PLASITE® 4550

PRODUCT DESCRIPTION
PLASITE 4550 is a 100% solids, flake-filled reinforced, premium novolac PHYSICAL CHARACTERISTICS
epoxy coating for internal tank lining. It is applied using plural component
spray equipment, for a total thickness of 20-60 mils (500-1500 microns)
Tensile Strength……………………………..8,000 psi (ASTM D-638)
in a single coat application for a variety of applications. Its wide range of
chemical resistance properties makes it ideal for exposures where Flexural Strength…………………………..10,000 psi (ASTM D-790)
numerous aggressive chemicals are present. Plasite 4550 has been 6
tested in crude oil/water mixture up to 250°F with excellent results and
Flexural Modulus of Elasticity…….……7.8 psi x 10 (ASTM D-790)
would be an excellent candidate lining for these type applications. It has Hardness…………………………………...80(ASTM D-2240 Shore D)
outstanding adhesion to stainless steel, even with low blast profiles and
is well suited to protect alloy steels typically used in wet FGD systems
Weight per Mixed Gallon…………………………………………9.3 lbs
where pitting and crevice corrosion often occur. Depending on the Pot-life ……………………………..……..@ 35°F/2°C 30-40 minutes
application, the material can be placed into service within 36 hours.
………………………………………..…...@75°F/24°C: 15-25 minutes
USES/APPLICATIONS Cure Time (Approx.):
ƒ Chemical Storage Tanks Dry To Touch …………………………………. @ 35°F/2°C: 8 hours
ƒ Wastewater Clarifiers
@ 75°F/24°C: 6 hours
ƒ Plating Vats
ƒ Wet FGD Scrubbers and associated equipment Firm ……………………………………………. @ 35°F/2°C: 16 hours
ƒ Oil Storage Tanks and Process Equipment @ 75°F/24°C: 8 hours
ƒ Ethanol Storage Tanks Cure for Immersion Service (See Curing Section) (min 35°F)
PRODUCT ADVANTAGES Crude oil or aliphatic hydrocarbons .@ 35°F/2°C or above: 36 hours
ƒ High impact resistance All others: @ 35°F/2°C or above: 5 days
ƒ Superior adhesion to metal substrates and concrete
ƒ Fast-cure to service properties
ƒ Excellent resistance to a broad range of chemicals STORAGE CONDITIONS
Keep PLASITE 4550 products tightly sealed in their original containers
ƒ Can be applied in temperatures as low as 35°F
until ready for use. Store at 50-85°F/10-29°C, out of direct sunlight.
ƒ Can be applied as a one-coat system Properly stored, PLASITE 4550 products have a shelf life of 6 months.
CHEMICAL RESISTANCE
To ensure maximum film build (30 mils), material should be used within
PLASITE 4550 is resistant to a broad range of chemicals such as fuels, three months from date of manufacture. Proper jobsite storage of
salts, alkalis, strong inorganic acids, some solvents, and 98% sulfuric PLASITE 4550 is essential to its performance. Follow these general
acid. procedures for storage at the jobsite:

COLORS Store components (Part A and Part B) unopened, in a dry place, at 50-
PLASITE 4550 is offered in light gray, light blue, tile red and white. 85°F/10-29°C, out of direct sunlight, and protected from the elements.
Keep away from heat and flame.
FILM THICKNESS
Depends on service and existing substrate condition, PLASITE 4550 is For the 24-48 hours just prior to use, narrow the storage temperature to
typically applied at 20 mils in a single coat application. 70-85°F/21-29°C to facilitate ease of mixing.
PACKAGING
SURFACE PREPARATION
PLASITE 4550 is available in one, five and twenty gallon units.
Steel
1’s 5’s 20’s Immediately prior to application of the coating or, the steel substrate
Part A 1-gal 4-gals Four 4-gals must be clean of all oil, grease, dirt, dust, mill scale, rust, flash rust,
Part B 1-quart 1-gal One 4-gals corrosion products, salts, solvents, chlorides, other chemicals, and
existing coatings.
COVERAGE
One gallon of PLASITE 4550 will cover 1,604 mil sq. ft./gal or 80 sq. All welds must be smooth and continuous; no skip welds. All weld
ft./gal. at 20 mils. Jobsite conditions will affect material losses and splatter, buckshot, laminations, and slivers must be removed and ground
should be taken into account. smooth; undercuts and pinholes must be ground smooth and filled with
weld metal. All projections, sharp edges, high points and fillets must be
THINNERS ground smooth to a radius of at least 1/8 inch and all corners must be
No thinners are recommended for the application of PLASITE 4550. likewise rounded.
CLEANUP THINNER: Thinner #71 All pitting, gouges, scratches, and other defects must be repaired either
by welding or by filling with repair materials that are compatible with the
VOC CONTENT coating or lining system and suitable for the intended service conditions.
Coating as Supplied (Determined Theoretically)
All surfaces to be coated or lined must be readily accessible. The steel
lbs./gal. g/l
must be blasted to a minimum near White Metal Finish (NACE No. 2,
0 0
SSPC SP 10) with a 4 mil/100 microns dense, sharp anchor profile free
of peening, as measured by ASTM D 4417. For special applications
involving stainless steels used in wet FGD applications a minimum of 2
mils/50 microns dense angular anchor profile is acceptable.

March 2011 replaces September 2010 119P

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 Plasite® are registered
trademarks of Carboline Company.
PLASITE®4550
SURFACE PREPARATION GUIDELINES APPLICATION
Concrete Before mixing and applying any material, make sure environmental
Immediately prior to application of coating, concrete substrate must be: conditions are satisfactory for application. Weather conditions, and
ƒ Adequately cured (generally, at least 28 days; check with Carboline if especially dew point, should be constantly monitored in light of the
concrete has cured less than 28 days). work being done. Final blast cleaning and application of the lining
ƒ Structurally sound. system must only be performed when it is clear the temperature of
ƒ Free of all dirt, dust, debris, oil, grease, fats, chemical contamination, the steel substrate will not fall within 5°F/3°C of the dew point.
salts, solvents, surface hardeners, incompatible curing compounds Dehumidification and/or temperature control may be necessary to
and form release agents, laitance and efflorescence. meet this requirement. Use a surface thermometer to frequently
ƒ Concrete surface must be dry. monitor the temperature of the steel substrate.

And must have: EQUIPMENT

ƒ Tensile strength of at least 300 psi. Use a fixed ratio (4:1 by volume) plural component spray rig such
ƒ pH in the range of 7 to 11. as: Graco King Hydro-Cat (or equal) with heated hoppers, heated
ƒ All fins, projections and splatter removed. hoses to a mixer manifold through a static mixer to a 50 whip hose
ƒ All defects repaired using patching as described herein. followed by a silver gun (Binks 1M or equal) utilizing self-cleaning
ƒ Failed or otherwise incompatible old coatings removed. reverse “a” tips from 0.017 to 0.035 inches. See equipment
ƒ A surface texture similar to medium sandpaper (40 to 60 grit). specifications for more details.

Refer to Carboline’s separate document “Surface Preparation – Concrete” Note: The “A” side should be at a minimum of 110°F/43°C and
for further instruction in the preparation of concrete surfaces. the “B” side at 90-100°F/32-37°C. This will ensure proper
spraying of PLASITE 4550.
Locate all expansion joints, control joints, floor drains, equipment base
plates, and mid-floor termination points. Handle them as per Carboline’s Take care to prevent the mixed material from setting up in your
separate document “Construction Details”. hoses. For best results, keep your hoses as short as possible, purge
them immediately if work is interrupted, keep them out of direct
Degraded concrete on horizontal surfaces should be restored using sunlight and insulated from hot surfaces.
Carboguard 510 Concrete Repair Mortar or specified restoration materials.
APPLICATION
Honeycombs or any form voids in vertical surfaces must be filled. Use a MIXING
putty made with Carboguard 510 Concrete Repair Mortar. For touch-up only
We recommend using Jiffy type mixers for all mixing and stirring.
Concrete is a very porous material. As it warms during the day it expels air, When operating the mixer avoid plunging it up and down in the
or “outgases”. A coating applied while the concrete is outgassing likely will bucket. This can fold air into the resin, which may cause bubbles to
develop bubbles and pinholes. form in the coating after it has been applied.

To avoid this, the material should be applied when the temperature of the Individually stir each separate Part A and Part B component to a
concrete is falling. Usually this is from late afternoon into the night. Stop smooth, uniform consistency and color. Any sediment in the
applying the material well before dawn, so it has time to set up firm to the container must be thoroughly scraped up and redispersed.
touch before outgassing begins. This may be anywhere from 1 to 6 hours,
depending upon the weather conditions. In addition, it is a good idea to Spray
shade the work area from direct sunlight. Do not apply material when Immediately before applying a spray coat, stripe all continuous
temperature will fall within 5°F/3°C of the dew point. welds and edges with a brush-coat to assure adequate protection of
these areas.
Priming may be required in situations where outgassing could be a
problem. Consult Carboline for primer recommendations. All spray equipment should be clean and in proper working order.
Contact Technical Service for start-up and clean-up procedures.
Adjust pressure to 50-70 pounds and open the valves at the
manifold and purge materials at the spray gun. Attach spray tip and
MASKING & PROTECTION begin to spray. Dependent upon tip size, each pass will be 8-14
Mask or remove adjacent surfaces and equipment that are not to be lined. mil/200-350 microns per pass. Apply material to specified thickness
Once applied, PLASITE 4550 is difficult to remove. (for example: tank lining 35-40 mil/875-1000 microns, structural steel
15-20 mil/375-500 microns).
Protect nearby pumps, motors and other equipment from spent abrasive
venting from the tank during blasting. Apply criss-cross multi-passes, moving gun at a fairly rapid rate,
maintaining a wet appearing film. Use a wet film thickness gauge to
monitor film build.

CURING
PLASITE 4550 will be dry to the touch in 8 hours at 35°F/2°C or 6
hours at 75°F/24°C. The PLASITE lining will be ready for most
immersion service in 5 days at 35°F/2°C or above.

Note: Force curing (elevated temperature) may be desirable in

certain circumstances and can improve the performance with
particularly aggressive exposures. Check with Carboline Technical
Service Department.

March 2011 replaces September 2010

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 Plasite® are registered trademarks of Carboline Company.
 PLASITE® 4550
LINING REPAIR
Before any touch-up or recoat material can be applied, the first coat
must be properly prepared for intercoat adhesion. The first coat
must be cured firm to the touch. Coating on floors must be able to
support foot traffic. Scrub the first coat with soap and water and
thoroughly rinse and dry it. If the first coat cures more than 24-
hours, lightly sand or mechanically abrade the surface after
scrubbing it down with soap and water. Any surface to be touched
up or recoated should be protected. When the recoat material is
applied, the surface must be dry and free of all dirt, dust, debris, oil,
grease and other contamination.

INSPECTION
Degree of surface preparation shall conform to appropriate
specifications as outlined in SURFACE PREPARATION section.
Film thickness of each coat and total dry film thickness of the
coating system shall be determined with a non-destructive magnetic
gauge properly calibrated.

RECOMMENDATIONS
• Apply only on a clean, sound, properly prepared substrate.
• Minimum ambient and surface temperatures are 35°F/2°C
at the time of application.
• Maximum ambient and surface temperatures are
90°F/32°C at the time of application.
• Relative humidity should be between 0-85%.
• Substrate temperature should be 5°F/3°C above the dew
point.
• Application and curing times are dependent upon
ambient conditions. Consult Carboline’s Technical
Service Department if conditions are not within
recommended guidelines.

PRECAUTIONS
• PLASITE Thinner #71 is recommended for clean up of the
PLASITE 4550 material.
• Before handling and application of this material consult the
MSDS sheets. As with any product, those handling
PLASITE 4550 materials should employ proper safety
practice. Hypersensitive persons should wear protective
clothing, gloves, and use protective cream on any exposed
areas.
• When PLASITE 4550 is used as a tank lining or in an
enclosed area circulation should be used during and after
the installation. Circulation can be discontinued once the
material has cured. The ventilation equipment should be
capable of preventing the solvent concentration from
reaching the lower explosion level for the solvents used.
The applicator should monitor the exposure levels or use
MSHA/NIOSH approved air respirators.

NOTES
• Material Safety Data Sheets on PLASITE 4550 are available
upon request.
• Specific information regarding the chemical resistance of
PLASITE 4550 can be found by contacting Carboline’s
Technical Service Department.
• A staff of technical service engineers is available to assist
with product application, or to answer questions related to
Carboline products.
• Requests for technical literature or service can be made
through local sales representatives and offices worldwide.

March 2011 replaces September 2010

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 Plasite® are registered trademarks of Carboline Company.