Application Instructions
TC Ceramic Application Instructions
Equipment needed
Equipment needed in the application of TC Ceramic
Airless sprayer:
Recommended sprayer would be a
Graco Bulldog 33:1 or 41:1, Graco electric 1095 or 1595,
Graco Mark V, Mark X electric
sprayer or the GM 5900, 7900 or 10000 gasoline powered units.
Pump must be capable of pumping
no less than 1.25 gallons (4.7 liters) per minute at 3000 psi.
For Bulldog pumps, adjust the
pressure to create 3000psi in the hose.
Tips:
Recommended tip size is a .021” reversible nozzle tip,
depending on the surface to be coated. (Tips 419 to 727)
Spray gun:
Graco Contractor gun.
Recommended is the Silver Plus with a 3/8inch (0.95cm) hose
swivel.
NOTE:
Remove all filters in the
gun handle and pick up tube! For
smaller jobs an AR-1 spray gun can be used.
This gun requires compressed air at 80-120 psi with a air tank of
20 gallons/75 liters.
Hose:
50 feet (15 meters) of 3/8 inch (9.5mm) hose.
From the pump to the spray gun,
never use a ¼ inch (6.35mm)
hose. Always use a 3/8 inch
(9.5mm) inch hose or larger.
When the distance from the pump to the point of applications
exceeds 100 feet (30 meters), the first 2 sections of 50 foot (15meter)
hose needs to be ½ inch (1.3cm), then stepped down to 3/8 inch (9.5mm)
hose for no more than 2 sections of 20 meters each.
Keep in mind, the longer the hose and then higher the elevation
from the pump to the spray gun, the greater the problems.
In this case a ½” (1.3cm) hose may be required.
Mixing equipment:
½ inch (1.3cm) variable speed electric drill with “mud
paddle”.
Brushes or Rollers:
Smooth textured 4” (10cm)
brush and TC Ceramic roller.
Cleanup:
Access to water and water based solvents or paint thinner.
Surface Preparation
1.
Clean the surface to be coated with a pressure washer, leaving the
substrate free of
solvents, grease, dirt or dust.
2.
If the surface has been cleaned with a solvent, make sure that all
solvent oils and protective compounds have been removed from the
surface.
3.
Once cleaned, make sure the surface to be coated is completely dry.
4.
Although primer is not required for most surfaces, if rust or other
conditions persist after cleaning we would recommend a high temperature
inorganic zinc primer that can withstand the temperature of the surface
to be coated.
5.
Some surfaces, such as glossy paint, or glaze, can be sanded for optimal
adhesion.
Product Preparation
-
For ease of mixing and storing, TC Ceramic is packaged in five
gallon (19 liter) hard plastic pails.
TC Ceramic is ready to use as packaged.
No additives or product combination is required.
-
TC Ceramic is best mixed using a standard “Mud” paddle (normally
used to mix light plaster materials or dry wall compound) powered by
a ½ inch (1.25 cm) electric variable speed drill.
Drill power should be 5 amps or more.
When properly mixed, TC Ceramic will have a smooth creamy texture with
no lumps or foreign matter.
TC Ceramic is not a type of paint.
It is an insulating coating.
Do not use TC Ceramic with high speeds with the mud paddle trying
to make it look like ordinary paint.
High speed mixing can break the microshperes.
Application Parameters
The temperature parameters for TC Ceramic allow the product to be
applied, in most cases, without disruption of service or having to shut
down a hot surface. The
application temperature range is 45°F to 300°F (7.2°C to 150°C).
If a hotter surface needs to be
coated, contact Capstone Mfg. for additional instructions. TC Ceramic
must be applied in successive thin coats and each coat must be allowed
to dry completely prior to the application of the next coat.
One “coat” is approximately 15 mils (15/1000 of an inch or
0.375mm) which is approximately
two to three passes with the spray gun. One Gallon of TC Ceramic will
cover approximately 50-60 square feet (4.65 to 5.58 square meters) at a
thickness of 15 mils 0.375mm) to
18 (0.5mm). To calculate an
uneven surface such as uneven metals or corrugated metal surfaces it is
best to add 25% of product in the calculation of the amount of product
to be used.
Mixing Procedures and Application Instructions
-
Remove the top from a five gallon (19 liter) pail.
-
Install mud paddle onto heavy duty ½ inch (1.3cm) variable speed
electric 5 amp drill with handles.
-
If necessary, push the mud
paddle through the top crust repeatedly, changing angles of the
paddle to break up the crust.
Push the paddle down into the liquid at the bottom of the
bucket and pull up and down until the mixture is semi-blended
-
Once semi blended, insert the paddle though all of the solids and
into the liquid. Activate
the drill and slowly start to rotate the paddle.
Be sure to hold the sides of the pail with feet and knees to
prevent it from spilling
5. Mix slowly,
until the TC ceramic is the consistency of marshmallow cream, or
thick pudding. Never use
high speeds. Do not exceed
300rpm.
-
Remove all screens from the sprayer feed tube and remove the filters
in the gun and in the sprayer.
Filters do not help in the use of TC Ceramic.
-
Prime the sprayer using a bucket of clean water.
With the pump running, and
the spray gun spraying water, switch the feed pipe on the sprayer
from the water to the TC Ceramic feed bucket.
Running water through the spray gun during this transition
will keep the water from backing up into the TC Ceramic feed bucket.
-
When all of the water has been expelled through the spray gun, the
pump will sound noticeably different and TC ceramic will begin to
flow.
Tips and Techniques
1. Make smooth, overlapping
passes over the same area, using a steady uniform motion.
2. Two or three passes with
the spray gun, depending on the power, will generally
give
you about a 15 mil (15/1000
inch) (0.4mm) coating. It
is okay to have slight holidays, or to see lightly covered metal through
the product.
3. If the spray gun stops
up, rotate the Revers-A-Clean tip and spray into a spare bucket.
Rotate the tip back into position and resume spraying.
4. Keep a spare tip
with you, and if one stops up, exchange for a clean one.
Soak the stopped up tip in water and clean out.
5. On hot surfaces
(hot pipes and valves over 200F/93C) apply one misting coat.
This can be done by standing farther from the substrate, and
allow to cure completely to avoid moisture bubbles.
If moisture bubbles appear, scrape the bubble off with a putty
knife and re-mist. On the
next coat, come a little closer and use the same technique.
The substrate should reduce in temperature with each coat.
6. If applying TC to a
substrate with the operating temperatures between 40F/5C and -40F/-40C,
the surface and ambient air must be warm enough to cure TC Ceramic
(60F/16C or warmer.) Each
coat must be allowed to cure 24 hours or longer with as much air flow
and heat as possible. If
the substrate can be brought up to 150F/65C, let it operate at that
temperature for several hours, then bring it back down to ambient.
Once you have attained ambient temperature, lower the temperature
of the substrate to 35F/2C for several hours.
7. Let each coat cure
completely. While normal
dry time is 24 hours per coat, ambient conditions can affect this time.
Humidity or cold weather can increase dry time, while good air
flow and higher heat can speed up curing of the product.
When coating a surface at ambient
temperatures that will be operating at temperatures over 150F/65C, unit
should be brought up to 150F/65C for a period of 8 to 12 hours prior to
elevating to the actual operating temperature.
This will cause the remaining moisture to cure out of the
product. Without the slow
increase in temperature, there is a good chance that moisture will be
trapped, which will create moisture blisters or bubbles.
9. Cleanup and care of the
equipment is vital both during and after the application.
Always keep a pail of water near the gun at all times.
If there is a need to stop spraying for even a moment or two,
place the gun inside the pail of water.
This will keep the spray gun cool and will help keep product from
curing inside the tip or the gun.
If leaving the equipment unused or unattended for more than 10
minutes, follow the cleanup techniques listed below.
10.
When spraying on a roof or during bright sunlight, the applicator
must be wearing sunglasses to protect their eyes from sun reflection off
of the roof surface.
Cleanup
When finished with the application, immediately cover all buckets with
unused product still in them. Remove pump from the product bucket and
move pump to the water bucket.
Run water through the pump until all product is out of the hose.
Also run water through the primer valve.
Clean the gun and tip with
water. Run water based
solvent through the pump and primer valve. Then run paint thinner or
solvent through the pump and primer valve and leave some in the pump
until the next time the pump is used.