tel: 01344 381 400
Fax: 01344 381 401
E-mail: technicaluk@promat.co.uk

PCTDS 032 CAFCO Topcoat 200 application onto

Cafco FENDOLITE MII Structural Steel Refurbishment
The Cafco FENDOLITE MII should first be allowed to cure and dry for at least 5 days and
until the surface colour of the Cafco FENDOLITE MII has changed from a dark grey to an
off-white colour.
During cold, wet periods the Cafco FENDOLITE MII drying time will be extended.
After 5 days, the moisture level of the Cafco FENDOLITE MII should be measured using
the recommended GE Protimeter Timbermaster moisture meter as follows:
1. Switch on the Protimeter Timbermaster meter and set the scale to option A (the
default setting).
2. Push the two probes into the Cafco FENDOLITE MII up to the body of the machine
and hold in place until the display equalises, this may take between 30-40 seconds.
3. Take three to four readings per sections to get an average moisture figure. If any
single figure is considerably large than the others then the reading may be ignored
and another reading taken.
4. Once the average Protimeter Timbermaster meter reading is below 45% then the
Cafco FENDOLITE MII may be painted provided that all the other climatic
conditions are achieved.
NOTE: Where the Cafco FENDOLITE MII is exposed to the elements, any periods of
rainfall will extend the drying time.
4. Final Cleaning of the Cafco FENDOLITE MII
Immediately prior to application of the top coat system, ensure that all surfaces are free from
surface lying dust, dirt and other forms of contamination, where necessary, using brushes,
scrapers or air lines as appropriate.
NOTE: Exercise suitable precautions when using high pressure equipment. Care needs to be
taken by the operative to limit damage to the sound Cafco FENDOLITE MII by the use of
high pressure air lines.
5. Application of 1st coat of CAFCO Topcoat 200
Brush, roller or spray apply a single coat of CAFCO Topcoat 200 to a nominal wet film
thickness of 150-200 microns. Care should be taken to ensure that a wet film thickness
greater than 200 microns is not applied as this will lower the breathability rate of the
CAFCO Topcoat 200, which in turn can lead to blistering of the paint. Thickness
measurements must be taken and recorded.
6. Application of 2nd coat of CAFCO Topcoat 200
Once the initial coat of CAFCO Topcoat 200 has fully dried, apply a second coat of
CAFCO Topcoat 200 to a nominal wet film thickness of 150 200 microns. The top
coated areas should be fully protected from the elements until the CAFCO Topcoat 200
has fully dried and cured (minimum 24 hours).
AUTHORITY:

Promat Petrochemical Division

Promat UK Limited
Petrochemical
Technical Data
Sheet
PCTDS 032
Page 3 of 6
(April 2010)

Technical Services Department

The Sterling Centre, Eastern Road
Bracknell, Berkshire RG12 2TD
Tel: 01344 381 400
Fax: 01344 381 401
E-mail: technicaluk@promat.co.uk

PCTDS 032 CAFCO Topcoat 200 application onto

Cafco FENDOLITE MII Structural Steel Refurbishment
NOTE: It is necessary to maintain the correct environment conditions as stipulated in the
current Cafco FENDOLITE MII and Cafco FENDOLITE TG Petrochemical Application
Manual immediately before, during and after the particular application.
NOTE: In addition to the required colour change, minimum 5 days curing/drying after
spraying of the Cafco FENDOLITE MII and maximum 45% Protimeter Timbermaster
moisture meter reading, there must be no free water (dew, condensation or rain water)
on surface of Cafco FENDOLITE MII at time of application of the CAFCO Topcoat 200
and both the un-painted Cafco FENDOLITE MII and the CAFCO Topcoat 200 - painted
Cafco FENDOLITE MII must be protected from adverse weather for a minimum of 24
hours prior to and after application of the CAFCO Topcoat 200.
Where the application conditions are such that the above application criteria
cannot be fully achieved and in particular the 45% Protimeter Timbermaster
moisture meter reading. Promat recommends the use of an alternative solution
using LPL Decothane as detailed below:

Step 1 - Inspection of Cafco FENDOLITE MII

Step 2 - Cleaning the surface of the Cafco FENDOLITE MII
Step 3 - Final cleaning of the Cafco FENDOLITE MII
Step 4 - Primer Application
Step 5 - Application of 1st coat of LPL Decothane Top Coat
Step 6 - Application of the 2nd coat of LPL Decothane Top Coat

1. Inspection of Cafco FENDOLITE MII

Inspect the Cafco FENDOLITE MII all areas should be tap tested, small areas found to be
hollow or defective should be removed and made good using an appropriate LPL
Lightweight Repair Mortar or Cafco FENDOLITE TG and allowed to cure in accordance
with standard rendering procedures prior to further treatment. Leave for a minimum period
of 72 hours before overcoating. Large areas of repair should only be repaired with Cafco
FENDOLITE TG in accordance with the approved Promat application procedures.
2. Cleaning the surface of the Cafco FENDOLITE MII
Surface lying moisture and any other surface contamination should be removed from areas
to be coated using scrapers, wire brush or water jetting.
Fixed Items: Any fixed item which is not to be included in the coating schedule, including
wires, cables, etc., must either be totally removed or in order to allow access, be
suspended from the surfaces to be coated to allow access. Such items should not be
removed without proper authority. The top coat should be allowed to cure for a minimum
period of seven days before replacement of these fixtures.
Protrusions: Inspect any wall protrusion, ie., vents, pipes, etc., to ensure watertightness.
Repair or replace defective materials as necessary and prepare each protrusion as
required in order to accept the coating.

AUTHORITY:

Promat Petrochemical Division

Promat UK Limited
Petrochemical
Technical Data
Sheet
PCTDS 032
Page 4 of 6
(April 2010)

Technical Services Department

The Sterling Centre, Eastern Road
Bracknell, Berkshire RG12 2TD
Tel: 01344 381 400
Fax: 01344 381 401
E-mail: technicaluk@promat.co.uk

PCTDS 032 CAFCO Topcoat 200 application onto

Cafco FENDOLITE MII Structural Steel Refurbishment
Previous Repairs: Inspect any previous repair materials, patches, etc., any which are loose
or suspected to be loose should be removed.
Cracks/Gaps: Cracks, gaps, holes, etc., in the Cafco FENDOLITE MII should be raked
out, suitably prepared, cleaned and made good using an appropriate proprietary polymer
modified mortar prior to further treatment and dried / cured in accordance with the
manufacturers recommendations.
Exposed Metal Surfaces: Exposed metal surfaces to be included in the coating schedule
should be wire brushed or mechanically abraded to remove rust/scale or oxidation. Return to
a clean, bright metal wherever possible.
3. Final Cleaning
Immediately prior to application of the top coat system, ensure that all surfaces are free from
visible dampness and that surface lying dust, dirt and other forms of contamination are
removed using brushes, scrapers or air lines as appropriate.
NOTE: Exercise suitable precautions when using high pressure air lines. Care needs to be
taken by the operative to limit damage to the sound Cafco FENDOLITE MII by the use of
high pressure equipment.
NOTE: If the Cafco FENDOLITE MII has been left uncoated for a significant period of time,
any visible growths or vegetation should be removed prior to treating with concentrate LPL
NEW BIOWASH, by brush, at a maximum spread rate of 10 m per litre (equivalent to a
minimum quantity of 0.1 litres per m). Allow to dry onto absorbent surfaces and leave to
react but thoroughly rinse from non-absorbent surfaces before continuing with the
application.
4. Primer Application
Exposed Metallic Surfaces: Apply a full coat of LPL METAL PRIMER to all prepared,
exposed metallic surfaces and allow to dry for a minimum of period of 9 hours before
overcoating.
Note: Brush application is recommended for smaller areas or where airless spray application
is impractical. Do not apply too thickly.
Vessel Surfaces: Apply a coat of LPL BONDING PRIMER to all prepared, existing and new
rendered surfaces at a maximum spread rate of 8 m per litre (equivalent to a minimum
quantity of 0.125 litres per m) and leave to dry for a minimum of 1-2 hours. Ensure the
primer is fully dry prior to overcoating.
5. Application of 1st coat of LPL Decothane Top Coat:
Apply a coat of LPL DECOTHANE Top Coat using a minimum quantity of 0.75 litres per
m (equivalent to a maximum spread rate of 1.33 m per litre). Allow to dry for minimum of
24 hours.
AUTHORITY:

Promat Petrochemical Division

Promat UK Limited
Petrochemical
Technical Data
Sheet
PCTDS 032
Page 5 of 6
(April 2010)

Technical Services Department

The Sterling Centre, Eastern Road
Bracknell, Berkshire RG12 2TD
Tel: 01344 381 400
Fax: 01344 381 401
E-mail: technicaluk@promat.co.uk

PCTDS 032 CAFCO Topcoat 200 application onto

Cafco FENDOLITE MII Structural Steel Refurbishment
6. Application of 2nd coat of LPL Decothane Top Coat:
Apply a coat of LPL DECOTHANE Top Coat by roller (brushes may be used for detail
work), using a minimum quantity of 0.75 litres per m (equivalent to a maximum spread rate
of 1.33 m per litre). Allow to dry.
Note: Where LPL DECOTHANE Top Coat is to be applied to vertical surfaces, it may well
be necessary to apply more than one coat to achieve the required finished dry film
thickness.
Material Coverage: When applying materials, use volume to area calculations and/or wet
film thickness readings where appropriate to ensure correct material coverage. Coverage
rates may vary depending on substrate condition.
NOTE: As LPL Decothane is typically used in roofing applications, contractors use volume /
area calculations. The LPL site QA team must check against wet and dry film thicknesses.

AUTHORITY:

Promat Petrochemical Division

Promat UK Limited
Petrochemical
Technical Data
Sheet
PCTDS 032
Page 6 of 6
(April 2010)

Technical Services Department

The Sterling Centre, Eastern Road
Bracknell, Berkshire RG12 2TD
Tel: 01344 381 400
Fax: 01344 381 401
E-mail: technicaluk@promat.co.uk