CIRCULAR LETTER

HEMPEL
Fire Protection Support
Group R&D
Date:
TO:

Technical Service, Protective Sales

Copy:

R&D Fire Protection, Anton de Castro,

Martin Boegsted

30 May 2014

Ref. No.: evsc405271

SUBJECT: Revision of Dry-to-handle times of HEMPACORE ONE

Executive summary:
Based on field experience and new laboratory test data, the Application Instructions of
HEMPACORE ONE 43600 and HEMPACORE ONE FD 43601 have been updated with changes
in the Dry-to-handle times, recommended film build up and over-coating times for high DFTs and
handling procedures in order to minimise damages of the intumescent system during handling
and transportation.

The following recommendations contain even more detailed information about the best practices
for Hempacore applications.
Hempacore ONE 43600 and Hempacore ONE FD 43601 carry approval for fire protection of
structural steel, including 30, 60, 90 and 120 min fire protection. For up to 90 min fire protection of
open profiles (I- or H sections) the required Dry Film Thickness (DFT) for the product does not
generally exceed 3000m. For closed profiles (hollow sections) and 120 min open profiles the
required DFT can reach till approximately 5500 m. In all cases, the exact required DFT is
depending the massivity (Hp/A) of the relevant steel sections. High thicknesses will require
multiple coat applications.
Hempacore ONE 43600 can be applied up to 1500 m DFT per coat. Hempacore ONE FD 43601
can be applied at 1100 m per coat. This allows completion of application with minimum labour.
However, for specifications where the total DFT is above 3000 m DFT, drying times are
significantly extended due to the slower evaporation of the solvent retained in underlying layers
and solvent strike back. In such cases a dry film thickness built up in thinner coats will reduce the
overall drying time.
A distinguish shall be made for in shop (off-site) and (after erection) on-site applications. For in
shop applications often it is important that the handling of sections can be done quickly after
completion of the spray job. The fastest drying of the coating system is generally desired.
For on-site applications it is normally desirable to have minimum amount of coats to minimise the
labour, and fast drying time is generally of lower importance since handling of sections after the
application is normally not an issue. For on-site applications the high thickness per coat is
valuable.

CIRCULAR LETTERS are available on Hempels Intranet:

Product Portal / Instructions / Circular Letters

Drying studies have been done at Hempels laboratories under controlled conditions. These test
results are the basis for the drying times mentioned in the application instructions. Drying times of
Hempacore ONE 43600 / FD 43601 are dependent on temperature, ventilation, amount of air
refreshment, air movement, state of the dryness of previously applied coats, etc. Hence, the
provided values shall only be used as a guideline and the actual drying condition should be
verified in the actual application site under the real conditions.
It is recommended always to check the actual DFT and to make quick indicative measurements
for drying before you start with the application of a next coat of Hempacore. By pressing firm with
your thumb, the coating shall not be easily indented. If it is possible to make an indent with your
thumb without making much effort, it is not recommended to apply the next coat yet, but to leave
the coating to dry for a longer time and to postpone the application of the next intumescent coat. If
no indention can be made the coating is ready to accept a next coat.
In order to obtain the optimum drying of Hempacore ONE at high DFTs, say above 3000m
(DFT), we recommend the following:
Spray 750m DFT (1000m WFT) per coat
Leave each coating to dry for approximately 24 hours
Control and monitor the WFT and DFT applied
Use the before mentioned indicative drying test with the thumb to decide if the coating is
ready to accept next coat.
Alternatively, long recoat times could be used to speed up the final drying, e.g.
Spray 1500m DFT (2000m WFT) Hempacore ONE 43600. For Hempacore ONE FD 43601
the max DFT is 1100m (approx. 1450m WFT).
Leave the coating to dry for approximately 48 hours
Control and monitor the WFT and DFT applied
Again, use the before mentioned indicative drying test with the thumb.
As an intermediate solution the application of high DFTs can be build up as
Spray the first two coats of Hempacore ONE 43600 at 1500m DFT (2000m WFT)
Spray the remaining coats at 750m DFT (1000m WFT)
Leave each coating to dry for minimum 24 hours
Control and monitor the WFT and DFT applied
Use the before mentioned indicative drying test with the thumb.
The throughput for the total coating system will be faster when longer recoat time is used in
between the application of two coats of Hempacore.
At areas where spray applications have overlapped, the DFT may be way higher as the average
DFT. As the speed of drying is directly related to the DFT of the coating, the drying of the
complete coat will depend the thickest areas.
In case the practices mentioned in this document are not respected, and the appearance of a
coating system is very soft, the only possible means to improve hardness is time. During time the
solvent will slowly evaporate and hardness will develop. For a 5000m DFT coating this may take
very long time. Times up to 1 - 2 months have been measured, before acceptable hardness
was achieved. When applications have been made at higher DFTs as 1500m per coat, this time
is even significantly prolonged further.
Before application of a topcoat the Hempacore product shall be dry hard, except when an
approved acrylic topcoat is used. For the most speedy in-shop times it can be sometimes a
solution to apply the topcoat on-site, or use acrylic topcoats.

CIRCULAR LETTERS are available on Hempels Intranet:

Product Portal / Instructions / Circular Letters

After drying of the coating system, off-site applied the steel sections will need to be handled. It is
important to address that due to the thermoplastic nature of acrylic intumescent coatings, they are
sensitive to damage, also after full drying. Generally it is more of a matter to minimise the damage
as to prevent damage. Therefore special care should be taken to smartly handle the coated steel
sections. If the steel sections have areas that are not sprayed with intumescent paint (e.g. areas
left blank as welding/botling area), the lifting straps should be installed in those places when
possible. This reduces the amount of damage, and therefore also the required repair. The amount
of supporting beams normally of wood, shall be limited to the minimum required, in order to
minimise the damaged areas. Areas where the sections lean on the supporting beams are likely
to be damaged
Maintain sufficient ventilation, also when the product is considered dry. Therefore, do not cover
up the sections as this will affect the final drying properties.
For any questions, please contact Fire Protection Support (FireProtection.Support@hempel.com)
Erik van Schaijk
Research Engineer
Group R&D Fire Protection
Poliny (Barcelona)

CIRCULAR LETTERS are available on Hempels Intranet:

Product Portal / Instructions / Circular Letters