Pyrocrete® 241
Application Instructions
Substrates & Surface Preparation Application Equipment
Listed below are general equipment guidelines for the application of this
General Before applying Pyrocrete 241, the substrate product. Job site conditions may require modifications to these
coating must be free of all oil, grease, guidelines to achieve the desired results.
condensation, or other contamination. General Guidelines:
Steel Steel preparation before priming should be done Mixer Use a heavy-duty mortar mixer with rubber tipped
in accordance with the recommended primer’s blades that will scrape the sides and bottom of the
Product Data Sheet. mixer. A 50 lb. (22.7 kg.) bag of Pyrocrete 241
3 3
Carbon Steel Carbozinc 11
® typically requires a mixer volume of 8 ft. (.23 m )
®
Carboguard 888 minimum.
®
Carbozinc 11 VOC
® Pumps Mfg. Model Type Size
Carboguard 893
®
Rustbond Penetrating Sealer FM9, Rotor
Essick 2L4
FM5E Stator
Galvanized Normally not required, but may be required Dual
Steel under corrosive conditions. Use Carboline Mayco PF3
Piston
Rustbond Penetrating Sealer. Airtech Swinger Piston N/A
Non-Ferrous Aluminum, copper, etc. shall be primed with one Dual
Thomsen PTV 700 N/A
Metals coat of Carboline Rustbond Penetrating Sealer. Piston
Rotor
Concrete The primer recommended is Carboguard 1340.
® Putzmeister S5EV 2L6
Stator
Rotor
Sunspray 220 2L4
Stator
Lathing & Attachments (Where required) Rotor Super
2 2 Sunspray EZ88
3.4 lbs./yd (1.85 kg/m ) galvanized metal lath, may be pre-bent and Stator 2L6
tie-wired into place for appropriate design. Optionally, beam furring
clips or electrically welded, pneumatic or self-tapping screws or studs, Trowels Standard plasterers’ hawk and trowel may be
may be used. used. A rubber float may also aid in finishing.
A. Contour Design: 3.4 galvanized metal lath wrapped around the
flange edges toward the web approximately 1½” (3.8 cm). Contour Compressor Be certain that the air supply is a minimum 22 cfm
columns allow the use of chicken wire with beam furring clips as an at 100 psi (6.9 kPa) and higher when distances
alternate to the 3.4 metal lath. Please refer to design details. longer than 75’ (22 m) are required.
For contour applications on structural members with web span greater
than 16” (41 cm) or flange widths greater than 12” (31 cm) refer to the Material Line Minimum 1” (2.5 cm) I.D. hose with 300 psi
U.L. Fire Resistance Directory under “Coating Materials” section. minimum bursting pressure. For lengths over 50”
(15 m) use 1½” to 3” (3.8 to 7.6 cm) I.D. hose. Do
B. Boxed Design: 3.4 galvanized metal lath wrapped around not reduce hose diameter by more than ¼’ (7mm)
member spanning the web, overlapped 1” (2.5 cm) and tie-wired on the per 25’ (7.5 m) unless a tapered conical reducer
flange face 12” (31 cm) on center. For large webbed members, equipped with swivel fitting is used. A 10’ (3m)
additional support for lath may be needed for ease of installation. length of ¾” (1.9 cm) I.D. hose may be added at
Optional use of plastic-nose corner beads may be used for better the gun for use as a whip.
thickness control and aesthetics.
C. Tower Skirts and Flat Surfaces: Require that 3.4 galvanized Air line Use ½” (1.3 cm) I.D. line, with a minimum bursting
metal lath be anchored on 12” to 24” (31-61 cm) centers depending pressure of 100 psi (6.9 kPa).
upon requirements. The lath should overlap and be tie-wired. On tower
skirts only, PVC coated mesh can be used in lieu of 3.4 galvanized Spray Guns Mfg. Model Fluid Tip Air Cap
lath. Mesh shall be 2” x 2” 20 gauge wire coated with PVC as furnished Binks 7E2 47 or 49 3/8” or ½”
by Carboline. Graco 204000 167331 160658
3/8” – ½” 3/8” – ½”
When ram set or welding is prohibited; a pneumatic fastener may be SpeeFlo 701
(9 mm) (9 mm)
used. 3/8” – ½”
Plasterers NA N/A
On very large areas, control joints are made by scoring halfway (9 mm)
through the thickness of Pyrocrete 241. This is achieved by using the Internal
Air Tech 3/8” – ½” N/A
trowel blade edge or an appropriate scoring tool. A preferred option Mix
would be the use of plastic nosed corner beads. Spacing should be on
10’ (3 m) centers, both horizontally and vertically. Please refer to
design details.
August 2004 replaces March 2003 0148
To the best of our knowledge the technical data contained herein is true and accurate on the date of publication and is subject to change without prior notice. User must contact Carboline Company to
verify correctness before specifying or ordering. No guarantee of accuracy is given or implied. We guarantee our products to conform to Carboline quality control. We assume no responsibility for
coverage, performance or injuries resulting from use. Liability, if any, is limited to replacement of products. NO OTHER WARRANTY OR GUARANTEE OF ANY KIND IS MADE BY CARBOLINE,
EXPRESS OR IMPLIED, STATUTORY, BY OPERATION OF LAW, OR OTHERWISE, INCLUDING MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE. Carboline® and
PYROCRETE® are registered trademarks of Carboline Company.
Pyrocrete® 241
Mixing & Thinning Finishing
Mixing Add 4½ + ¾ gallons (17 + 3 liters) of clean, If a smooth finish is required, this may be done by trowel, roller or
potable water to a mortar mixer with rubber brush typically within 1 to 2 hours after final application of Pyrocrete
tipped blades. With mixer running slowly, add 241.
powder and mix for 5 minutes minimum (10
minutes maximum) until a homogeneous mortar-
like consistency is achieved. Total water must Protection of Adjacent Surfaces
not exceed 5¼ gallons (20 liters) per 50 lb. (22.7
kg) bag. In cool weather, warm water may be Finished surfaces shall be protected from damage and overspray.
used to enhance application. In hot weather, Encapsulation of aluminum electrical conduits is not recommended.
cool/cold water may be used.
Pot Life 2 hours at 70°F (21°C) and less at higher
Curing
temperatures. Pot life ends when the material
Fresh Pyrocrete 241 must be protected from rain or running water
thickens and becomes unusable.
for 24 hours at 70°F (21°C). In low humidity, high temperature,
Density
direct sun or wind, the Pyrocrete surface should be kept damp for at
Wet density measurements are critical to obtaining correct dry
least 12 hours by applying a water mist or wrapping in plastic
densities. Mixer wet density should be 74-80 lbs/ft3 ( 1.1 – 1.2 sheets to reduce rapid water loss.
g/cm3). To check wet densities, fill a Dixie cup (or other suitable Caution: Do not start work if ambient temperatures are expected to
container of known volume in ounces) with mixed material. Screed drop below 35°F (2°C) for 24 hours after application.
the excess until even with the rim of the container and weigh it on a
gram scale. Multiply the weight (in grams) by a conversion factor
based on the size of the container. (Conversion factor is calculated
Topcoating
by taking 2.107 and dividing by the ounces of the cup used). This
Seal Coat – In corrosive environments, use an appropriate topcoat. If
will yield density in lbs/ft3. topcoating is required, apply Carboguard 1340 as a seal coat.
Carboguard 1340 may be applied after 24 hours of final application of
Cup Used Conversion Cup Used Conversion Factor Pyrocrete 241. Consult the Carboguard 1340 Product Data Sheet for
Factor minimum and maximum cure times.
3 oz. .702 7 oz. .301
4 oz. .527 8 oz. .263 Top Coat – Surface hardness should be a minimum Shore D 40 as
5 oz. .421 12 oz. .175 measured with a Durometer prior to application of the topcoat.
6 oz. .351 16 oz. .132 Normally, this minimum dry time is 10 days at 70°F (21°C) and 40 days
at 40°F (4°C), for thickness of 1” (2.5 cm) or less.
Caulking – For exterior installations a compatible caulk should be
Application Procedures applied at all termination joints between Pyrocrete 241 and the
substrate. Contact Carboline Technical Service for full information.
Pyrocrete 241 may be applied by spray and/or trowel. Film build will
depend on application method, weather conditions and equipment
used. For application overhead, a scratch coat of up to ½” (1.3 cm) is Cleanup & Safety
recommended to key into the lath. Allow to set for approximately 1 to 2
hours at 70°F (21°C) before applying the subsequent coats. It is Cleanup Pump, mixer and hose should be cleaned with
recommended that the total required thickness be applied within a 24 clean, potable water at least once every 4 hours
hour period. If this is not possible, the preceding coats should be left at 70°F (21°C), and more often at higher
as sprayed or scored after the initial 24 hour period, Pyrocrete 241 temperatures. Sponges should be run through
should then be dampened with water before application of additional the hoses to remove residual material. Wet
coats. Pyrocrete 241 overspray must be cleaned up
• Maximum time to achieve the full thickness is 3 days at with soapy or clean, potable water. Cured
70°F (21°) and 50% relative humidity. This would be overspray may require chipping and/or scraping
less at higher temperatures. to remove.
• All additional coats are applied monolithically to the
entire perimeter of the member. Safety 1. Do not breathe dust. Pyrocrete 241 is caustic
• At no time shall Pyrocrete 241 be applied at a thickness and will irritate mucous membranes. Use OSHA
less than ¼” (7 mm) or “skim” coated. approved dust mask while mixing.
2. For eye contact, flush with copious amount of
water in accordance with OSHA instructions.
Goggles or safety glasses are recommended.
Application Conditions 3. Wash skin with clean water to prevent
irritation.
Surface or Relative
Ambient Temp. Humidity Caution Encapsulation of aluminum electrical conduit is
Minimum Maximum Min. Max. not recommended.
Interior or
40°F (4°C) 100°F (38°C) 0% 95%
Exterior
August 2004 replaces March 2003
To the best of our knowledge the technical data contained herein is true and accurate on the date of publication and is subject to change without prior notice. User must contact Carboline Company to
verify correctness before specifying or ordering. No guarantee of accuracy is given or implied. We guarantee our products to conform to Carboline quality control. We assume no responsibility for
coverage, performance or injuries resulting from use. Liability, if any, is limited to replacement of products. NO OTHER WARRANTY OR GUARANTEE OF ANY KIND IS MADE BY CARBOLINE,
EXPRESS OR IMPLIED, STATUTORY, BY OPERATION OF LAW, OR OTHERWISE, INCLUDING MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE. Carboline® and
PYROCRETE® are registered trademarks of Carboline Company.
