Chem - glass™

200 Series
Polyester Glassflake System

DESCRIPTION
Chem-glass™ coatings are based on polyester resins, reinforced with screened glassflake particles
0.4mm, 0.8mm or 3.2mm diameter. For example:-

264 200 series reinforced with 1/64” or 0.4mm glassflake.

232 200 series reinforced with 1/32” or 0.8mm glassflake.
208 200 series reinforced with 1/8” or 3.2mm glassflake.

To obtain maximum performance, for which these coatings are formulated, strict adherence to
application instructions, precautions, conditions and limitations is necessary.

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SURFACE PREPARATION
STEEL SUBSTRATE

PRE TREATMENT

Clean surfaces to remove traces of grease, oil or wax-based residue and other contaminants with
Chemco cleaner (S11) so as to prevent contamination of the applied coating following surface
preparation.

BLAST CLEANING

Abrasive blast clean the substrate to achieve a “near-white” metal finish equivalent to Sa 2½ with a
surface profile of 75µ in accordance with ISO 8501-1. The choice of abrasive media is dependent upon
the profile and standard finish required, although due consideration of Health & Safety issues should be
taken into account. Typically, the preferred choice is either garnet or chilled iron grit, but other forms of
abrasive media, eg. expendable copper slag, etc. can be used. Remove dust and debris by vacuum
cleaning or brushing prior to application. Application should not be delayed otherwise quality of the
blast will be affected by the presence of flash rust forming on the substrate. Take all necessary and
appropriate measures to prevent risk of contaminating the blasted surface by adopting good
housekeeping standards and restricting access only to the applicators. In this way, the adverse effects
of contamination, moisture and humidity exposure, which reduces adhesion, may be minimised.

HAND MECHANICAL PREPARATION

Chem-glass™ coatings are ideal for protecting substrates prepared by hand mechanical methods due
mainly to the excellent properties obtained, even on inferior or rusted surfaces. Whilst abrasive blasting
is always the preferred choice it might not always be feasible or practical. Power tool methods may be
considered for repairing of damaged coating or in circumstances where specified by the client. The
substrate may be prepared using chipping hammers, wire brushing, pneumatic or electrically powered
rotary brushes, needle guns, grinders and/or sanders. The applicator should endeavour to remove
loose paint, rust and other contaminants to achieve a clean metal finish equivalent to St 3 in
accordance with ISO 8501-1. Exposed edges should be ground to remove sharp edges, loose slivers,
mill scale, etc. Treat welds by grinding to remove loose flux, weld cap, slag, etc. When using powered
tool methods ensure correct grade of disc grinders, needles are used. Contact Chemco technical
department for advice, assistance or further information.

Rev: December 2017

SURFACE PREPARATION (cont’d).
CONCRETE SUBSTRATE

NEW CONCRETE - May require light abrasive blasting for keying purposes. It is normally standard
practice to allow the concrete to fully cure (a minimum of 28 days prior to coating). However, by
application of Chemco’s damp/wet concrete primer followed by an anti-corrosion protective coating
system, the curing period for the concrete may be substantially reduced.

OLD CONCRETE - Pre-treatment may be required to remove contaminants from substrate and provide a
uniform roughened substrate. Approximately 0.5 to 1.0 cm should be removed.
Depending on condition of substrate and operating environment, pre-treatment may involve a
number of methods, i.e.: -

• abrasive blasting followed by dusting

• wire brushing
• multi-plane/scarifying
• flame blasting
• acid etching

Mechanical pre-treatment to be followed by thorough cleaning, preferably by vacuum.

It is important to strengthen and seal surface by saturating pores with concrete primer. One or two
coats (depending on condition of concrete) should be applied by brush, roller or spray.

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APPLICATION EQUIPMENT
The following equipment is recommended for application of Chemco coatings, although other
choices capable of providing a high quality finish may be used:-

• Airless spray pump: Minimum 45:1 ratio (preferably 63:1) with a fluid twist:.

Tip size: 264(21 - 27 thou. Ideal 23 thou.)

Tip size: 232(33 - 39 thou. Ideal 35 thou.)

• Trowel, spatula, brush, short bristled roller medium nap.

Prior to application it is important to plan the work and make careful selection decisions concerning size
of tip and fan angle since this will help to minimise waste and enable a good quality spray grade finish
to be achieved.

The pump should be fitted with leather and teflon seals. Fluid hoses should be of a nylon type
[size ⅜” (10mm), although for some projects a larger dia. of ½” (13mm) may be required]. The
whip end hose is ¼” (6mm) (provided the length does not exceed 1.0 m).

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MIXING & APPLICATION INSTRUCTIONS

MIXING

Prior to mixing, when removing container lid avoid contaminating material with dust and dirt. Mix resin
(part A) with 1 - 3% (weight by volume) of recommended hardener using a mechanical whip or
equivalent. Mix for a sufficient length of time to ensure thorough mixing. When the coating is applied
at temperatures above 20ºC Chemco adjusts the material prior to receipt of materials, there-fore no
accelerator or inhibitor should be added to the coating.
NEVER THIN THE COATING BY ADDITION OF ANOTHER CHEMICAL.
Chem - glass™
200 Series
Polyester Glassflake System

MIXING & APPLICATION INSTRUCTIONS (cont’d).

BRUSH APPLICATION

For application with brush or spatula, mix a maximum of 5 kgs of resin with 1 - 3% of hardener (weight by
volume).

Stir both components thoroughly to an even consistency on a flat surface. Try to avoid narrow cylindrical
pots, as this may shorten pot life. The catalysed coating must be used within the pot life gel times. Do
not apply the coating if gelling has started. Since the pot life is limited and shortened by high
temperatures, do not mix more material than will be used within the pot life limitations.

If applying heavier grade material (208) use a roller dipped in Chemco’s S12 (rolling aid) to obtain
correct orientation of the glassflake particles. Roll carefully, applying pressure to the coating in order to
have a closed and even film.

TROWEL APPLICATION

This method of application is mainly used for application of 208 heavy duty grade. This material (208)
is a high viscosity material which can only be applied by brush/roller or trowel. Trowel is used for large
areas and is the fastest method of applying this grade. S12 (rolling aid) should be used to smooth out
the coating and to obtain correct orientation of the glassflake particles. Please note that excess S12
liquid should be taken off the roller or trowel prior to contact with the material. Excessive amount of
S12 will weaken the coating and will be detrimental to the coating system.

The mixing and application method is virtually the same as for plastering. Using the same equipment,
mix appropriate amount and transfer onto the board and mix again prior to the application.

SPRAY APPLICATION

Check prior to application that equipment is fit for intended purpose. Remove fluid filters from pump,
both at suction and discharge ends. Ensure hoses are in good condition (no kinks), of correct size and
type. Pump should be primed with S12 (rolling aid/flow agent) or S11 (cleaner) prior to commencing
application. Apply high pressure and spray the priming fluid to ensure there is no blockage and that
equipment is functioning at correct pressure. Remove the priming container and place material
container directly under pump taking care to minimise risk of contamination since cleanliness is of
paramount importance. The spraying action should continue until the material appears at the gun head.
Make sure that all diluted material is sprayed into a waste container.

When mixing materials for application it is important to work at a rate similar to the sprayer. Never mix
too many drums otherwise coating will harden and may cause thickening or lumps to form. If too slow,
then inconsistency in finished quality will result. Catalysed material has a shortened pot life which is
reduced by temperature and pressure, it is therefore important to mix only what is required for the
work to proceed and to avoid delays. Once spraying is finished, immediately flush out equipment with
S11 cleaner, circulated through the pump and lines for at least 10-15 minutes.

Apply a wet coat of 200 series coating in even parallel passes. Overlap each pass to avoid bare areas,
pinholes or holidays, giving special attention to cones, welds, rough areas, edges and cavities. Do not
attempt to wet out the surface fully at a single pass but mist coat the area with several passes until at
least 80 - 90% coverage is achieved. To spray the whole area, start by spraying vertically from top to
bottom/bottom to top and move to an adjacent area using the same method as before then return to
previous area and build up coating thickness with horizontal passes. This method of vertical followed
by horizontal passes should be used for treating the complete area.

Clean all equipment with S11 cleaner immediately after use and dry with a clean rag.

Airless spray application is suitable only for all Chemco 200 series coatings reinforced with 0.4 mm
(1/64”) and 0.8mm (1/32”) screened glassflake particles.

Rev: December 2017

INSPECTION
VISUAL INSPECTION

Ensure no irregularities such as raised areas, soft spots, disbondment, poor joints, surface
discontinuities and delaminations. Any defects shall be marked for subsequent repair.

THICKNESS TEST

Monitor thickness of lining/coating during application by wet film and/or dry film methods. Wet film
monitoring is made by use of a wet film comb whereby the comb is pushed into the coating and the
actual thickness value read off the gauge.

Dry film thickness (dft) measurements are taken after coating/lining has fully cured. The probe
measures the depth of coating via an electronic signal, which is converted to an analogue digital value.
Following calibration using shims or foils (of known dft) the area coated should be monitored and the
values recorded. Recommended for ferrous and non-ferrous metal substrates (several types of probe
are required for monitoring the various types of ferrous and non-ferrous substrates).

POROSITY & HOLIDAY TEST

Spark test coated area with a porosity/holiday DC spark detector instrument (voltage output 0 - 20kV)
which should be set to the correct voltage (dependent upon coating thickness but generally about 4V
per microns of coating). The instrument is used to detect any pinholes or holidays. The probe is
passed across the surface of the coating, which if fully sealed would act as an insulator. A pinhole or
holiday means that the coating has not fully covered the substrate and therefore an electric current
would emit a spark triggering off the alarm. Defects are marked off for subsequent repair.

This method of test is recommended for final inspection and is suitable for ferrous substrates and
concrete (containing a ferrous or other type of conductive admixture).