Brosteel Ultra 60 - NEW, IMPROVED formula!

Brosteel Ultra 60 is a revolutionary new thin-film waterborne white intumescent paint designed to provide 30 and 60 minutes fire resistance on standard, interior structural steel members. Its new, improved water-based formulation is quick drying and provides easy application - it can be applied by brush, roller or airless spray straight from the can.

Once a steel surface has been primed with a suitable anti-corrosive primer, Brosteel Ultra 60 can be applied. This quick drying, matt white, thin-film intumescent coating is a hugely popular fire resistant product for interior structural steel in the UK and provides 30 and 60 minutes fire resistance. Please download the product data sheets available from the 'Download' tab above for full details and/or contact Rawlins Paints' Technical Department on 0113 2455450 (option 2) or [email protected].

Generally Rust-Oleum 3369/3380 CombiPrimer Anti-Corrosion is recommended as a compatible primer for suitably prepared mild steel. Galvanised steel will require thorough degreasing to remove oils and must be completely dry, clean and free from any surface contamination prior to priming with Zinsser Bulls Eye 1-2-3.

Brosteel Ultra 60 can also be overcoated with its own range of Flameguard Ultra approved topcoats to provide a desired colour, finish and protection.

System packs available to protect suitably primed, standard Square, Rectangular and Circular hollow section steel, and standard ‘ɪ’ shape structural steel beams and columns, to 30 and 60 minute fire resistance

If you would like our Technical Team to calculate how much product you require for your project, please download and complete the 'Bollom Steelwork Form' and return by email to [email protected]

If you have any questions regarding this process consult our technical department on 0113 2455450 (option 2).

Features & Benefits

• New, improved formula
• Made with the professional painter and decorator in mind
• Provides 30 minutes fire protection in only one coat, 60 minutes can be achieved in two coats.*
• To be applied to suitably primed structural steel
• Simplicity - Simplified specification and simple application procedures.
• Cost effective - Due to its easy-to-apply, water-based formulation
• Brosteel Ultra 60 is a specialist water-based product that a competent contractor will find easy to apply. Application is by brush, roller or airless spray.
• Suitable for C1 and C2 environments.
• Certified - Certificates of Conformance and Installation can be supplied with every purchase.
• Refer below for details
• If a finish is required, either for decoration or protection against moisture Brosteel Ultra 60 can be overcoated with Bollom Flameguard Ultra Topcoats
• Fully fire tested BS476:Part 20/21:1987.
• Can be applied with a roller, brush or airless spray.
• Certain types of primers can cause adhesion problems and should be avoided:
• Chlorinated rubbers
• Bitumen
• Thermoplastic primers

Fire Protection Simplified

Brosteel Ultra 60 is designed to take the guesswork out of intumescent specification, the simplified formulation provides 30 minutes fire protection in only one coat - 60 minutes can be achieved in two coats.*

*Subject to the required film thickness being achieved.

Certification & Approval

Brosteel Ultra 60 Intumescent Paint for Structural Steel has been fully fire tested BS476:Part 20/21:1987, and Installation and Conformance Certificates are supplied with every correctly applied purchase upon request.

How to get Fire Certification

To obtain the completed certificates for a project customers should email [email protected] with the following details:

• Proof of purchase
• The contractors/applicators name and contact details (tel. no, email, address)
• Batch number(s) of product(s) used
• Site address

Product Specification

Note: The volume solids content of this material has been measured in accordance with the method laid down in ISO 3233: 1998.

Application

Coverage & Application Rates

Brosteel Ultra 60 is suitable for all types of structural steel, subject to the following minimum steel thicknesses:

Loadings based on steel section factor (Hp/A) of 300M -1 for UB & UC’s and 205M -1 for Hollow Sections and 130m -1 for Hollow Beam Sections

Loadings based on a critical temperature of 620˚C for horizontal I-section beams supporting a concrete slab, 550˚C for all other I-sections and 520˚C for all Hollow sections. The table below gives the recommended coverage rates in m 2 /litre and wet and dry film thicknesses (WFT & DFT).

Maximum Wet Film Thickness per coat: Brush/roller: 0.61mm. Airless spray: 1.0mm.

Check List

The following instructions are for on-site application only. For off- site application, refer to Tor Coatings/Rawlins Paints Technical

Ensure that:

• The primer is compatible with Brosteel Ultra 60 and has been applied correctly.
• The overcoating period for the primer has not been exceeded.
• The correct primer is used for galvanised steel.
• All damage to the primer has been repaired & re-primed.
• Site and weather conditions are within specification.
• Brosteel Ultra 60 is stored correctly.
• Surface is clean, dry and free from contamination.
• Correct spray equipment is available, if appropriate.
• Application instructions have been read prior to commencement of work.
• Ensure different basecoats are not applied on the same section of steel.
• Equipment should be clean and free from contaminants or dried material.
• Wet film gauges are available for use.

Surface Preparation

Brosteel Ultra 60 should be applied onto a clean, undamaged, dry and primed steel surface.

Certain types of primers can cause adhesion problems and should be avoided. These include:

• Chlorinated rubbers
• Bitumen
• Thermoplastic primers

Tor Coatings have carried out compatibility testing on a wide range of primers and can be contacted on +44 (0)191 410 6611 for confirmation of compatibility with Brosteel Ultra 60.

Galvanised surfaces should be prepared by an application of T-wash or mordant solution followed by a compatible non- saponifiable primer. The primer should be applied in accordance with the manufacturer’s instructions.

If a zinc rich primer is used, it is advisable to seal this with a suitable tie coat or travel coat prior to shipment to site. If the steel is left exposed to the atmosphere with just a zinc rich primer, surface salts may build up on the steel. These salts, if not adequately removed, may cause adhesion problems for any subsequent coating applied. Removal of the salts can be achieved by high- pressure washing.

If adequate removal of the salts cannot be guaranteed, a suitable tie coat may have to be applied prior to the application of the Brosteel Ultra 60. Tor Coatings should be consulted for technical advice when zinc rich primers or the overcoating of existing paints are specified for use.

Site Conditions During Application

Brosteel Ultra 60 is recommended for application and use on dry protected structural steel only. If the basecoat is allowed to get wet, it is likely to be damaged – blistering and wrinkling may occur. Brosteel Ultra 60 should only be applied when the air and steel temperatures are above 5°C. Relative humidity should be below 80% for successful application. Steel surface temperature should be a minimum of 3°C above the dew point. Ensure the steel is dry and free from contact with rain or condensation during the application and drying of Brosteel Ultra 60.

Application Methods

Brosteel Ultra 60 must be thoroughly mechanically stirred prior to use.

Airless Spraying:

Brosteel Ultra 60 may be applied up to a maximum wet film thickness (WFT) of 1.0mm in a single spray coat comprising of several quick passes. Achieving maximum loadings will depend on site conditions. Build up thickness to achieve loading required in several quick passes. It may be possible to apply two coats of Brosteel Ultra 60 in one day particularly if the atmospheric temperature is above 20°C and relative humidity below 70%. However, before doing this, ensure that the previously applied coat is dry, particularly in the web/flange junctions. The airless spray equipment recommended is a Graco King unit (or equivalent) with a pump ratio no less than 45:1.

• Operating Pressure: 2500 - 3000psi (175 - 210 kg/cm² )
• Tip Size: 17 - 21 thou
• Fan Angle: 20° - 40°
• Hose Diameter: 10mm (3/8”) (Internal Diameter)
• Hose Length: Max. 60 metres, in-line filters should not normally be used.

Brush/Roller Application:

For brush application use a “laying on” technique to avoid heavy brush marking. Maximum wet film per coat when applied using a brush or roller is 6.1mm. A short piled roller will produce a light textured finish.

Thickness Requirements

During application, measure the wet film thickness frequently with a WFT gauge to ensure the correct thickness is being applied. To use the gauge, insert the teeth into the wet basecoat. The last tooth to be coated indicates the wet film thickness achieved. In the event of over or under applications, adjustments to the loading rates of subsequent coats will be required.

Final Thickness Check

Take dry film thickness (DFT) readings as soon as the coating is sufficiently hard to allow a reading to be made without indenting the surface.

DFT’s may be taken using equipment such as a magnetic pull off gauge, electronic dry film gauge, or a measure of sample flake with Micrometer. Ensure that the DFT of the primer is deducted from the reading of the basecoat. Do not apply finish until the readings are in accordance with the specified thicknesses.

Application of Finish

Once DFT’s have been achieved as specified, a finish can be applied, either for decoration or protection against moisture. A range of finishes are available, please consult Tor Coatings for an approved list of finishes. Ensure the Brosteel Ultra 60 is completely dry before applying finish.

Maintenance

Damaged areas should be abraded back to a sound surface. The surface should then be clean and dry before re-applying. Once repaired finish should be re-applied.

Drying Times

Drying of Brosteel Ultra 60 is dependent upon a number of factors including:

• Temperature
• Air movement
• Humidity
• Method of Application
• Thickness of coating

High humidity and low air movement or low steel temperatures can result in condensation on the steelwork causing prolonged drying times and possibly poor basecoat adhesion.

Recoat Times In Hours

Indications of recoat or finishing times taking into account loading areas and application methods are given below:

• Hours per application (0.2mm wft) - Thin coat
• Hours per application (0.5mm wft) - Medium coat
• Hours per application (1.0mm wft) - Thick coat

*Wet Film Thickness

• Brushing or rollering adds about 20% to drying time (compared to spraying).
• Drying times are doubled at 5°C or at over 75% relative humidity.
• Final drying time before finishing is a minimum of 16 hours.
• These figures are based on constant conditions, fluctuations up or down will give variations to the drying time. If overnight condensation causes wetting a further full drying period should be allowed.

Storage

Brosteel Ultra 60 should be stored internally between 5°C and 30°C. Do not store below 5°C. At temperatures above 25°C, the shelf life will be reduced. Shelf life is normally 9 months in sealed containers (see Date of Manufacture).

IMPORTANT FIRE PRODUCTS NOTICE: The information displayed on this website should be used as a guide ONLY and our Technical Department should be contacted to obtain a tailored specification and any advice necessary before you place an order for fire protection products. Fire protection products are non-returnable except in accordance with Condition 8 of the Terms and Conditions and should be applied only by an individual with the necessary expertise and experience. We will not be held liable for any resulting damage to property, human life or monetary costs incurred due to the incorrect specification you have prepared or use of fire protection products caused by your negligence, including your failure to have contacted us to obtain the relevant advice/specification.