Document 5bqyNXBYpN67wejVRrzk8n7y5

Monokote' Equipmenfand Efficient Application Procedures 04S0311* Index I Site and Project Pre-Planning Page 3 Mixer. Delivery & ApDhcation EauiDment Page 3-7 Pump Station Setup Page 7-8 Mixing Procedure Page 8 Start Up and Shut Down Page 8-9 Cold Weather Application Page 9 Job Records and Meeting Production Quotas Page 9 Fig 1 Dust Control Page 5 Fig. 2 High Production Conversion Kits Page 10 Fig. 3 Schematic Work Diagram Page ii The information contained within this brochure has been generated by fireproofing applicators for the specific purpose of maximizing profit potential through improvements in both equipment and methods of installation. Over the last decade fireproofing contractors have continued to improve, fine-tune and upgrade their operations. These improvements have resulted in higher pumping rates, lower pumping pressures, more efficient application equipment and higher profits when applying Monokote. This sixth revision to the Monokote Equipment and Efficient Application Procedures manual attempts to incorporate more than 10 years' worth of ideas into one place for the specific purpose of keeping production up and costs down. Before starting your next job. review the contents of this manual, compare its recommendations to your present job set-up. then upgrade wherever possible. Keep in mind that no single improvement will have a significant effect on your operation, but the combination of various recommendations can result m a more efficient and. therefore, more profitable job. Our joint efforts will help keep sprayed plaster fireproofing a viable and profitable business for the plastering industry. 2 Zonollte' Sales Offices ALABAMA ARIZONA ARKANSAS CALIFORNIA COLORADO FLORIDA GEORGIA ILLINOIS KENTUCKY LOUISIANA MARYLAND MASSACHUSETTS ORANGE COUNT-4 Santa ana SAN FRANCISCO OAKLAND JACKSONVILLE POMPANO BEACH TAMPA WINTER park ZELIWOOD CHICAGO W CHICAGO BOSTON MICHIGAN MINNESOTA MISSOURI NEBRASKA NEW JERSEY NEW YORK NORTH CAROLINA OHIO OKLAHOMA OREGON PENNSYLVANIA BOSTON SPRINGFIELD WORCESTER SYRACUSE NEW YORK CITY PITTSBURGH "h'LADELPh'A TENNESSEE TEXAS WASHINGTON WISCONSIN DALLAS HOUSTON SAN ANTONIO 04S03127 260i Commerce Bva ;ronaaie 35210 4223 West G'e'-'csa PC 3c '4273 ~ee~ * 85C53 "C 5oa 294 \c';n L"e ac: '2"5 >-33 = i? Avenue So-?*' Gale 90252 2503 Sour Gamsev Sfee* 3C 5c* 2503 3a-*a A~a 90 665: A^e^ue P0 Be* 2,? 9455? ''5 \-. Street 0'e~.e'5!00j E Agars St Jac-scnvuie 32202 `200 N W Pitteenrn Avenue Pcrca-'O Beac"1 33060 PO Box 5047 Yoor Staton Tampa 33605 225 Wes; Carton Ave $u te 1O1 W nter Parn 32'89 PO 3c< 759 Ze-;wooC 32798 6300 Button Gwinnett D've At'anta 30362 1580 N ;v Hwv Park a cce 60068 Fenton mcusna1 park 603 Fenton Lr w C?'Cago 60105 !i2 Norm St Wilder 41071 PO Box 10245 je^erscn 70i8i 12340 Conwav Rd . Be'tsviiie 20705 62 Whitterore Avenue Cambridge 02140 Wemeico Way. Easthamoton 01027 14300 Henn Avenue. Dearborn 48126 1720 Madison St N E . Minneapolis 55413 1705 Sulphur Avenue. St Louis 63110 3520 ' Street Omaha 63107 '2i5 ,.v.rgston Avenue Norm Brunswick C8902 PO 3cx 3i0 Weeosoort 13166 `215 Livingston Avenue. North Brunswick. NJ 08902 PO Box 008, High Point 27261 112 Ncrtr- St . Wilder. KY 41071 PO Box H402. Oklahoma City 73136 2303 N Haramg St. Portland 97227 202 E Cherry St. PO Box 2207 New Castle 16102 '2`5 L ^"cston Avenue Nrrr Bru^swc* NJ 08902 - f S -'CuSt' 2 - ' -*: T. " . - 4 4061 Powei' Avenue Nd5" e 3"2CA -O 3;* 225336 Da:'a= "5255 PO Box 7253 Heights Staton. Houston 77C03 PO Box 9114, San Antonio 78204 102C St SW PO Box A Auburn 96002 9C0 No'tn 43rd St. Milwaukee 53208 205: 956-9545 9C4- 555-343' 305; 954-5200 :3`3; 246-' 554 13C5 529-5657 '3C5-939-362' 1404i440-5880 3^2 6?4-3;44 ;312; 231-6660 :606i 29'-3500 5C4i 733-2934 1301 ] 953-2863 ;61 -71 376-1400 <171 (4 13i 527.1890 1313! 846-1010 1612) 789-8845 (3141 645-8780 '402i '31-3662 231; 528-5100 < 3151 334-6671 i20' i 828-5100 (9191 886-4807 (6061 291-3500 (405) 232-2133 15031 288-5195 4)2 55J-7-2! 4'2. 654.?'24 526-5*00 6'5 _95-3355 2'- 437-0900 "3; 564-2657 -5121 223-5781 ! 2061 852-5725 4*4; 344-6657 Canada ONTARIO ALBERTA BRITISH COLUMBIA MANITOBA QUEBEC WARTIMES Zonolite Processing Distributors MONTANA NEW VEX CO TEX A 3 UTAH CANADA 294 C events Road West Ajax LiS 3Co 583C Bu'Sanx Roao S c Caga'v T2m *Z2 u3i0-*23"3 Avenue Ec^o^fon T5i_ 2v5 - *6 '"wSmat Ave Vancouver V6A 233 * c Avenue W.m.oeg R3E `G6 255 eu Avenue La Sa< e *-*6R 3h4 e'-cusmai = . A^nue Da'--o-r N S 533 tw4 Roc *scn insulation Co PO Box 1419 t2r St a /pf Or Great ca>'s 59403 '.o-~ ?. r - -7 -0 ? v ! "i i-8. 683-3561 -C3 253-iC*3 -03< 454-4511 r 54- 669-4642 2*-' ~56-563l f ' - 1 366-3352 -69 9453 405 453 1291 04503126 Figure 3. Schematic Work Diagram <> ^4503126 Figure 3. Schematic Work Diagram * 1 04503i24 3. if a aram is used several minutes o: oean water should clear the nozzle before the Dump c shut oh Tnen close the ball valve and disconnect tne surge hose from he Dump Securer/ arm:.' * to a suitaoie aram Reopen tne vaive and bach `:usn the system as quicmv 3S ooss b e Caution: The surge hose must be securely anchored to prevent violent whipping action during back flushing. 4, if no aram pipe -s avarabie dirty 'water o collected on me spray floor m a 55 gaion arum Wnen clear water reacnes tne nozzle it should be collected m a second arum When the second drum is nearly full, snut oh tne pump and remove the nozzle. Place tne end of the scarfold nose m the first drum of dirty water Close the bail valve, connect-the surge nose to a suitable aram and reooen the bail valve The dirty water will be sucked back Pown througn the system emptying the first arum As the water level approaches the bottom of the arum quickly transfer the hose to the drum of clean water. This water >s sucked down, purging the entire system or old material and dirty water. 5. Never !eave water m the mces overworn S:"a- amounts or m.atenai settle out m emeus arc /: "a areas hue mater,a: sets overman: ce.us ng o ace a w rests cions me :o; cwmg oav 6. Sac*. hus^'.ng can oe acec oy ccn-ie-:- "a a" a source *c hie .vhm nose ana 'cre no :"e -'.ate' onctnroucr me system Tpe mc'easec speed c oac-. fiusnmg 3'ds m d'Sioagmg any mmainwg mazer.,a raz- ^usnmg securer; ancrcr the sw:e "cse -i s compressible ana w (> cause a strong ; m am me nose coenmc Worn crev.-s snowc -eeo cea- w surge nose during baCK riusning a: 7. The only time you should add retarder to your pumping operation is A) in the water used to prime the pump in the morning (this will minimize the potential for flash sets due to material build-up in hoses and fittings) and B) in the wash out water at night. It should not be necessary to add retarder to Monokote on the job site and is not recommended! VI. Cold Weather Application During winter, we occasionally receive bond strength complaints due to delamination of the fireproofing typically from the steel floor or roof deck. Three reasons why these problems occur m tne winter time are: 1. Steel temperature at the interface of Monokote and the steel deck may be at or below freezing Steel deck exposed to a 10F temperature overnight may take up to 2b hours to reach 40 :F 2. increased drying time Air absorbs and retains moisture m direct relation to the temperature The lower the temoerature tne smaller the quantity of water that can be absorbed by a given volume of air 3. Lack of adequate ventilation Once tne a/oecc"saturated the drymg process stops until the saturated is removed and recacea with fresh warm dry az Based on this ^formation our present Monokote application instructions are An az ana suostrate temoerature o; 40 W id r: be maintained *or 24 hours before and after ac;e ; of the fireproofing or until aaeauate drying has occurred This will depend on iob conditions : temperatures Provisions snai' oe maae 'or . e''; 'e.t'on w ary tne sreoroofmg afer 3cc caf-on m a/ww s area lacking natura> .'enwaro" 'orcea a c . z drying conditions should be ore. aec VII. Job Records and Meeting Production Quotas Experience is one of the best teachers and the best way to improve on experience is to record it A close count by the mixer man and foreman -- noting each aay s production and floor change -- is invaluable m checking ana improving production rates and quantity usage Keep a permanent log it will tell you each day if you re winning or losing. Determine the actual pumping rate by timing several consecutive batches at tne mixer Est'mafe oc w ' and set realistic average daily production ouoms Pumping rates that vary from 100 to 300 bags we with averages of less than 200 are often .no'caio' strong constructive on-ske management ;s nee: With close contractor coordnation-anc ebeef-c management most Monokote ioos average -n of 200 bags oer day ft Figur^^figt^roductior^onversionKits 0$$0312b * 3 A ' CSSS' ea 'emcc rg -"ater a so mat : ca~ ce accurate . c ?.cea Do not use air to ` blast'' the material to the steel. >so Or^3* , r^C . ? 3 `"3'' coss b'e conss?* see s^ou a ce as c.-. as a" aaeouate scra. ca:`er" e * e ruccer ze.c ~ ^ ^ a ~ s e.o ^ c.oa off if there s a nezze b oceage ~n.s s a sa'ety `eature and snoina not be oircum.ented bv t-gm > wr ng me cac to me 2j" '"e mcc-r cac . oe CC'^^SCtSC *C tP*9 ,-'633 0* *''3 3^.' ,^r, C '3 'r' S Cr0-0n*S 'OSS 0; C3C *' C O.'.-O*' OCC /S E. Scaffold A ro img scaffo'd must be bust to prowae stao i, ana sa;efy to me nozze man It $nou a ce easv -o c ea-' ana move Any strong 'ignt'.veign.t sca'fo'amg ^3. oe usea croviaea the `onowmg are -ncorporatec 1. Wnee's snouid be 8-12 men d ameter `cr secern easy movement so tnat spm.mg can cent -me men: interruption 2. Floor should be of the ooen grate tyce e^ canoed aluminum lath >s 'deal Th-s oermits mater.a; to hathrough the wa'kmg surface and prevents bu-.auD o- a shpoery layer underfoot. Plywood or wood o-acKS are ooor surfaces and inhibit smooth ,od operation 3. 3 mch side guards should oe oiaceo arounci tre edge of the scaf'oid floor to prevent tne sca"oio nose from slipping off the edge 4. Guard rails should be placed wa:st mgn ana mm y 21 - m r<a 3 '''djd 33 3 ^'-c 04503122 C*;;' 6. Put ogs as o~g as 22 u-ev . cant e\ereo sca"c a emr" oer"...... a .'i-. e-:er c scamoe cev"~ 3-a' m F. Tarps 'arc ng mater a cc-"cr-" m c: >. ye.:- - : c0n0 t 0:1 s For ;u-''-"er use `arcs cc-'"c.:m : coarse ; cerg ass screen am a. a ace ' : acoci vent at o~ a"0 C'C'"c:e e v . .0. "a a ' : streno;n neve cement in some a/ea? 3 - "mater a. may ce reou rec s.,cn as r as- c 1 - C Ctn G. Communication '.Vr>enever the nozz'e s out ?' s-cmr m *"e c ; t,ce o; commun cat on s essem a to ;ccr : w ana spra\er Wa^-e-ta'". es te'em'O'O' : r on o" -gnt are >. a uao e tcc-s in sc-"-' re s te eonone comoan-, w n$ta a c-c--' v-- 1 `ee Care snou a oe taKen se ect n : a - because ,00 eauement ana stee cc-'S'r . " nter'ere w-tn some maxes Var-abie sceeo control m3 , be aaciea ; Essick TM-30'wa the Tnomsen A-3'5 T,`- ; tne soray man -o adiList pump soeea con' " .vn-ie spraying HI. Pump Station Setup The entire working and storage area snou'd oe covered and protected from weather wnerever possible A. Pump Placement Place the pump as close as possible to the 3 -nch diameter standpipe This permits a snort surge rose to be utilized It is very important that the ground be high enough -o permit wash water to dram away `rom the pump base B. Mixer Place the mixer above the pump hopper it snou o be high enough to permit full rotation to the complete dump position C. Working Platform 1. Build a platform directly behind the mixer so tnat the mixer man s waist is level with the top edge of tne mixer. It should be large enough to hold at least 20 bags o' Mcncmc'-'- E sae o: 'na - -e-no..... tne a-'-.i -eoc c a" --: c 2. Tne storage area snou a ce arge e-'o-u c 600-1000 oags c l.'o 'o-ote or 3 er ao: T5 !eet 'ong 3. Tne storaqe am-a ce-:c, re::.": protected ;rom m - .ma cr cans" .-c' sm -c- ` must oe stored to r,revem an-, cc-n`ac` c tne `ioor 4. Pallets mane exce-er" s'omoe caseMonokote oti unpro:ecea'mo-i-'-i a i,<y- snoca be placed -.mae' n,a e?s a-':: a sc stackea bags 'p-s pre.ents gmuna n-o v damaging tne lowest :eve of cage Tne yc -. : snouia be immeaiate-y aaiacent to tne :.re- : c-aform 5. Keep an inventory o' at mast c-e aa, ; : Monokote to cover any une/pectea oe .er. : i D. Multiple Pump Setups On i^rge :oos a 'C ier conveyor hems 'c- `eea ma:er a out o' a van ana ac.vn-e me o' mwem Tnrge cumcs 045^t23 . n 0 ^3,^; ^ ~ - --- IV. Mixing Procedure A umform mix cons'Sie^c,- 5 essem^ *c m am'sin a nign croauction m-xingipumoing oceraton To cotam tne orooer density isee mixing instructions on ;ne oac* ot me bag) fciiow tms procedure 1. Set mixer sDeeo between 30-40 RPM 2. VVitn b]aaes turning aad water ('apcrox-matei / 28-32 galions-3 cag batch) 3. Turn mixer o'f anb clean mixer biaaes 4. Aao two bags of Monokote 5. Restart mixer aaa a third bag and mix for aoproximately 30 seconds. The mix will initially loo* dry and will gradually cream out The mix is usually correct if it ,s stopped just as the ' grainy look oegms to disabDear 6. Stoo mixer and check the material for density if not within the recommended tolerance stated on tne back of tne bag restart mixer and adjust density by varying the mixing time, amount of mixing water and'Or SDeed of the blades (a longer mixing time or increased mixing speed will lower the density level additional water will increase the mixer density) Once a nixing procedure is determined, subsequent mixes will give similar results and this step need not be repeated 7. Restart mixer (3-5 seconds) then dump entire batch into the pump hopper The mixer must empty completely when dumped to avoid leaving any old mix to be re-worked in the succeeding batch Notes 2. iVa-r v-mi enougn ~fa:ena> nas cee" cm'-c me nccoer to avow so'nc er: rzc~ m- --e aoc gr anr:re> C'3tCr ir0'rv~ '^6 3. If tne cu'-p hopper .mi npt ta*e an ew m c s:co me m.xer until tne remaining mater.a; Restart tne mixer tor 2 to 3 seconas ana w remammg material 4. Do not ;e' me pump suc' a<r 5. For maximum yield and minimal cacK as much water as possiDie. consistent wtn cr hangabihty Tne water ratio rs correct w n~ than 5/3 men of Monoxcte can be hung j Pare flat steel This will allow approximate buiio-up on beam flanges V. Start Up and Shut Down A. Start Up 1. Nozzle should be detached from the whip hose at the swivel or nozzle snut-off valve. 2. Add about ten gallons of slightly retarded water to the mixer with the biaaes turning. Then dump water mto the pump hopoer 3. Prepare the first Monokote mix ana start tne pumo Dump mix into the Dump hopper when the last of the retarded water enters the pump intake 4. Continue pumping until a small amount of Monokote appears at the end of the open hose. Connect nozz'e and start production B. Shut Down Procedure ''borough wasn out :s necessarv to creven* --a setting ana accumulating n smews arc at _w : 1. After the last mix has cearea tne "'ooce' snould be siowea ana "eavw -etaraea ..ater c through the system a sconge can aisc ce cu~ through the system if a sconge s to be usee nose ana nose reducers must ' rst be ` usrea a disconnected A large sconge couia ciug tne s wnen reaenmg this area 2. Dirty water can be pumped mto a amm c c collected m a 55 gallon arum on tne f'oor Figure 1. Dust Control tor Plaster Mixers ' iXOlhJH. 04503120 One version o' thm meter can be pre-set to shut off amomaticai'y when a oreaetermnned number of gallons has oee.n delivered VVnere ic.v oressure is a prob!em .nstan a smaii centr ruga! pump in the 'me of the meter This boosts water pressure ana flow rate 3. Quick Fill Tanks Gunck til! tanks must hoid at least 36 gallons o` water ana should be eauuooea witn =.niet shutoffs `or accurate 'water measurements I met mater must be snut of' wnne tne tank s dumping Recovery rate of tms system s o'ten s;ow ana depends upon miet water pressure ana nose diameter Precise water measurement is diwcuo 4. The 'S-Gallon Bucket" Method This method is not recommended Usually tne m^er man tires eariy in the day resulting m a reducea production rate and inconsistent mix unrormity The area around the mixer often becomes a mud ^o'e due to sobed or overflowed water resulting m damage to surrounding materia! Again, this method is specifically NOT recommended. D. Conveying Equipment can omv ce assume: ' a scan s,'oc,r .-.a : system Drag sr'cu :: fee " .test rmo : o' as unnecessarv re?mct:cns arm: oenas ^oss- edges tor-ms'er-a c-u cur For distance or ro smooth-wanea 3 .-c:' aiom-n.-m o :m c a mm- AH convevng eqummem sreu'd be cnec-eo for e*cess wear or ::ete-r mater Cor .o. -w : : snouia be "'Stems: n -; or. r-a vr-wm m-m 3'i cumc o'an `c:d.---------- os-re; , tmessi.ro- v'3:v'6 ~ -------- ^i ,00r 1 3 PC'" - nose---------- ^3 'nc^ oa .a ve ---------- n ai,jO'"nijn conau *------- non. 2 :ncr ; 1 Op>gr nrep 1 acer90 r0r:oCO'-- '.vn-c nose---------- a.vi.e1-----------r, - vaice-------------- -- scrav gon--------------- o': ce ; ~z") vVnen setong oc. cnoco ;C'r 'ea^s c,- onn'n water tnreugn me system Te`!on taoe or erne s an tnreaded unions ne!os seal me system men corrosive lock-ub ana prevent damage ro awm tnreaas 1. Safety/Pressure Release Valve ~r-e 03'i ana sea: srcco ce c'ec-ec 2rz regret r2Cl2'3riV ^^6 r~-3233 Or253:Jre ShCu'C 02 3d,uSt60 accorcmg ;g co~c ~ammacfurer 3 reccmmensafons 30.3 shou!o ce ccns.srem .vth rated ^rnor Q ^ .j -5- g / S * G1 cassures 2. Bell Reducers (2" x 3") (1 '/2" x 2") (1 Va" x 1 v*") Z^o-. .^arc ,7*^;; po 0* CC^'CS1 v5O0rGG `',00 .,.,Tr' w>t0'T-3i rr.^acs c : q-.\c ?no ,:00 C* *0'v'S'6 $ eeves s^.c/or ^g^G'.g $/. .-0 " ^gs 3 3. 3** 000 r23oc2rs are ,vGe-v jsea w trout crooie-^s Black iron plumbing fittings are unacceptable because severe material buildup often occurs, restricting material flow and causing premature material set. 3. Surge Hose The surge nose snouia be 3 men m.nir^jr * 300 DS; worxmg cressure w-ire-Praiaed ease Connect mose cirectiy to toe reducer c.n toe pump T grout'd cess spua ana 1 ttmg ^e'd wtn a ooit-on came Surge nose snouid oe 3S snort as possible laporowmatew 25 teet) 4. Ball Valve A 3 men (approximately 23-> mches full ;iovvi starless bail vaive snouia be used to permit urrestnetea "o.'. of material from tne surge nose into tne aluminum s ee 5. Elbow Eicov/s should be long radius 3 men inside diameter r gid aiummum pme with no angle less tnan 90 degrees. Tne msiae diameter of the elbow snouid be tne same as the standpipe 6. Standpipe a 3 inch rigid aluminum pipe is the only pipe recommended for Monokote application. b T,ght lean-tree pme unions may be obtained by using tun-taper threaded galvanized steei pipe couplings- grouna umons or victauiic couD'mgs to ;om tne fO toot lengths of pipe Do not use standard, straight-thread conduit couplings often sold with electrical conduit. They will leak, c Vertical ana nonzontai pipe must be wen anenorea ana suooorted to prevent movement due to pump surge Spot-weia damps to beams and columns 'or secure attachment Repeated flexing of aluminum pipe -.v111 cause metal 'atigue and pipe breakage a Horizontal pipe snouid be siooed so tnat .-.asn cut water drams weeiv and completely aurmg oac* "usning 7. Floor Hose a Rubber-reinforced 2 men high-pressure `acrebraided piaster nose with full flow `ittmgs w-mcn present as little restriction as oossibie to material "ow sreed ce used b Pressure-rated fittings snouid be compat cne .-. m rated nose pressure and should be checKeo regu.ar.v for wear or damage A double female swivei .-ictau c coupling or other aevice is recommenoed to a a m making ana breaking hose junctions without t.vs: ng the entire nose 04503421 8. Whip Hose ^3 2CC2 : me sc?."c c Length of 1 v4 inch whip should not exceed 20 feet. The total whip (if 112 inch and 1 v4 inch hose are used) should not exceed 50 ft. 9. Gun ';-3 `-recrOCmO 300 S 3'C2'2n! -n crampeo SC 232:.rara tne stanoard gun s toe cumbersome ' PC'S guns should oe useo wen caution w'-ee r'a,;or areas o; concern are overspray m cness centre: arc proper application to me tecs c '"3 pot'om Ganges ot ceams Tnougn net 'ecc-"-"3-cec a sceca- gun with a croon -n me sna-: :.r cr a --s "'2 nocz e down on tne toe of tne cottom -arge "as seen used .vtn some success Witn tms method two passes are made Use the special cent nozzie to ce a: 'oo :anges m a given -yea Make a secona pass w m -e stanoara nozzle i` "ecessary to finish me .-.or- -"a-3 a th'ro pass using 3 scaffoio and stanaaro sren 'eacr spray gun increased material usage rate must be coseiv monitored and balanced agamst an,- ?.ccsavings d L gntwe'gnt nezz e-snutc" car v a-. es ?/e avanaDie wmen s'orv canry reduce ovempra-. a-a waste When nozzle shutoffs are used, be extremely careful not to start the machine with the valve closed. The machine on/off switch should be located at the nozzle and must be in perfect working order. 10. Nozzle and Spray Adjustments 3 Tin0 n0J0 0 SHQl. 0 . 0 3 '0C0530O d'TrV ' :rp ' 00 5 C0n',3r*:iG -* J ;'Cr' 0' 'C- S '0CG:^^e:'jea 'or :-g icc ca* c-'s :r0* GrOGl.Ct Gr> ra*e irG0r 'r0 r0G'j r0G ' 00 r An air control valve and movable air stem are absolutely essential. ' e a2 stem mus- ce mcdugmy ceaneo a-.o glased oar, to pre.e-weeze-up 0 r'n0 g r d ^ r * 'jj y- m ~00'0 ""'r'0 a ' -- 0j m p aC0 `r~' screw if-"ust ce easw. amusrap.e dur-ng -u cpr- r : c `"3 s.stem s!e.r- s-'-ou'd be as ~ar cac- as P0SS03 consistent w tn 3 good 'am-mg ac cn con"cmat.on c` air pressure ano stem pose on create a -cw `rsauenc, cuzz ng sounc a n g requenc> oecn namates ^crocer aa.ustment 6 r?il'x.-. I. Site and Project Planning 04503118 Pre-setup Planning 1. Review the specifications and drawings and be sure the general contractor and inspectors nave the same interpretation as you do 2. Arrange with the general contractor's representative to meet and walk tne site to establish the location of your permanent pumping station a Select a primary and an alternative setup location Where possible, pump up the outside or through me core of the building from a single site During tne winter, the core will provide some heat ana neic prevent line freeze-up. b. Be sure of adequate space for unloading and handling of material for the duration of the |0b Space and access routes often change as the oroiect progresses c. Find a water source with adequate volume and pressure. Also check on washout procedure and local water regulations. For example, a settling tanK may be required 3. Determine if any protection for interior surfaces is required. 4. Check to see if tarps are necessary for overspray protection outside the building, 5. With the general contractor, carefully plan the means for maintaining proper temperature and ventilation for your phase of the work m all weather conqitions 6. 3e certain steei and concrete are reasonably c can ;or proper MonoKOte application Remove loose -..or mill scale with a Duriao rag neavy Prusn or mgr pressure compressea air Oil on steel or concrete snouid be removea with msodium pnospnate or omer cleaners On concrete, check close:-/ for form ons ana curing compounds 7. Arrange your application scneauie with the ob superintendent a Insist that you be on the floor as soon as tne concrete is poured but before plumbing ana sheet metal work have begun WorKing around obstacles such as stacked wall board pipes and nanging ducts can cut your application rate in half and drastically increase labor costs and material waste. b When fireproofing steel roof decks, tne roo: system (insulation and membrane) must be complete ana watertight All roof traffic must be prohibited during and after Monokote application until the fireproofing has dried and full bond strength is attained Items 7a & 7b Should be included in your bid and production commitment Tell the superintendent that clear work areas mean you will be out of his wav a lot faster II. Mixer, Delivery & Application Equipment Select a pump with a production capacity wen above the desired daily average. Large 30 HP pumps nave performed at heights m excess of 50 stories The delivery system greatly affects pumping rate Study the conveying equipment and system information in section I ID and in Figure 3 at the oacK o; this manual Establish a routine preventive maintenance program on all equipment 1. Pressure release valves should be kept mean and in good working order, 2. Any equipment abnormality -- such as a new noise, uneven surge, etc. -- should be cnec-ea immediately Waiting until something makimc' " ; could result in a system plugged with set mate' 3. Install time clocks to measure machine mm' ug time. These provide an accurate gauge on wr cn 'c base routine maintenance and evaluate iaocr efficiency. The single most -mocham aeveiooment m the application of Mono-ote nas been the mtroauct-or of nigh production ccm.ersion Kits These kits are avanaoie from Thcmsen EauiDment ana ;rom Ess.c* Manufacturing Co mg or.ncoa1 benefit is tne reauction, of aeaa space at tne end of the p'Ston stroke. These kgs :ai dramatically increase Dumping rates, (b) make comps :ess sensitive to overmixmg. ana (c) enable s;-"er m,<es to be pumpec at higher rates The latter enao.es tmcker scratch coats resulting n fewer passes Labor savings impugn npreased pump efficiency w:ti pay for the kits n a snort t-me Specific pumps and then corresponding conversion Kits are aiscussea be'ow A. Pumps 1. Essick TM-30 A very high volume pump which should be fitted with a high production conversion kit, 8-mch diameter mghproduction pulley and urethane or steel balls Tne Essie* TM-3G ccn.-emc-n -m (see ^ give 2! cons o: oistcn e/tencers ana -ea., carero "ant ;c.e'S ; 5! jcc 6 T'6'"3 " ' 3 3 .'6^S 0 3 ,/0 i3S0'"1 3C3!0C '3 use me stanaara me; oa: stop pm wr.e -reau 0a1,'.'ave: A!ier ^ a * a1: ^ g re conversion *: -e-c.-e :ra j3'j,'TC *3 0 300 rC`3f0 f00 Ou^C C . 30.3 :r01jqt, 03^ 3O^C'0:0 3v'C'0 sO 00 ^jr*2* rr5i 'r0r0 -v -- 00 03'3!,3t:On 00rOr3 700-r0 0~j$* 00 3 03r3~C0 O0``.V060 !00 000 3` r~0 0 5*00 0*[00'Cj0r 3n0 `00 : 0 3* roe '0:0* can s:oc 0-0 a: *00 00a o* *00 0 s:c~ 303-0 Caution: Due to increased efficiency, it will be necessary to slow the pump down to avoid overloading the nozzle. Do not over stiffen the mix, as excessive pressures and low yield will result. Tag 3-mcn cmiey replaces me stanaara (C- nc- ou e, installed on the transmission outout shag 7.'.m the e-ngme turning at a ma^mum ;2 600 romi me 3-mcn DuM'ey turns the Dump at acoroximateiy `30 rcm - a 40: increase over the Stanaara 10-mcn cuney Steei bails and soeoai steel seats nave oeen successfully Substituted `or tne top three 13i bans amc seats Since the 'od seats are the oressure sea's contmuai reolacement of uretnane bails -s ec--matea Electric motors and aiesei engines nave aisc been successful1'/ substituted for tne stanaara 30 fiP gas engines Proauction rates m excess of i bag,minute ;420 bags, 7 hours) are possible 2. Thomsen A-3.75 The A-3 75 is another nigh volume Dump wnicn snou'C be fitted with steel Palis and a nign production *' Seat woe must oe that soecifiea for use with stee' bails isee Thomsen Builetm *23) The steel ball and seat assembly require much !ess maintenance ana oumo Monokote more efficiently man tne correspcnamg plastic ball/seat combmat'on T.-.e Thomsen A-3 75 conversion kit (see Figure 2) consists of a plug 'or tne manifold, the Thomsen Marvel and an uocer ban stop pin that spreaas me snocK of tne bans moact over the entire length o: me Din reducing pin breakage The Marvel !S installed by (1) removing the oumc housing (2) removing and discarding the '0'.\er na stoo (socket read cao screw and sieevei (3i mac ng me oiug m the mousing with the flat surface aov.n 4; threading the ooit provided through the noie n me housing where me bail stop pm was removed i5i tightening me bon ana (6) remounting me Dump manifoia With tnese modifications the oumc cutpu1 often exceeds the advertised 33-o increase ana can aoDroach 420 bags,7 hours Vanous Thomsen distributors have taken t uccn memseives to moony tne model A-3 75 oumc m diesel engines 3 men mannoids over-seed 0'Sicri ana other improvements For specific information on the location of these distributors contact your Zonolite sales representame 4 3. Essick MG-30 B. Mixers 1. Choosing a Mixer "-e-sen Mode, t`0 Esse- Mcce-s '20 a-a '5' ,\Ver Mode's '0 ana '2CF are e/ce e-- - Mc-o*ote ana meet me accve cme' a Rotatespeeds oet.veen 30-40 RPM are most e~ c en '-c-acn-ng prooer aens.ty ana mv ccns-s'e-c . . - ; rucber .veer Diaaes where avauace 2. Dust Control for Plaster Mixers in oraer to central nu'sance oust >n p.aste' -- areas c`aster mixers sroua oe `nteo .. -- - m Dust Covers (Patent No 4 2'f 491) sue--a; : !:ustraiea vn F-gure 1 nave lowered oust e-. e 5 general mixing areas aiiowmg men ana ea c perform :.n a cleaner nealthier environment 4- y._; aavantage -s rec-.cea engine mamtenance rem.' rcm e'eaner air gas ana oil f-ners Far more mtormat on on .00 s-te OCera'-C'S .v'- ' cover contact ycur local Zone: te sa-es reerese-' v C. Water Measuring De vices --e casc 'eau remen's a --e!er - 0 s. c-y- : - cceea c* ae; .erv a-a me ac *. ; ece?.'-?:: . : pre-set amount o' w ate' A asn 00.'.- a-wavs ce usea ,n con unct c-' .-. -- a . vs....... per-- ts cean-xg c '-e - -c ?.-n ' - e v- .-c oaten-to-baten mix cons ste-cy 1. Timed Sump Pump Meters Timed sump pump systems are the best water delivery methods available. Tnese systems ut ce 3 eo" : 3 . -n :: . . ce- .er apcrox'mate , :re ga c- r . ate- n cre-se' ouant t.es me tc 50 a3 o-s 4 55 a a - 3 usea as a reserve r y-cr -g water m' -e --- . c n 'e rn xmg ana bump ng proceed r- 3 '.::e svstem ,s esoeoaT, aa/antagec.,: .-. - .. pressures ana cow mates 2. Neptune Water Meters For accurate water --easurmg 3-0 - g- soee:; operation a h;gn pressure water somce ?-"u .1; used A :arge diameter water supply -ose c;--e."a,reedy to the meter w;i( ncrease wa!er ce .am Monokote Equipment and Efficient Application Procedures 04S03U7 Index Site ana Project Pre-Planning p 3Q0 j Mixer Delivery & Application Eauicment Pump Station Setup Page 3-' P330 7-5 Mixing Procedure Start Up and Shut Down P 3CS 5 d- 3.^0 wa.D- Cold Weather Application Face 9 Job Records and Meeting Production Quo!tas Page 9 Fig 1 Dust Control Fig 2 High production Conversion Kits Page "C Fig 3 Schematic Work Diagram Page * The information contained within this brochure has been generated by fireproofing applicators for the specific ourpose of maximizing profit potential through mprovements m both equipment and methods of installation. Over the last decade fireproofing contractors have continued to improve, fine-tune and upgrade their operations. These improvements have resulted m nigner pumping rates, lower pumping pressures, more efficient application equipment and higher profits when applying Monokote. This sixth revision to the Monokote Equipment and Efficient Application Procedures manual attempts to incorporate more than 10 years' worth of ideas into one place for the specific purpose of keeping production up and costs down Before starting your next job. review the contents of this manual, compare its recommendations to your present job set-up. then upgrade wherever oossipie. Keep m mind that no single improvement will have a significant effect on your operation, but the combination of various recommendations can result m a more efficient and. therefore, more profitaoie job Our joint efforts will help keep sprayed plaster fireproofing a viable and profitable business for the plastering industry. 2