PI

Protective Coatings

INTERZONE 485
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Recommended Working Procedures
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1. INTRODUCTION Interzone 485 is an ultra high build epoxy recommended for a wide range of uses including
exterior of buried pipe, offshore production and drilling structure decks and heliports,
lining of tanks where abrasion and mild acid products are present, and many other service
environments where a single-coat, ultra high build impact-and abrasion-resistant product is
suitable, including a limited range of elevated application and service conditions.
Interzone 485 is a specialist product that looks and behaves differently from
conventional epoxy products and from coatings used for similar applications. In
addition, because of its ‘niche’ nature, many applicators will not have had previous
experience in handling and applying this product.
This document gives detailed guidance on the use and application of Interzone
485 and should be read in conjunction with the Interzone 485 technical data
sheet and material safety data sheet.
2. WHERE TO APPLY Interzone 485 may be applied at a fabricator’s shop or on-site. When properly applied and
INTERZONE 485 fully cured, Interzone 485 is tough enough to survive normal transportation, laydown and
installation with no damage, and will require little or no touchup repairs except for coating
field weld joints.
Interzone 485 is an exceptionally impact and abrasion resistant coating when properly
applied, provided that sufficient time is allowed for through drying (hard dry) before
handling. Care should be taken during transport and erection to minimise damage.
3. SURFACE Interzone 485 is recommended for application directly to properly prepared bare steel
PREPARATION substrates, properly prepared concrete, and a limited number of other properly prepared
surfaces. For the use of Interline 982 hold primer, or for application over International
Interplate preconstruction primers, please consult International Protective Coatings.
Interzone 485 is not recommended for application over Inorganic Zinc or over normal
primers. For instructions regarding overcoating of Interzone 485 with itself, see below.
All surfaces to be coated should be clean, dry and free from contamination. Prior to paint
application all surfaces should be assessed and treated in accordance with ISO 8504:1992.
Where necessary, remove weld spatter, and where required smooth weld seams and sharp
edges.
All surfaces to be coated should be correctly prepared prior to application of the Interzone
485 coating system.

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Protective Coatings

INTERZONE 485
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Recommended Working Procedures

4. SURFACE Existing coating systems other than Interzone 485 may be unsound, of unknown type, or be
PREPARATION – breaking down, and will have an unquantifiable effect on any subsequently applied coating
MAINTENANCE system. They should be completely removed. Topcoats previously applied over Interzone
485 should also be removed before application of additional Interzone 485. Where such
coatings exist, they should be removed by abrasive blast cleaning to Sa2½ (ISO 8501-
1:1988) or SSPC-SP6, except where sound Interzone 485 exists beneath topcoats.

5. STORAGE OF Interzone 485 should be stored in covered, dry conditions and kept in the temperature range
MATERIALS of 0ºC-40ºC (32ºF-104ºF) until the day before application. Ideal application ambient
temperature is between 25ºC and 35ºC (77ºF and 95ºF), although it is feasible to apply at
higher and lower ambient temperatures.
Overnight, prior to application, Interzone 485 should be stored in a warm area, preferably
between 30ºC and 35ºC (86ºF and 95ºF); the material should be kept warm until actually
catalysed and applied. In this way, Interzone 485 may be applied to colder surfaces while
still keeping ideal application characteristics.

6. STANDARD OF The appearance of applied Interzone 485 may vary, depending upon the application
APPEARANCE conditions such as temperature and humidity, equipment used, applicator motion, distance
from spray gun to surface during spray passes, and the material itself.
Interzone 485 is not designed to provide a high degree of cosmetic appearance. During
normal application at recommended film thicknesses, a very heavy orange peel effect is
often noticed, especially on piping and small structural steel surfaces. Occasional very
small crater-like voids may be observed in the applied coating. These should be repaired
by application of additional Interzone 485 unless DFT at the bottom of these craters is
above required minimum. Where a smoother finish is required, an additional coat of
Interzone 485 thinned beyond normal recommendations may be applied after the initial
build coat has dried. This additional appearance coat should be 15 mils DFT or less. Over-
thinning the initial build coat of Interzone 485 will not achieve a smooth surface finish.

7. ENVIRONMENTAL Interzone 485 cures by reaction with the provided curing agent. Environmental monitoring
CONDITONS FOR is essential for Interzone 485 application and cure. The following parameters apply, and
APPLICATION should be measured and recorded:
• The surface onto which Interzone 485 is to be applied must be clean, dry and free from
contaminants.
• Steel temperatures must always be 3ºC (5ºF) above the dew point.
• Optimum conditions are those of high surface and air temperature, i.e. in excess of 77
degrees F. If ambient and surface temperature are below 77 degrees F. then care should
be should be taken during application of Interzone 485, use of pre-warmed material is
even more important, and drying times will tend to be longer.
• When desired, Interzone 485 may be applied to properly prepared surfaces at surface
temperatures up to 90ºC (194ºF). Care should be taken to provide safe working
conditions around hot equipment, and it should be noted that at such surface
temperatures, Interzone 485 dries very quickly. Application to heated surfaces does
not affect the strength or long-term performance of Interzone 485.
Ambient and surface conditions should be measured, in stable conditions, typically twice
per day (or twice per shift). If conditions are subject to change, measurements should be
taken more frequently, depending upon the speed of change.

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Protective Coatings

INTERZONE 485
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Recommended Working Procedures

8. MIXING OF This product is supplied in two components, a pigmented base component supplied in a
INTERZONE 485 five- gallon can, and a gallon can of curing agent. Both containers are short-filled for ease
of mixing and handling. Mixed volume of the complete kit is 3.75 gallons.
Product should be mixed as a complete kit, as packaged.
Due to the ultra high build, high-solids nature of Interzone 485, sedimentation of the base
component can occur over time and as a consequence of transportation, particularly where
long distances are involved. Due to the heavy bodied nature of this material, it is not
possible to sieve Interzone 485, and therefore correct mixing is essential to ensure that all
material is properly mixed before application is attempted.
The importance of correct mixing cannot be over-emphasised.
Mixing must be carried out using heavy-duty mechanical mixers. Compressed air driven
drum or paddle mixers are recommended for mixing Interzone 485. Site experience has
shown that an air driven reversible drill, capable of achieving 800 r.p.m. and fitted with a
suitable mixing blade will prove satisfactory for this purpose. It will be necessary to ensure
that the air supply to the mixer is maintained at >75 p.s.i. to ensure that mixing efficiency is
maintained.
The main points to remember when mixing Interzone 485 are:
• Do not mix more material than can be used within the pot life of the material.
• Open the base can—there should be little or no liquid material, and the Interzone 485
base should have the consistency of heavy wax.
• Thoroughly mix the base component. The Interzone 485 base will “loosen” slightly
during mixing.
• Slowly add the entire can of Interzone 485 Curing Agent into the base component with
efficient mixing, ensuring that flooding does not occur. The kit is short packed to
allow vigorous mixing without having product creep up the side of the can and
overflow.
• When the base and curing agent are well-mixed, uniform in appearance and relatively
free from lumps, add one quart per kit of International GTA 415 thinner slowly,
making sure that it is thoroughly incorporated. After mixing, the Interzone 485 should
be noticeably thinner bodied than when the base was first opened.
• Ensure that during the mixing of the material the sides of the containers are scraped to
remove unmixed material from the sides. This should be done several times during the
mixing operation.
Note: Interzone 485 is a chemically cured material. Once base and curing
agent have been mixed, the material should be used soon as possible.

9. POT LIFE Interzone 485 becomes very difficult to spray if the stated pot life is exceeded, and material
may harden in the airless pump, or pressure pot, hoses and gun. Mixed material should be
sprayed out at once after curing agent and thinner have been added, and equipment should
be cleaned or flushed out well within stated pot life. Remember to judge pot life based
on material temperature of the Interzone 485, not on air or surface temperature.
Interzone 485 must not be applied after the stated pot life has been exceeded.
Pot life times for Interzone 485 are as per below:
10ºC (50ºF) - 1 hour
15ºC (59ºF) - 1 hour
25ºC (77ºF) - 45 minutes
40ºC (104ºF) - 30 minutes

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Protective Coatings

INTERZONE 485
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Recommended Working Procedures

10. AIRLESS SPRAY Due to the high solids and heavy body characteristics of Interzone 485, which inhibit good
APPLICATION OF flow, it is necessary to use a large diameter paint line - ½ inch (12.5mm) is recommended
INTERZONE 485 with all inline filters removed. Fluid lines should be as short as possible consistent with the
size of the work. The snout and pickup hose should also be removed, and the foot of the
airless pump should be stood directly in a bucket of mixed, ready-to-spray Interzone 485.
Selection of the correct type of airless spray gun is important to achieving problem free
application. The gun used should have the minimum amount of constrictions to paint flow,
and preferably should feed material close to the airless spray tip.
The preferred gun is a Silver Gun, Model 235-463, Series D (Graco), or an equivalent
design where the paint is fed direct to the tip; alternative designs where paint is fed through
the gun handle may result in dead spots developing, with consequent ‘blockages’ and
‘packing’ of the pigment occurring.
Tip size can be from a minimum of 19 thou (0.48mm) up to 30 thou (0.77mm), depending
on application requirements, and also may be dictated by the occurrence of ‘blocking’
which can occur occasionally as a result of the heavy bodied nature of Interzone 485 and
therefore some blocking of the tip is considered normal. A reversa-Tip or similar easy to
clean tip is strongly recommended for ease of application
To enable optimum cure and film strength, it is necessary to apply a wet coat as free from
overspray (dry spray) as possible by keeping the spray gun relatively close to the substrate
and using slow passes to give even coverage. Additional passes should be made until the
recommended film thickness is achieved.

11. AIR SPRAY Conventional air spray with attached pressure pot should be through a DeVilbiss MBC 516-
APPLICATION OF 792M mastic gun with 492 M nozzle or equivalent. The pressure pot should be bottom fed
INTERZONE 485 with ¾ inch fluid line as short as consistent with the size of the work.
Pot pressure should be sufficient to move product, and atomisation air used should be the
minimum required to produce a fan. Excessive atomisation air will provide unacceptable
dry spray characteristics.
Where a rounded profile non-slip surface is desired on decks or walkways, a “splatter coat”
effect may be achieved by reducing pot pressure, increasing atomisation air, aiming the
spray gun above the deck and allowing droplets of Interzone 485 to “splatter” on the deck
surface. The splatter coat should be applied after the initial application has set but not
dried; required DFT must be reached before the splatter coat is applied.
Where a sharp, angular profile non-slip surface is desired on decks or walkways, special
non-slip grit may be incorporated into Interzone 485 and sprayed in a single application.
Contact International for additional details and information.

12. INSPECTION OF Once the coating has been allowed to dry, the integrity of the final film should be checked
DRY FILM to monitor the effectiveness of curing, to check for surface defects, and to record film
thickness. If defects are evident then the appropriate remedial measures should be taken.
13. POSSIBLE FILM The function of the Interzone 485 is to provide corrosion protection and an ultra-high-build,
DEFECTS impact and abrasion resistant coating. As the surfaces coated are often large and complex
in design, a number of potential film defects can occur. The manner of application should
be such that these are avoided or minimised. A number of potential defects are detailed
below, together with recommended remedial treatment.
Dirt Pick-up Due to the highly pigmented nature of Interzone 485, the final film has a degree of surface
roughness which can, in certain circumstances, make it prone to dirt pick-up from air borne
particulates and contaminants, e.g. dust, soot etc. While this does not cause any problems
in terms of performance, cosmetic appearance may not prove acceptable if such films are to
be permanently exposed.

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Protective Coatings

INTERZONE 485
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Recommended Working Procedures

Discolouration Interzone 485 has been designed as a functional coating to provide corrosion resistance in
high temperature service up to continuous operating temperatures of 120ºC (250ºF). At
continuous operating temperatures near120ºC (250ºF), Interzone 485 may be prone to
discolouration due to physical changes in the colouring pigments used. While this
phenomenon may be an issue from a cosmetics standpoint, it will not be detrimental to
performance or corrosion resistance of the Interzone 485.
‘Orange-peel’ Difficult to avoid but can be minimised by good spray technique, recommended thinning of
the material and ensuring that the material is at a working temperature between 30ºC and
35ºC (86ºF and 95ºF) during application.
Overspray/ Can be minimised by work planning and good spray technique, recommended thinning, and
Dry Spray reduction of air pressure. Increasing airless tip size and using fewer “passes” to achieve a
wet film may assist. If the effect is severe, the surface must be cleaned by dry brushing
after the applied Interzone 485 has dried and prior to application to adjacent areas.
Small Craters May occur as a result of hesitant application, and/or as a result of poor coalescence of
Interzone 485. A few craters per 100 sq. ft. applied material are to be expected and should
be repaired. Excessive numbers of craters indicate equipment problems or improper
application.
SLIGHT Ripples Can often be unavoidable on complex sections, but can always be minimised by good spray
technique.
Sagging The result of excessive film thickness and poor spray technique. If the areas are greater
than 100mm equivalent diameter, the coating should be removed and re-applied.
Soft Films Can occur when Interzone 485 is applied in ambient conditions where the surface
temperature and/or ambient temperature are very low. Often such films will become
progressively harder with time, and provided care is taken to avoid mechanical damage,
problems will be avoided. Exposing the coated piece to sunlight or a hot air blower will
speed cure.
Films which do not begin to show signs of becoming harder with time are indicative of lack
of cure. This may be as a result of poor mixing, or even of omission of the curing agent
component. If this is suspected, the affected areas will require removal, and re-application
of Interzone 485.
LOW FILM THICKNESS Application of films at or below 40 mils DFT are inadequate for immersion or buried
service and will provide poor performance. For immersion or underground service, apply
at least 60 mils (1500 microns) of Interzone 485.
14. MEASUREMENT OF An electronic DFT gauge capable of storing statistical data is very strongly recommended,
DRY FILM to enable a meaningful DFT survey to be conducted. Gauges should be calibrated on
THICKNESS smooth plate. Ordinary “banana” magnetic pull-off gauges usually do not have a high
enough range to be useful for the recommended DFT of Interzone 485.

Method Use a gauge which has been properly calibrated and is suitable for the normal application
range of Interzone 485 (40-120 mils per coat, 1000-3000 microns) . An average thickness
must then be calculated, and if the average is less than the specified average DFT,
additional Interzone 485 must be applied. Where a specification states a minimum DFT of
Interzone 485, any areas below the specified minimum must be marked and spot repaired
with additional Interzone 485.

Tolerances Care shall be taken to achieve the nominal dry film thickness and to avoid areas of
excessive thickness. It is recommended that the maximum dry film thickness is not greater
than 2 times the nominal film thickness. In the case of excessive maximum dry film
thickness, expert agreement shall be found between the parties.

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Protective Coatings

INTERZONE 485
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Recommended Working Procedures

15. HANDLING OF Interzone 485 is normally specified to be applied as a single coat in the 40-120 mil range
INTERZONE 485 (1000-3000 microns). Freshly applied films are soft, liquid, very sticky, and very
susceptible to damage. Care should be taken to prevent damage to or removal of freshly
applied Interzone 485 by hoses dragged over newly coated surfaces, newly coated pipe
sections being rolled too much or allowed to touch each other, or contamination from
environmental fallout.
Once dry, Interzone 485 is an extremely tough, durable and abrasion resistant surface. Care
should be taken, as with any newly coated surface, but no unusual precautions are needed.

16. REPAIR OF Where mechanical damage is unavoidable, the following repair procedure should be
DAMAGE adopted:
• Surface damage to applied Interzone 485 where substrate is not exposed:
Remove any contaminants and any loosely adhering bits of Interzone 485.
Wipe the damaged area with International GTA 415 thinner; allow to dry.
Apply additional mixed Interzone 485 to repair the damaged area.
Interzone 485 may be applied to small areas by brush, trowel or putty knife.
• Damage to applied Interzone 485 where substrate has been exposed:
Prepare damaged area to SSPC SP 11.
Apply additional mixed Interzone 485 to repair the damaged area.
Overlap into surrounding intact Interzone 485.

17. HEALTH & Interzone 485 is intended for use only by professional applicators in industrial situations in
SAFETY accordance with the advice given in this leaflet and on containers, and should not be used
without reference to the Material Health and Safety Data Sheets (MSDS) which
International Protective Coatings has provided to its customers. If for any reason a copy of
the relevant Material Health and Safety Data Sheets are not immediately available the user
should obtain a copy before using the product.
Minimum safety precautions in dealing with all paints are:-
– Take precautions to avoid skin and eye contact (i.e. use overalls, gloves, goggles, face
mask, barrier creams etc.)
– Provide adequate ventilation.
– If product comes in contact with the skin, wash thoroughly with lukewarm water and
soap or suitable industrial cleaner. Do not wash with solvents. If the eyes are
contaminated flush with water (minimum 10 minutes) and obtain medical attention at
once.
– These coatings contain flammable materials, so keep away from sparks and open
flames. Smoking should be prohibited in the area.
Observe all precautionary notices on containers.

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Protective Coatings

INTERZONE 485
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Recommended Working Procedures

PI2098a
12/01

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