hpc headder

HPC® COATING is designed to control heat transfer for temperatures up to 932°F (500°C). It is lightweight and smooth in appearance after mixing. HPC® COATING is a water-borne system using a special acrylic/urethane blend with specific ceramic compounds to provide a non-conductive block against heat transfer. HPC® COATING offers a nonflammable/non-toxic formula for hot surface applications over standardsteam pipe or oven wall construction, but can be used for insulation of vessels well below freezing, after cured. The coating was designed to create a monolithic insulation system that can be sprayed over most surfaces and higher temperatures. It can be applied over metal,concrete, wood, gypsum, and most other substrates.

SURFACE PREPARATION
Surface must be clean from oil, tar, rust, grease, salts, and films.
  1. Clean ambient surfaces using TSP (tri-sodium-phosphate) or a citrus cleaner to release dirt and degreaser residue and pressure-wash if possible @ 3500 psi. and allow to dry
  2. Salt contamination on a surface can come as a result of salt water, fertilizers, and car exhaust. Use Chlor*Rid or equivalent to decontaminate surface if salts are present. Acceptable levels: Nitrates: 5-10 mcg/cm², Sulfates: 5-10 mcg/cm², Chlorides: 3-5 mcg/cm²
  3. Clean hot surfaces by removing pack rust, loose dirt and rust using a metal brush or mechanical tool. Remove milscale by grit blast, power tool or needle gun.
  4. Prime the surface with RUSTGRIP ® if specified.
NOTE:
The temperature of a pipe, valve, or tank cannot be determined by taking the exterior surface temperature where heat is released into the atmosphere. Surface temperatures will rise to match the temperature of the fluid or gas contained once the surface is coated and the heat is held back.
MIXING

1) Mix with commercial drill and a 6” diameter dispersion blade at low or medium speed for 2 minutes to loosen product. Coating will initially look dry and have a “cakelike” appearance.
2) Mechanically stir using blade until water and resins are mixed and coating appears as a thick whipped cream with no lumps. Use an up and down pumping motion while stirring. If it still appears to be dry, slowly add water while continuing to mix.

NOTE: For start & stop (lunch), drop gun into pail of water and cover unused pail or hopper with plastic to prevent evaporation of water.
APPLICATION
HPC® COATING must be applied by spray.
  1. Use a hopper gun for small applications.
  2. Use a Graco GTX 2000EX sprayer using a 6-8 mm nozzle.
  3. See the SPI Application Equipment sheet to reference suggested machines. For specialty applications, contact SPI.
  4. For operating temperature below 302°F (150°C) use either HOT SURFACE COATING ® or HPC® COATING applied between 40°F (5°C) and 120°F (49°C) ambiant. Applied HPC® COATING should never be put into or exposed to below 40°F (5°C) until it is totally cured and moisture has evaporated from the coating. Use a moisture meter to determine moisture content. (5% or less)
Hot Surface Applications above 302°F (150°C):

Apply a thin priming coat of HPC® COATING at 50 mils wet (1.25mm) and allow coating to cure down and moisture to steam off. (Approx. 5 minutes) Once HPC® COATING at 100-200 mils wet per coat (depending on surface temp) to build to specified thickness. Allow coating to completely steam off between coats before applying additional product. After proper thickness is achieved, allow 24 hours to fully dry and cure before top-coating. Top-coat cured HPC® COATING with SUPERTHERM ® to toughen and weatherize the surface. RUSTGRIP ® or ENAMOGRIP ® can be used over SUPERTHERM ® to strengthen surface or add color when specified.

NOTE: For application over hot, flat steel surfaces,
            see manufacturer for instructions.

NOTE
:

If initial coat or additional coats are applied too thick, bubbles will appear and begin to rise. Bubbles can be punctured to release trapped air and pressed down to allow bubble to adhere.

Hot pipe Applications:

HPC Multi-Mesh Membrane System is used on hot pipes when continuous cycles cause movement, and where impact caused by workers handling the hot pipe is unavoidable. Apply Multi-Mesh Membrane between layers if RUST GRIP ® or MOIST METAL GRIP ® for exterior toughness (first coat 8 mils wet/203 microns then top-coat Mesh with 8 mils wet/203 microns or until Mesh is completely coated). Multi-Mesh Membrane combined with RUST GRIP ® or MOIST METAL GRIP ® forms a hard cast for exterior strength and moisture barrier to protect
HPC system. A final top-coat of SP LIQUID MEMBRANE ® should be added for impact resistance and to prevent stress cracks due to moment from elongation during heat cycle (two coats 20 mils wet/508 microns)

Cold Surface Applications with operating temperature under 150°C:

Apply a thin priming coat at 50 mils wet (1.25 mm) and allow to dry down by evaporation. Build desired thickness to the specified amount using several applications giving each coat time to mostly dry. (Approximately 4 hours at 70° (21°C). Curing can be enhanced by introduction of dehumidification and heat into the surrounding environment.

Manufacturing or OEM Applications: Please contact SPI office.

High-Heat System:
a) HPC applied over hot surface at thickness according to temperature level, b) RUST GRIP applied @ 150sf (145sm) for toughness, then c) SP LIQUID MEMBRANE for water/air seal plus rubber flex for movement. HPC® Coating must be completely dry before applying top coat.

CLEAN-UP EQUIPMENT
During breaks, spray systems should be flushed with water. After completion, spray systems should be flushed and cleaned with soap and water.

Storage of Product: Store HPC® COATING between 40°F (5°C) and 120°F (49°C)

The surfaces must be clean and dry before application. Loose or flaking old paints or corrosion must be removed from surface before applying. Surface must be clean of all residues and debris. Surfaces can be cleaned by power washing the surfaces ( SSPC - SP12 \ NACE No 5 ), sandblasted as a "brush off blast or sweep blast" ( SSPC - SP 7 \ NACE No 4 ), hand tool cleaned ( SSPC - SP 2 ) or power tool cleaned ( SSPC - SP 3 ).

 

FEATURES:

Percent Solid: 75% solids by volume
Weight 5 pounds per gallon 50.49% solids by weight
Dry Times: 5 - 10 minutes as primer at up to 80.2 mils WFT = 62.65 mils DFT @ 20 sq. ft. per gallon over hot surfaces then build up as needed. Allow 24 hours to set. Full dry by next day
Spread: 23 sq. ft. per gallon = 50 mils DFT as a primer coat
11.5 sq. ft. per gallon = 100 mils DFT as a build coat
5.75 sq. ft. per gallon = 200 mils DFT as a build coat
4.7 sq. ft. per gallon = 250 mils DFT as a build coat
pipe calculation
Elongation: 125%
pH 8.5 - 9.0
VOC 15 grams per liter USDA Approved

Surface Preparation for Temperature over 350°F / 176°C

Application Video

HPC COATING Graco Texspray RTX Application Video

Additional Videos

HPC COATING Gazprom Refinery in Omsk Application Video

HPC COATING Air Pot Application Video

HPC COATING Hopper gun Application Video

PRE-APPLICATION APPEARANCE AND PREPARATION OF HPC® COATING

QUESTION: After delivery and storage, the top of a pail of HPC Coating has swollen and expanded and appears too dry and chunky to use. Is it defective? What causes the swelling of the pail and the dryness?

HOT PIPE COATING HOT PIPE COATING

ANSWER: HPC® COATING is a water-based, ceramic coating and is delivered in a 5 gallon pail. After the pail is sealed and stored, HPC Coating will gradually absorb and dissipate its own water over time. Some air pressure is created in the pail during this process and may cause the top of the pail to expand and swell. This absorption/dissipation process is commonly known as rheology and does not harm or adversely affect the use or performance of the coating.

HOT PIPE COATINGHOT PIPE COATING

HPC - Before Mixing In Pail Early Stage During Mixing in Pail

Rheology occurs when a coating begins to set up because of non-activity. When the coating is stirred and water is added, the rheology allows the coating to relax and loosen and to return to its original consistency. After opening the pail, the top surface of HPC Coating may appear very dry and dusty with some cracking. As a result, the applicator may believe that HPC Coating idefective or too dry to use. This is not the case, and the appearance of HPC Coating will change dramatically upon proper mixing.

HOT PIPE COATING HOT PIPE COATING

Six Inch Dispersion Blade Six Inch Dispersion Blade

Stir HPC® COATING with a six inch (6”) diameter dispersion blade on a drill at a low to medium speed while adding water gradually. The coating will slowly return to a paste form as water is added during mixing. Continue to add water gradually while stirring until HPC® COATING becomes smooth, light, and fluffy and has the appearance of thick whipped cream. The amount of additional water that will be required will depend on the age of the coating and environmental conditions, but it can vary from one cup of added water to one to two quarts of added water. When properly mixed, HPC Coating will be a smooth paste that is wet to the touch and will adhere easily to the surface. It will not appear lumpy or dry when properly mixed.

HOT PIPE COATING HOT PIPE COATING

Late Stage During Mixing in Pail After Proper Mixing / Ready to Apply

Each pail of HPC® COATING must be mechanically stirred for at least three minutes just before spraying. It cannot be shaken or stirred by hand to reach the proper mix and texture.

HPC® COATING was designed to be sprayed using a conventional HOPPER GUN or a GRACO Texspray RTX 1000 - 1500 hopper feed texture sprayer. For small pipe, difficult access or small repair applications it can also be gloved or trowelled on.

 

HOT PIPE COATING - Applied by Trowel

Use a thickness gauge to check the wet thickness being applied. The number of coats and total thickness of the HPC® COATING will vary depending upon the desired results required and the application temperature ie. ambient temperature or operational temperature.

Whenever possible coat the entire surface one meter \ yard at a time. In the case of a pipe, start at the 12 o'clock position and spray a one meter length to the 6 o'clock position and then continue on the other side from the 12 o'clock to the 6 o'clock position for the same one meter length.

If a smoother surface for HPC® COATING is desired after application, use a wet, foam roller to lightly roll over the surface of the coating to obtain the desired smoothness.

OPERATIONAL APPLICATIONS - Applied directly to a surface temperature of between 200°F \ 93.3°C - 600°F \ 315.5°C. If the surface temperature exceeds 600°F \ 315.5°C and cannot be lowered within that range Contact Eagle for exact application instructions. Applications to a hot surface must be done with thin primer coats to steam the water out of each primer coat until the surface temperature settles down and stops doing the quick steam out of the coat -- usually two coats. Then the remaining mils WFT ( Wet Film Thickness ) can be applied to the required thickness needed. Allow to operate at the operational temperature overnight or for a couple of days and it is dry. This is multiple coat application.
NOTE - 1 mil = 1 thousandths of an inch 1/1000"
First apply a primer coat at 32 sf per gallon giving a thickness of 50 mils WFT or 38.5 mils DFT. Once the primer coats have finished steaming off, apply the desired mils WFT. Three nozzles are included with the machine and hopper gun. Use the small size ( 6mm ) nozzle. Adjust the airflow to the highest setting to start spraying the product onto the hot surface as the primer coat at 32 sf per gallon giving approximately 50 mils WFT or 38.5 mils DFT, to an in service heated pipe and allow to dry. This will only take a few minutes. Once the primer coat is complete, adjust the air pressure down to 60% - 75% to reduce the force of air and avoid blowing the product off while applying the build coat to the desired thickness. See Temperature Reduction Chart.

AMBIENT APPLICATIONS - Applied to a DRY non operating pipe or surface. Apply a primer coat at 32 sf per gallon giving a thickness of 50 mils WFT or 38.5 mils DFT. Allow the primer coat to set up for at least 8 hours @ 70°F \ 21°C. Then apply a build coat to the desired WFT.

NOTE : Allow each coat to dry between applications. Dry times will vary depending on the temperature of the sprayed surface. Applications done on non operational surfaces will need sufficient time to dry and firm up between coats. This time can be shortened by applying heat at 200°F \ 93.3°C and \ or air to speed the drying process. Apply heat for up to two weeks or as long as possible. All moisture must be evaporated from the coating before bringing the substrate to full operational temperature otherwise it may steam out causing bubbles and \ or knocking the coating off.

TOPCOATING REQUIREMENTS

If a durable protective finish is required because of the surrounding environment, such as physical, mechanical abuse or over pipes subject to vibration, apply as follows. After the last coat is applied but before it dries, wrap polyester or fiberglass mesh around the pipe with the edges slightly overlapping to provide complete coverage. Allow this to dry. Topcoat with SUPERTHERM ®.

For exterior applications subjected to WEATHERING apply SUPERTHERM ® at 9 m2 \ 95 f2 per gallon giving 16 mils WFT or 250 microns \ 10 mils DFT or SP LIQUID MEMBRANE ® Water based aliphatic polyurethane at 18 m2 \ 200 f2 per gallon at 8 mils WFT or 92.5 microns \ 3.22 mils DFT. Allow to dry and cure over night.

For resistance from CHEMICALS apply ENAMOGRIP ® Solvent ( White or Coloured ) or RUSTGRIP ® at 18 m2 \ 200 f2 per gallon at 8 mils WFT or 92.5 microns \ 3.7 mils DFT. Allow to dry and cure over night.

For applications with HIGH HUMIDITY or SUBMERGED UNDER WATER allow the HPC® COATING to dry then apply EPOXOTHERM ® at 9 m2 \ 100 f2 per gallon giving 16 mils WFT or 312.5 microns \ 12.5 mils DFT. The total system can be submerged under water in two days. The full cure for the EPOXOTHERM ® is 10 days but in two days it has cured enough to allow for submersion while it completes its curing cycle.

IMPORTANT:
Do not take internally. Avoid contact with eyes. If solution does come in contact with eyes, flush immediately with water and contact a physician for medical attention. Avoid prolonged contact with skin or breathing of spray mist. For quickest removal from skin, wash with water before drying. 

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