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Noah's Ark Much like the project itself, which was designed in two phases, the coatings and crews were also divisible by twos: Tere were two total crews (one shop and one feld), the shop crew was made up of two shifts (60 crew members each for a total of 120), and the intumescent ofered a fre rating of two hours. Te shop, which is where the coatings story begins, breaks that pattern; it operates in six zones. Using overhead cranes, the 120-person crew — although not working all at one time or in one zone — was able to start working on the steel beams. "Once the steel is set, it doesn't have to move; the people and processes move around it, which makes it quite a bit more efcient than other shop processes in the industry," explained Derek Stallard, group manager, freproofng division, for J. T. Torpe & Son. Te diferent zones allowed the crew to be divided again and work independently down the length of the beam. Tat way, the process was able to move along without having to coordinate with diferent zones. "Each zone may be in a diferent stage, but it allows us to process our steel in batches," Stallard said. To start, the crew prepped the hot dipped galvanized steel beams — anywhere between 2- and 29-feet (0.6–8.8 m) long — to Society for Protective Coatings (SSPC) Surface Preparation (SP) 1: Solvent Cleaning. Tey used International Paint (IP)'s GTA007 solvent to remove all oils, dust, and debris from the surface. Tey also prepared the steel using SSPC-SP-16: Brush- Of Blast Cleaning of Non-Ferrous Metals to achieve a 2- to 3-mil (50.8–76.2 microns) profle. Te crew then spray-applied a two-part epoxy, International Paint's Intergard 251, at 2 to 3 mils (50.8–76.2 microns) dry flm thickness (DFT). Wearing steel-toed boots, hard hats, safety glasses, fre-retardant coveralls, and 3M respirators, they applied up to 4 mils (101.6 microns) of the primer in overlapping areas. Te application process on all 40,000 square feet (3,716.1 m²) of steel cruised along with no hiccups or holdups. Next up: the PFP workhorse! Wielding Graco Xtreme PFP Single Leg Airless Sprayers and using Graco XM PFP Heated Plural Pumps, the crew applied the intumescent coating in three stages. To a total average minimum thickness of 417 mils (10,591.8 microns), they applied one layer of International Paint's Chartek 1709 to achieve about half that thickness initially. Ten they laid in a layer of HK-1 carbon fber mesh, and they fnally fnished of the system with another layer of the 100-percent solids Chartek (again at about half of the total thickness). To help keep things consistent, the crew used a wet bridge gage on the frst wet layer of coating and then a tool from Elcometer called the 456 at the end to test the total thickness once everything was dry. Te Chartek was covered with a thinly layered topcoat. Te epoxy topcoat, International Paint's 990HS, was spray-applied at 2- to 3-mils (50.8–76.2 microns) thick. A long with the rest of the materials, it helped the PFP system achieve a two-hour UL1709 fre rating. Tat means that this system adheres to the Underwriters' Laboratories (UL) Standard for Rapid Rise Fire Tests of Protection Materials for Structural Steel. Tis topcoat, though, wasn't just used for function. It was also used at the Marcus Hook complex for looks. "Now the customer can choose whatever they want the color to be, so it does have an aesthetic aspect to it as well, but it is part of the 58 MARCH 2016 COATINGSPROMAG.COM With 120 people working in the shop and 19 finishing it in the field, the crew will take eight months over the course of three years to finish the two-phase project at this petrochemical facility. The coating journey for the hot dipped galvanized steel beams started in the shop near Pittsburgh, Pa. The beams ranged between 2 and 29 feet (0.6–8.8 m) in length. Sunoco Logistics Partners wanted to expand one of their facilities in eastern Pennsylvania. They called in J. T. Thorpe & Son to apply the intumescent coating system to 40,000 square feet (3,716.1 m²) of steel. Passive Fire Protection System