PYROCRETE® 239
Substrates & Surface Preparation Application Equipment
Listed below are general equipment guidelines for the application of this
General Before applying PYROCRETE 239, the substrate product. Job site conditions may require modifications to these guidelines to
achieve the desired results.
coating must be free of all oil, grease,
General Guidelines:
condensation, or other contamination.
Steel Steel preparation before priming should be done Mixer Use a heavy-duty mortar mixer with rubber
in accordance with the recommended primers� tipped blades that scrape the sides and bottom
Product Data Sheet. of the mixer. A 50 lb. (20.7kg) bag of
PYROCRETE 239 typically requires a mixer
Carbozinc® 11
Carbon Steel
volume of 8 ft3 (.23m3) minimum.
Carboguard® 888
Carbozinc® 11 VOC
Mfg. Model Type Size
Carbozinc® 11 HS Pumps
Carboguard® 893
Essick FM9/FME51 Rotor /Stator 2L4
Carboguard® 1340
Muller R-Tex Rotor /Stator 2L6
Rustbond Penetrating Sealer®
Goldblatt Supertex Rotor /Stator 2L6
Galvanized Normally not required, but may be required Sunspray 220 Rotor/Stator 2L4
Steel under corrosive conditions. Use Carboline ZP3 (HM2
PFT Rotor/Stator N/A
Rustbond Penetrating Sealer. mixer)
Mayco PF30 Piston N/A
Non-Ferrous Aluminum, copper, etc. shall be primed with one
Sunspray HP 320E Piston N/A
Metals coat of Carboline Rustbond Penetrating Sealer.
Thomsen N/A
Putzmeister Piston
The primer recommended is Carboguard® 1340.
Concrete PTV 700
Putzmeister S5EV Rotor/Stator 2L6
Lathing & Attachments (Where required) Trowels Standard plasterers� hawk and trowel may be
used. A rubber float may also aid in finishing.
2 2
3.4 lbs./yd (1.85 kg/m ) galvanized metal lath, may be pre-bent and
tie-wired into place for appropriate design. Optionally, beam furring
Compressor Be certain that the air supply is a minimum 22
clips, electrically welded, pneumatic, self-tapping screws or studs, may
cfm at 100 psi (6.9 kPa) and higher when
be used.
distances longer than 75� (23 m) are required.
A. Contour Design: 3.4 galvanized metal lath wrapped around the
Material Line Minimum 1� (2.54 cm) I.D. hose with 300 psi
flange edges toward the web approximately 1½� (3.8 cm). Contour
minimum bursting pressure. For lengths over
columns allow the use of chicken wire with beam furring clips as an
50� (15 m) use 1½� to 3� (3.8 to 7.6cm) I.D.
alternate to the 3.4 metal lath. Please refer to design details.
hose.
For contour applications on structural members with web span greater
Do not reduce hose diameter by more than ¼�
than 16� (41 cm) or flange widths greater than 12� (31 cm), refer to the
U.L. Fire Resistance Directory under “Coating Materials� section. (7 mm) per 25� (7.6 m) unless a tapered conical
reducer equipped with a swivel fitting is used.
B. Boxed Design: 3.4 galvanized metal lath wrapped around A 10� (3 m) length of ¾� I.D. hose may be added
member spanning the web, overlapped 1� (2.5 cm) and tie-wired on the at the gun for use as a whip.
flange face 12� (31 cm) on center. For large webbed members,
additional support for lath may be needed for ease of installation. Air Line Use ½� (1.27 cm) I.D. line, with a minimum
Optional use of plastic-nose corner beads may be used for better
bursting pressure of 100 psi (6.9 kPa).
thickness control and aesthetics. See design details.
Spray Guns Mfg. Model Fluid Tip Air Cap
C. Tower Skirts and Flat Surfaces: Require that 3.4 galvanized
3/8�-1/2�
3/8�-1/2�
metal lath be anchored on 12� to 24� (31-61 cm) centers depending SpeeFlo 701 (9.5-13mm)
(9.5-13mm)
upon requirements. The Lath should overlap and be tie-wired. On
Plasterer 3/8�-1/2�
tower skirts only, PVC coated mesh can be used in lieu of 3.4
N/A N/A
(9.5-13mm)
s
galvanized lath. Mesh shall be 2� x 2� 20 gauge wire coated with PVC.
Internal 3/8�-1/2�
Air Tech N/A
When ram set or welding is prohibited; a pneumatic fastener may be (9.5-13mm)
Mix
used.
On very large areas control joints are made by scoring halfway through
the thickness of PYROCRETE 239. This is achieved by using the
trowel blade edge or an appropriate scoring tool. A preferred option
would be the use of plastic nosed corner beads. Spacing should be on
10� (3 m) centers, both horizontally and vertically. Please refer to
design details.
July 2004 replaces March 2003 0145
To the best of our knowledge the technical data contained herein is true and accurate on the date of publication and is subject to change without prior notice. User must contact Carboline Company to
verify correctness before specifying or ordering. No guarantee of accuracy is given or implied. We guarantee our products to conform to Carboline quality control. We assume no responsibility for
coverage, performance or injuries resulting from use. Liability, if any, is limited to replacement of products. NO OTHER WARRANTY OR GUARANTEE OF ANY KIND IS MADE BY CARBOLINE,
EXPRESS OR IMPLIED, STATUTORY, BY OPERATION OF LAW, OR OTHERWISE, INCLUDING MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE. Carboline® and
PYROCRETE® are registered trademarks of Carboline Company.
PYROCRETE®239
Mixing & Thinning Application Conditions
Surface or Relative
Add 4 ¾-7 gallons (18-26.5 liters) of clean, potable
Mixing Ambient Temperature Humidity
water to a mortar mixer with rubber tipped blades. With Minimum Maximum Min. Max.
Interior
mixer running slowly, add powder and mix for 2 minutes
or 40°F(4°C) 100°F(38°C) 0% 95%
minimum until a homogeneous mortar-like consistency is
Exterior
achieved. Total water must not exceed 7 gallons (26.5
liters) per 50 lb. (22.7 kg) bag. In cool weather, warm
Finishing
water may be used to enhance application. In hot
weather, cool/cold water may be used.
If a smooth finish is required, this may be done by trowel, roller or
brush typically within 1 to 2 hours after final application of
For trowel applications mix 5 + ¼ gallons
PYROCRETE 239.
(19+ 1litres) clean potable water per 50 lb (22.7 kg) bag.
Wet nozzle density should be 37 lbs./ft3 (.59 g/cm3).
Protection of Adjacent Surfaces
For Spray applications mix with 6 + 1 gallons (23 + 3.5
Finished surfaces shall be protected from damage and overspray.
litres) of clean potable water per 50 lb. (22.7 kg) bag. See
Encapsulation of aluminum electrical conduits is not recommended.
table below.
Curing Schedule
2 hours at 70°F (21°C) and less at higher temperatures.
Pot Life
Pot life ends when the material thickens and becomes
Fresh PYROCRETE 239 must be protected from rain or running water
unusable.
for 24 hours at 70°F (21 °C). In low humidity, high temperature, direct
sun or wind, the PYROCRETE surface should be kept damp for at
Density
least 12 hours by applying a water mist or wrapping in plastic sheets to
Wet density measurements are critical to obtaining correct dry densities.
Mixer wet density should be 37-44 lbs/ft3 (.59-.71 g/cm3). To check wet reduce rapid water loss.
Caution: Do not start work if ambient temperatures are expected to
densities, fill a Dixie cup (or other suitable container of known volume in
drop below 35°F (2°C) for 24 hours after application.
ounces) with mixed material. Screed the excess until even with the rim of
the container and weigh it on a gram scale. Multiply the weight (in
Topcoating
grams) by a conversion factor based on the size of the container.
(Conversion factor is calculated by taking 2.107 and dividing by the
Seal Coat � In corrosive environments, use an appropriate topcoat. If
ounces of the cup used). This will yield density in lbs/ft3.
topcoating is required, apply Carboguard 1340 as a seal coat.
Cup Used Conversion Cup Used Conversion
Carboguard 1340 may be applied after 24 hours of final application of
Factor Factor
PYROCRETE 239. Consult the Carboguard 1340 Product Data Sheet
3 oz. .702 7 oz. .301
for minimum and maximum cure times.
4 oz. .527 8 oz. .263
5 oz. .421 12 oz. .175
Top Coat � Surface hardness should be a minimum shore D 15 as
6 oz. .351 16 oz. .132
measured with a Durometer prior to application of the topcoat.
Normally, this minimum dry time is 10 days at 70°F (21°C) and 40 days
Application Procedures at 40°F (4°C), for thickness of 1� (2.54 cm) or less.
Caulking � For exterior installations a compatible caulk should be
PYROCRETE 239 may be applied by spray and/or trowel. Film build will
applied at all termination joints between Pyrocrete 239 and the
depend on application method, weather conditions and equipment used.
substrate. Contact Carboline Technical Service for full information.
For application overhead, a scratch coat of up to ½" (1.3 cm) is
recommended to key into the lath. Allow to set for approximately 1-2 hours
Cleanup & Safety
at 70°F (21°C) before applying the subsequent coats. It is recommended
that the total required thickness be applied within a 24 hour period. If this is
Cleanup Pump, mixer and hose should be cleaned with
not possible, the preceding coats should be left as sprayed or scored after
clean, potable water at least once every 4 hours at
the initial 24 hour period, PYROCRETE 239 should then be dampened with
70°F (21°C), and more often at higher
water before application of additional coats.
temperatures. Sponges should be run through the
� Maximum time to achieve the full thickness is 3 days at 70°F (21°
hoses to remove material left in the lines.
C) and 50% RH. This would be less at higher temperatures.
Wet PYROCRETE 239 overspray must be cleaned
� All additional coats are to be applied monolithically to the entire
up with soapy or clean, potable water. Cured
perimeter of the member.
overspray may require chipping and/or scraping to
� At no time shall PYROCRETE 239 be applied at a thickness less
remove.
than ¼� (7mm) or “skim� coated.
Safety 1. Do not breathe dust. PYROCRETE 239 is
caustic and will irritate mucous membranes. Use
Water Spray Wet Dry Density Coverage
OSHA approved dust mask while mixing.
(board ft/per bag)
Level Density
2.For eye contact, flush with copious amount of
lbs/ft3 (g/cm3) lbs/ft3 (g/cm3)
(per bag)
water in accordance with OSHA Instructions.
4¾ gallon (18 l) 37 (.59) 28 (.45) 29.1
Goggles or safety glasses are always
40 (.64) 31 (.50) 26.9
recommended.
44 (.70) 34 (.55) 24.4
5 gallon (19 l) 37 (.59) 28 (.45) 29.7 3. Wash skin with clean water to prevent irritation.
40 (.64) 30 (.48) 27.5
44 (.70) 33 (.53) 25.0
5¼ gallon (20 l) 37 (.59) 27 (.43) 30.4
40 (.64) 29 (.47) 28.1
44 (.70) 32 (.51) 25.6
6 gallon (23 l) 41 (.66) 28 (.45) 29.3
44 (.70) 30 (.48) 27.3
47 (.75) 32 (.51) 25.5
7 gallon (26.5 l) 44 (.70) 28 (.45) 29.6
46 (.74) 29 (.47) 28.3
48 (.77) 30 (.48) 27.1
July 2004 replaces March 2003
To the best of our knowledge the technical data contained herein is true and accurate on the date of publication and is subject to change without prior notice. User must contact Carboline Company to
verify correctness before specifying or ordering. No guarantee of accuracy is given or implied. We guarantee our products to conform to Carboline quality control. We assume no responsibility for
coverage, performance or injuries resulting from use. Liability, if any, is limited to replacement of products. NO OTHER WARRANTY OR GUARANTEE OF ANY KIND IS MADE BY CARBOLINE,
EXPRESS OR IMPLIED, STATUTORY, BY OPERATION OF LAW, OR OTHERWISE, INCLUDING MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE. Carboline® and
PYROCRETE® are registered trademarks of Carboline Company.
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