Petrochemical Application

Take a 3-D animated tour of the various aspects of a Petrochemical facility. See our step-by-step illustrations of how our products are applied to Piperacks, Vertical Vessel Skirts, Support Legs for Vertical Vessels, Horizontal Vessels and Sphere Legs.


The animations contained herein are not intended to replace a thorough understanding of Isolatek application guidelines. For further information on all application methods contact Isolatek International or one of our business partners.

”CAFCO FENDOLITE TG is mixed
then hand applied using common masonry tools.”

In order to obtain optimal results, the following spray equipment setup for the CAFCO® FENDOLITE® family of products on Industrial, Chemical and Petrochemical processing sites is required:

  • A rotor stator type, open throat, screw feed pump with minimum “No. 4” soft rubber stators.
  • Compressed air is required and must be delivered to the spray nozzle at a minimum volume of 15 cfm
    (420 L/min) and a minimum pressure of 50 psi (3.51 kg/cm2) for CAFCO FENDOLITE M-II and 70-100 psi
    (4.92-7.03 kg/cm2) for CAFCO FENDOLITE M-II/P.
  • A paddle or ribbon-type mortar mixer with a safety cover, rubber tipped blades and provision for quick dumping of mix directly into the pump hopper is recommended. Mixers with an 8 cu. ft. (227 liters) capacity or larger, capable of operating speeds of 35 to 40 RPM.
  • Screw-on type quick connect/disconnect couplings that do not restrict product flow are required.
  • The spray nozzle assembly must consist of a minimum 1 in. (25 mm) ID aluminum pole with a blow-off type nozzle cap, a nozzle orifice and valves for product and air control. Nozzle orifice must be nominal 1/2 in. diameter (13 mm).

CAFCO® FENDOLITE® TG is mixed and then hand applied using common masonry tools.

Metal lath - Expanded metal lath

Metal Lath

3.4 lbs. / sq. yard Diamond Metal Lath.

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Metal Lath Suppliers
ISOLATEK INTERNATIONAL
41 Furnace Street
Stanhope NJ 07874, USA
Tel: 1-800-631-9600
isolatek.com
3.4 lb/yd² (1.8 kg/m²) galvanized expanded metal lath.

corner bead- Industrial Fireproofing

Corner Bead

Plastic nose to provide smooth and sturdy edges.

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Corner Bead Suppliers
ISOLATEK INTERNATIONAL
41 Furnace Street
Stanhope NJ 07874, USA
Tel: 1-800-631-9600
isolatek.com
Plastic nosed, 2” open leg, wire corner bead

Galvanized Mesh

Galvanized Mesh

Plastic Coated Galvanized Hexagonal Mesh

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Galvanized Mesh Suppliers
ISOLATEK INTERNATIONAL
41 Furnace Street
Stanhope NJ 07874, USA
Tel: 1-800-631-9600
isolatek.com

Stainless Steel Pins

Stainless Steel Pins

Grade 316. Stainless steel mesh reinforcement pins

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Stainless Steel Pins Suppliers
ISOLATEK INTERNATIONAL
41 Furnace Street
Stanhope NJ 07874, USA
Tel: 1-800-631-9600
isolatek.com

spraymate60-thumb

Sprayer Equipment

Rotor stator type with open throat and screw feed.

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Spray-Equipment Manufacturers
Mayco/Essicks
18910 Wilmington Avenue
Carson, CA 90746, USA
Tel: 800-421-1244
FM9 #4 Rotor-Stator Pump (discontinued)
Mixer, EM90SH8, EM90PH8 (plastic drum)
8 cu. ft. (225 liters) paddle & ribbon mixers
Thomsen/ Putzmeister-United States
18620 So. Broadway
Gardena, CA 90248, USA
Tel: 213-321-8380
putzmeister.com
putzmeisteramerica.com
S5-EV (electric), S5-GH (gas)
Putzmeister-United Kingdom
Putzmeister Ltd.
Chesterfield Trading Estate
Carrwood Road
S41 9QB
Chesterfield Derbyshire
United Kingdom
+44 (0) 1246-264200
Putzmeister.co.uk
SP-11
Spray-King Mfg. Inc.
3535 North Duke Avenue
Fresno, CA 93727, USA
Tel: 800-448-5555 or 559-291-5586
spraykingmfg.com
#4, #6 rotor/stator pumps
Hydrolic Dump Over, P88 or D88, 200 HYD, 300 HYD,
TH14, Terminator Super 450
Strong Mfg.
P.O. Box 8068
Pine Bluff, AR 71611, USA
Tel: 800-238-5042 or 870-535-4753
strongmfg.com
#4, #6 rotor/stator pumps – Spraymate 60
Hyflex Corp.
8774 South State Road. 109
Knightstown, IN 46148 USA
Tel: 1 765-571-5125 or 1 866-849-6246
hyflexcorp.com
#4, #6 rotor/stator pumps
HZ-30E (electric), HZ-30G (gas), HZ-30DM (diesel)

View Distributors >

Spray-Equipment Distributors
The Donnelly Company
753 Rowley Road
Victor, New York 14564, USA
Tel: 800-624-3530 or 716-924-0640
Putzmeister, Mayco/Essicks, Hyflex, J&M Service Inc., Quickspray Inc., Stone Construction Equipment Inc., Construction Forms Inc.
Walker Equipment
3009 South Jackson Avenue
S. Chicago Heights, IL 60411, USA
Tel: 708-754-7070 or 800-227-7072
walker-equipment.com
Equipment rentals – Putzmeister (S5-EV or S5-GH)
Nathan Kimmel Company, LLC
1213 South Santa Fe Avenue
Los Angeles, CA 90021, USA
Tel: 800-431-0005 or 213-627-8556
nathankimmel.com
8 cu. ft. (225 liter) paddle & ribbon mixers
American Spray Technology, Hyflex, Multiquip, Putzmeister, QuickSpray Inc., Toro
Hardline Services Inc.
PO Box 2884
Fullerton CA 92837
717F S State College Blvd Fullerton CA. 92831

Tel: 657-217-0703
Tel: 657-217-5250
Cell: 714-357-8260
sales@hardlineservices.com

Putzmeister, Mayco, Graco, GFI pumps, BR Pumps, Neptune

Nozzles - Fendolite fire damage protection

Nozzles/ Guns

Minimum 1” ID aluminum pole to provide minimum volume of 15 cfm (420 L / min).

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Nozzles/Guns Suppliers
The Donnelly Company
1753 Rowley Road
Victor, New York 14564, USA
Tel: 800-624-3530 or 716-924-0640
Walker Equipment
13009 South Jackson Avenue
S. Chicago Heights, IL 60411, USA
Tel: 708-754-7070 or 800-227-7072
walker-equipment.com
Nathan Kimmel Company, LLC
1213 South Santa Fe Avenue
Los Angeles, CA 90021, USA
Tel: 800-431-0005 or 213-627-8556
nathankimmel.com

Hoses/ Couplings/ Reducers - Fire prevention system

Hoses/ Couplings/ Reducers

High pressure grout hose for plaster, grout and cement applications. Screw-on type quick connect/disconnect couplings which do not restrict product flow reducers.

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Hoses/ Couplings/ Reducers Suppliers
The Donnelly Company
753 Rowley Road
Victor, NY 14564, USA
Tel: 800-624-3530 or 716-924-0640
Parts/accessories – Goodyear Hoses and fittings.
Miscellaneous equipment
Walker Equipment
3009 South Jackson Avenue
S. Chicago Heights, IL 60411, USA
Tel: 708-754-7070 or 800-227-7072
walker-equipment.com
Parts/accessories – Goodyear Hoses and fittings.
Miscellaneous equipment
Nathan Kimmel Company, LLC
1213 South Santa Fe Avenue
Los Angeles, CA 90021, USA
Tel: 800-431-0005 or 213-627-8556
nathankimmel.com

Industrial Grade Fireproofing - Insulate steel structures

“Proper preparation of
substrates is important in providing adhesion and durability over time.”

Careful preparation of substrates is important. Correct preparation ensures that the durability of the fire protection system is maintained and the required level of adhesion is achieved. Poorly prepared substrates may compromise the long term corrosion protection to the structure. Where mechanical fixings are attached to the substrate, careful attention is required in order to reinstate the corrosion system after the fixings have been attached. It is required that the substrates are prepared in accordance with Isolatek’s written instructions.

The CAFCO® FENDOLITE® family of products does not cause corrosion to steel. However, for petrochemical environments, the steelwork must be suitably primed, painted or galvanized prior to the application of either of the CAFCO FENDOLITE systems. All primer/paint systems must be fully cured in accordance with the manufacturers’ application instructions.

The substrate to be protected with either of the CAFCO FENDOLITE systems must be prepared such that it is free from dirt, dust, oil or other contamination that would impair the adhesion of the CAFCO FENDOLITE M-II or M-II/P system. For applications where galvanized diamond lath is not used as a substrate, pre-existing protective primers and coatings must be sealed prior to the installation of the CAFCO FENDOLITE M-II or M-II/P system with ISOLATEK® SBK-113 sealer / keycoat.

For steelwork, such as pipe racks and steel saddles, galvanized diamond lath may be used. The lath is secured to the substrate in either a contour or boxed configuration in accordance with Isolatek’s application Instructions and design guidelines.

For certain applications, the reinforcement system for steel structures is plastic coated galvanized hexagonal mesh. The mesh is secured to the steel by use of stud welded, helical or powder actuated fasteners. The reinforcing mesh is held to the substrate at the fixing points, and then pulled away from the substrate to the middle third of the total thickness of the CAFCO FENDOLITE system, as it is being applied.

For storage vessels and spheres, galvanized diamond lath or the mesh retention system is installed such that no mechanical fixings are required to be attached to the substrate. The method of installation depends on the type and size of the vessel to be protected.

One of the CAFCO FENDOLITE products is then applied to the surface of the mechanical reinforced substrate in accordance with our written application instructions. Refer to our Application Techniques section for more details regarding the step by step processes to be used.

”A Maintenance program is essential to maintain the
integrity of a completely
installed fireproofing system.”

CAFCO® FENDOLITE® M-II & TG

Maintenance and Repair Procedures of the CAFCO® FENDOLITE® M-II and
CAFCO® FENDOLITE® TG System for Petrochemical Facilities – Short Form

Routine maintenance performed through testing and inspection of Spray-Applied Fire Resistive Materials (SFRMs) ensures that the product will be
in-place for its intended life cycle.

Petrochemical structures are continually exposed to severe environments. As a result, the fireproofing system is susceptible to damage caused by
items such as impact and weathering.

A Maintenance program is essential to maintain the integrity of a completely installed fireproofing system. The complete system consists of the steel substrate (i.e. galvanized or primed/coated), metal lath or mesh, anchoring system (i.e. shots, pins, studs and/or wire ties), the fireproofing material, along with the sealer/top coat (if required) and caulking system.

A complete survey of the fireproofing is needed in order to maintain the system and project future cost of the Maintenance Program.

The survey must be conducted by a N.A.C.E. Inspector with knowledge of the fireproofing system, and recommended and approved by Isolatek International.

The procedures outlined below are intended as a guide for conducting your maintenance program. The N.A.C.E. inspector will need a complete copy of the drawings (steel, equipment and support) for mark up, along with access to the project site. The drawings are to remain with owner and/or owner’s rep upon completion of survey.

The N.A.C.E. Inspector will divide the survey in segments (i.e. pipe rack, equipment, HCU unit, Alkyd unit, Diesel unit, etc.) so that all areas and units have their own cost / breakdown for tracking purposes.

1.0 INSPECTION

  • 1.1
    The N.A.C.E. Inspector will inspect and record on the drawings all areas of concern including but not limited to locations where:
    • Fireproofing system is damaged
    • Corner bead is damaged (if used)
    • Previous repaired areas
    • Delamination areas
    • Cracking
    • Mildew
    • Chemical stain/damage areas
    • Wet areas
    • Top coat/sealer failure
    • No caulk or improperly applied caulk
    • Areas that may have steam discharge onto the system
  • 1.2
    The N.A.C.E. Inspector shall submit to the owner and/or owners representative all of the drawings with the mark ups, along
    with a written procedure to complete all of the necessary repairs of the fireproofing system in accordance with Isolatek International’s guidelines.

2.0 DECISION

  • 2.1
    Inspector must ascertain which observed items require attention within the current maintenance cycle, based on one or both of the following criteria:
    • A repair (i.e. fissure or crack) which may allow moisture and chemical ingress / accumulation behind the fireproofing material.
    • Aesthetic appeal.

3.0 REPAIR

  • 3.1
    Termination Seal Delamination and/or Cracking.
    1. Strip away the old caulk to reveal the original surfaces. This must occur a minimum of 6 inches (150 mm) beyond the problem area in both directions.
    2. Re-apply an approved compatible caulk in its place.
  • 3.2
    Topcoat Failure
    1. Remove all peeling topcoat by adhering to SSPC-SP 2 (hand tool cleaning).
    2. Ensure surface is free from dust and other contaminants.
    3. Apply new approved topcoat.
  • 3.3
    Prior Repair or Patch Failure
    1. Remove existing/damaged patching material down to steel substrate/reinforcement, chamfering sharp edges to leave only sound material
      in place.
    2. Attach a new piece of 3.4 lb/yd² (1.84 kg/m2) expanded metal lath or mesh reinforcement into the void by either attaching to existing reinforcement via No. 18 SWG tie wire, or by attaching to the substrate via powder actuated fastener or studwelder. If hexagonal mesh is used in the original application, attach a new piece of plastic coated hexagonal mesh or mesh of 50mm x 50mm x 1.4mm – 1.6mm
      galvanized hexagonal mesh to the existing mesh using 18 SWG wire ties (or twist cut ends together) and maintain a 2 inch (50 mm) overlap at all joints.
    3. Position the new reinforcement within the middle third of fireproofing thickness.
    4. Pre-wet the existing CAFCO FENDOLITE M-II fireproofing material.
    5. Apply freshly mixed CAFCO® FENDOLITE® M-II or CAFCO® FENDOLITE® TG (Trowel Grade) material into the void, taking care to push the material behind the reinforcement and completely filling the void.
    6. Wait approximately 7 to 10 days before re-applying the approved topcoat (if necessary).
  • 3.4
    DAMAGE TO CORNER BEAD AND/OR OTHER REINFORCEMENT
    1. Cut away bent or broken corner bead, lath or mesh and strip away adjacent fireproofing a minimum of 6 inches (150 mm) beyond the repair area in all directions down to steel substrate / reinforcement and chamfer all sharp edges leaving only sound material in place.
    2. Attach a new piece of corner bead to the existing 3.4 lb/yd² (1.84 kg/m2 ) expanded metal lath using No. 18 SWG steel tie wire. If hexagonal mesh was used in the original application, attach a new piece as previously described in 3.3.2 above and ensure that it will lie in the mid third of the freshly applied repair thickness.
    3. Pre-wet the existing CAFCO FENDOLITE M-II fireproofing material surrounding the repair area.
    4. Apply freshly mixed CAFCO FENDOLITE M-II or CAFCO FENDOLITE TG, flush with surrounding/existing material.
    5. Wait approximately 7 to 10 days before re-applying approved topcoat (if necessary).
  • 3.5
    SIGNS OF RUSTING BEHIND FIREPROOFING (BLEED-THROUGH)
    1. Remove all CAFCO FENDOLITE M-II material to a minimum of a 12 inch (300 mm) radius around the problem area, down to the steel substrate/reinforcement.
    2. Observe rusting of surface of steel. In the case that the project inspector feels that the rusting goes beyond the exposed area, strip away the CAFCO FENDOLITE M-II until the rusting has ceased.
    3. Strip away existing reinforcement.
    4. Remove loose rust from the steel surface as per SSPC-SP 2/3 Hand and/or Power tool cleaning.
    5. Ensure that the area is free from loose mill scale, oils, dust, or other contaminants.
    6. Apply Epoxy Mastic/DTR or other approved surface tolerant epoxy to the surface. The coating must be compatible with the existing coating and the fireproofing material.
    7. Apply new reinforcement. Attached with powder actuated fastener or studwelder. Studwelds will require additional surface preparation (i.e. grinding down areas to bare metal, pinning, and final touch-up with Mastic/DTR or approved surface tolerant epoxy).
    8. Pre-wet the existing CAFCO FENDOLITE M-II fireproofing material surrounding the repair area.
    9. Apply freshly mixed CAFCO FENDOLITE M-II or CAFCO FENDOLITE TG, flush with surrounding/existing material.

The above-mentioned application procedure is applicable to structural steelwork in petrochemical and hydrocarbon processing facilities and shall be read in conjunction with the specific requirements of the client as detailed in any specification prepared for the project.

Unless directed to the contrary in the procedure, CAFCO FENDOLITE M-II must be stored, mixed, applied, controlled and repaired in accordance with
Isolatek International’s latest CAFCO FENDOLITE M-II, CAFCO FENDOLITE TG, CAFCO® FENDOLITE® M-II/P Application and Installation Manual.

Should you have further questions pertaining to this matter, please contact the Isolatek International Technical Service Department at 800.631.9600,
extension 269.

CAFCO® FENDOLITE® M-II/P

Maintenance and Repair Procedures of the CAFCO® FENDOLITE® M-II/P System for Petrochemical Facilities – Short Form

Routine maintenance performed Routine maintenance performed through testing and inspection of Spray-Applied Fire Resistive Materials (SFRMs) ensures that the product will be in-place for its intended life cycle.

Petrochemical structures are continually exposed to severe environments. As a result, the fireproofing system is susceptible to damage caused by items such as impact and weathering.

A Maintenance program is essential to maintain the integrity of a completely installed fireproofing system. The complete system consists of the steel substrate (i.e. galvanized or primed/coated), metal lath or mesh, anchoring system (i.e. shots, pins, studs and/or wire ties), the fireproofing material, along with the sealer/top coat (if required) and caulking system.

A complete survey of the fireproofing is needed in order to maintain the system and project future cost of the Maintenance Program.

The survey must be conducted by a N.A.C.E. Inspector with knowledge of the fireproofing system, and recommended and approved by Isolatek International.

The procedures outlined below are intended as a guide for conducting your maintenance program. The N.A.C.E. inspector will need a complete copy of the drawings (steel, equipment and support) for mark up, along with access to the project site. The drawings are to remain with owner and/or owner’s rep upon completion of survey.

The N.A.C.E. Inspector will divide the survey in segments (i.e. pipe rack, equipment, HCU unit, Alkyd unit, Diesel unit, etc.) so that all areas and units have their own cost / breakdown for tracking purposes.

1.0 INSPECTION

  • 1.1
    The N.A.C.E. Inspector will inspect and record on the drawings all areas of concern including but not limited to locations where:
    • Fireproofing system is damaged
    • Corner bead is damaged (if used)
    • Previous repaired areas
    • Delamination areas
    • Cracking
    • Mildew
    • Chemical stain/damage areas
    • Wet areas
    • Top coat/sealer failure
    • No caulk or improperly applied caulk
    • Areas that may have steam discharge onto the system
  • 1.2
    The N.A.C.E. Inspector shall submit to the owner and/or owners representative all of the drawings with the mark ups, along
    with a written procedure to complete all of the necessary repairs of the fireproofing system in accordance with Isolatek International’s guidelines.

2.0 DECISION

  • 2.1
    Inspector must ascertain which observed items require attention within the current maintenance cycle, based on one or both of the following criteria:
    • A repair (i.e. fissure or crack) which may allow moisture and chemical ingress / accumulation behind the fireproofing material.
    • Aesthetic appeal.

3.0 REPAIR

  • 3.1
    Termination Seal Delamination and/or Cracking.
    1. Strip away the old caulk to reveal the original surfaces. This must occur a minimum of 6 inches (150 mm) beyond the problem area in both directions.
    2. Re-apply an approved compatible caulk in its place.
  • 3.2
    Topcoat Failure
    1. Remove all peeling topcoat by adhering to SSPC-SP 2 (hand tool cleaning).
    2. Ensure surface is free from dust and other contaminants.
    3. Apply new approved topcoat.
  • 3.3
    Prior Repair or Patch Failure
    1. Remove existing/damaged patching material down to steel substrate/reinforcement, chamfering sharp edges to leave only sound material
      in place.
    2. Attach a new piece of 3.4 lb/yd² (1.84 kg/m2) expanded metal lath or mesh reinforcement into the void by either attaching to existing reinforcement via No. 18 SWG tie wire, or by attaching to the substrate via powder actuated fastener or studwelder. If hexagonal mesh is used in the original application, attach a new piece of plastic coated hexagonal mesh or mesh of 50mm x 50mm x 1.4mm – 1.6mm galvanized hexagonal mesh to the existing mesh using 18 SWG wire ties (or twist cut ends together) and maintain a 2 inch (50 mm) overlap at all joints.
    3. Position the new reinforcement within the middle third of fireproofing thickness.
    4. Pre-wet the existing CAFCO® FENDOLITE® M-II/P fireproofing material.
    5. Apply freshly mixed CAFCO FENDOLITE M-II/P material into the void, taking care to push the material behind the reinforcement and completely filling the void.
    6. Wait approximately 7 to 10 days before re-applying the approved topcoat (if necessary).
  • 3.4
    DAMAGE TO CORNER BEAD (IF USED) AND/OR OTHER REINFORCEMENT
    1. Cut away bent or broken corner bead, lath or mesh and strip away adjacent fireproofing a minimum of 6 inches (150 mm) beyond the repair area in all directions down to steel substrate / reinforcement and chamfer all sharp edges leaving only sound material in place.
    2. Attach a new piece of corner bead to the existing 3.4 lb/yd² (1.84 kg/m2) expanded metal lath using No. 18 SWG steel tie wire. If hexagonal mesh was used in the original application, attach a new piece as previously described in 3.3.2 above and ensure that it will lie in the mid third of the freshly applied repair thickness.
    3. Pre-wet the existing CAFCO FENDOLITE M-II/P fireproofing material surrounding the repair area.
    4. Apply freshly mixed CAFCO FENDOLITE M-II/P, flush with surrounding/existing material.
    5. Wait approximately 7 to 10 days before re-applying approved topcoat (if necessary).
  • 3.5
    SIGNS OF RUSTING BEHIND FIREPROOFING (BLEED-THROUGH)
    1. Remove all CAFCO FENDOLITE M-II/P material to a minimum of a 12 inch (300 mm) radius around the problem area, down to the steel substrate/reinforcement.
    2. Observe rusting of surface of steel. In the case that the project inspector feels that the rusting goes beyond the exposed area, strip away the CAFCO FENDOLITE M-II/P until the rusting has ceased.
    3. Strip away existing reinforcement.
    4. Remove loose rust from the steel surface as per SSPC-SP 2/3 Hand and/or Power tool cleaning.
    5. Ensure that the area is free from loose mill scale, oils, dust, or other contaminants.
    6. Apply Epoxy Mastic/DTR or other approved surface tolerant epoxy to the surface. The coating must be compatible with the existing coating and the fireproofing material.
    7. Apply new reinforcement. Attached with powder actuated fastener or studwelder. Studwelds will require additional surface preparation (i.e. grinding down areas to bare metal, pinning, and final touch-up with Mastic/DTR or approved surface tolerant epoxy).
    8. Pre-wet the existing CAFCO FENDOLITE M-II/P fireproofing material surrounding the repair area.
    9. Apply freshly mixed CAFCO FENDOLITE M-II/P, flush with surrounding/existing material.

The above-mentioned application procedure is applicable to structural steelwork in petrochemical and hydrocarbon processing facilities and shall be read in conjunction with the specific requirements of the client as detailed in any specification prepared for the project.

Unless directed to the contrary in the procedure, CAFCO FENDOLITE M-II/P must be stored, mixed, applied, controlled and repaired in accordance with Isolatek International’s latest CAFCO® FENDOLITE® M-II, CAFCO® FENDOLITE® TG, CAFCO FENDOLITE M-II/P Application and Installation Manual.

Should you have further questions pertaining to this matter, please contact the Isolatek International Technical Service Department at 800.631.9600, extension 269.

Quality Control Test Data Report (Form # C01A)

In order to provide a method for our customers to monitor and maintain product quality during installation, we have developed the Quality Control Test Data Report (Form # C01A). This method provides a summary of quality as the product is installed and allows means to address non-conformities. At the end of the project there is a record that the product and the installation have met all performance standards and fulfills the Quality Control in Application (Section 9.4) of the API 2218; Fireproofing Practices in Petroleum and Petrochemical Processing Plants. This minimizes future risk and gives applicators, engineers and architects the highest degree of confidence in their fire resistive system.