PowerSystem
Guide

Coatings, Linings, and FireproofingAtmospheric Exposures
Clean to Bare Steel Substrates
PREP

PRIMER

PRIMERDESCRIPTION

MID-COAT

MID-COATDESCRIPTIONTOPCOATTOPCOATDESCRIPTION

Structural Steel, Piping, and Equipment – Carbon SteelApplications – Structural steel, inlet air ducts, pipe racks, piping, valves, ladders, handrails, pumps, motors, storage tankexteriors, process vessels, compressors, and other equipment operating up to 250°F (121°C)

SP 6

Carbozinc
11 Series-orCarbozinc
858 or 859 Series

Inorganic zincprimer for maximum
corrosion protection-orOrganic zinc forquick topcoating andadditional chemical
resistance

Carboguard
890 Series-orCarboguard
690-orCarboguard
60

High chemical
resistant epoxy-orMoisture tolerant, low temp
cure epoxy-orEpoxy polyamide for general
purposeCarbothane
134 Series-orCarbothane
133 Series-orCarboxane
2000 SeriesHigh gloss
weatherable acrylic
urethane-orSatin finish; high build
urethane hybrid-orUltra-weatherable
siloxane

SP 3

Carbomastic
15 Series-orCarbomastic
94-orCarbomastic 615

Aluminum surface
tolerant epoxy-orSurface tolerant
mastic in colors-orInert-flake filled,
moisture tolerant, lowtemp cure epoxy

Carboguard
890 Series-orCarboguard
690-orCarboguard
60

High chemicalresistant epoxy-orMoisture tolerant, low temp
cure epoxy-orEpoxy polyamide for general
purposeCarbothane
134 Series-orCarbothane
133 Series-orCarboxane
2000 SeriesHigh gloss
weatherable acrylic
urethane-orSatin finish; high build
urethane hybrid-orUltra-weatherable
siloxane

SPOT PRIMER

SPOT PRIMERDESCRIPTIONTOPCOATTOPCOATDESCRIPTION

Systems over Existing Coatings*PREPOVERCOATSEALER

OVERCOATDESCRIPTIONStructural Steel, Piping, and Equipment – Carbon SteelApplications – Structural steel, inlet air ducts, pipe racks, piping, valves, ladders, handrails, pumps, motors, storage tankexteriors, process vessels, compressors, and other equipment operating up to 250°F (121°C)

SP 1
and/orSP 7

Rustbond Series

Penetrating epoxy
sealerCarbomastic
15 Series-orCarboguard
60-orCarbomastic
615

Aluminum surface tolerant
epoxy-orEpoxy polyamide for general
purpose-orSurface tolerant epoxy
phenalkamine*Always determine suitability for overcoating prior to application (see Notes section).

2 | POWER SYSTEM GUIDE

Carbothane
134 Series-orCarbothane
133 Series-orCarboxane
2000 SeriesHigh gloss
weatherable acrylicurethane-orSatin finish; high build
urethane hybrid-orUltra-weatherable
siloxaneAtmospheric Exposures
High Heat Applications
PREP

PRIMER

PRIMERDESCRIPTIONTOPCOATTOPCOATDESCRIPTIONOPTIONAL
THIRD COAT

THIRD COATDESCRIPTION

Uninsulated Piping and Equipment – Steel operating to 300°F (148°C)
Applications – Piping, heaters, furnaces, boilers, stacks, columns, drums, vessels, heat exchangers, mufflers, HRSG steel, valvesand pumps and equipment operating up to 300°F (148°C)

SP 3

SP 10

Carbomastic
15 Series

Aluminum surface
tolerant epoxy

Carbomastic
15 Series

Aluminum surface tolerantepoxy

Carbozinc
859 Series-orCarboguard
890 Series-orCarboguard 690

Organic zinc forquick topcoating andadditional chemical
resistance-orHigh chemical
resistant epoxy-orMoisture tolerant, lowtemp cure epoxy

Carboguard
890 Series-orCarboguard
690

High chemical
resistant epoxy-orMoisture tolerant, low temp
cure epoxy

Uninsulated Piping and Equipment – Steel operating to 450°F (232°C)
Applications – Piping, heaters, furnaces, boilers, stacks, columns, drums, vessels, heat exchangers, mufflers, HRSG steel, valvesand pumps and equipment operating up to 250-450°F (121-232°C).

SP 10Carbozinc
11 Series

Inorganic zincprimer for maximum
corrosion protection

Thermaline 4000
-orThermaline 4900
SeriesInorganic silicate; no heat
cure requirement-orSilicone acrylic

Thermaline 4000
-orThermaline 4900
SeriesInorganic silicate; noheat cure requirement-orSilicone acrylic

Uninsulated Piping and Equipment – Steel operating up to 1000°F (538°C)
Applications – Piping, heaters, furnaces, boilers, stacks, columns, drums, vessels, heat exchangers, mufflers, valves and pumps
and equipment operating at 450-1000°F (232-538°C).

SP 10Carbozinc
11 Series

Inorganic zincprimer for maximum
corrosion protection

Thermaline 4000
-orThermaline 4700
SeriesInorganic silicate; no heat
cure requirement-orSilicone

Thermaline 4000
-orThermaline 4700
SeriesInorganic silicate; noheat cure requirement-orSilicone

DESCRIPTION

THIRD COATDESCRIPTION

Worker Protection and Insulation Needs
PREPPRIMERDESCRIPTIONINSULATIVECOATING

Uninsulated Piping and Equipment – Steel operating to 350°F (176°C)
Applications – Piping, heaters, furnaces, boilers, stacks, columns, drums, vessels, heat exchangers, mufflers, valves, pumps andequipment operating up to 350°F (176°C)

SP 10

Carbozinc 11
Series-orCarbozinc 859
SeriesInorganic zinc primer-orOrganic zinc primer

Carbotherm 3300
-orCarbotherm 551

Insulative acrylic coating-orInsulative waterborne epoxy

Carbocrylic 3359
SeriesWeatherable acrylicfinish

POWER SYSTEM GUIDE | 3Under Insulation
PREPPRIMERPRIMERDESCRIPTIONTOPCOATDESCRIPTIONTOPCOATDESCRIPTION

Insulated Piping and Equipment – Steel operating up to 300°F (148°C)
Applications – Insulated piping and equipment operating at elevated temperatures.
SP 3

Carbomastic
15 Series

Aluminum surface
tolerant epoxy

Carbomastic
15 Series

Aluminum surface
tolerant epoxy

SP 10

Carboguard
890 Series-orCarboguard 690

High chemical
resistant epoxy-orMoisture tolerant, lowtemp cure epoxy

Carboguard
890 Series-orCarboguard
690

High chemical
resistant epoxy-orMoisture tolerant, lowtemp cure epoxy

Insulated Piping and Equipment – Steel operating above 300°F to 1200°F (148°C to 649°C)
Applications – Insulated piping and equipment operating at elevated temperatures.
SP 10

Thermaline
450 EP

Epoxy phenolic;amine cured

Thermaline
450 EP

SP 10

Thermaline 450

Glass-flake
epoxy novolac

SP 10

Thermoline 4001

MIO reinforced polymer

Epoxy phenolic,amine cured

Good to 400°F (204°C)
continuous
Single coat; good to 450°F(232°C) non-continuous

Thermoline 4001

MIO reinforced polymer

Good to 1200°F (649°C)
continuous

Fireproofing
RATINGPRIMERCOATPRIMERDESCRIPTION

2ND
COAT

2ND COATDESCRIPTIONFINISHCOAT

FINISHDESCRIPTION

Fireproofing – SteelApplications – Structural steel, decks, bulkheads, vessel supports, living quarters, control buildings.
Up to 3 hours
UL 263

Carbocoat
150 UP

Latex based or
alkyd primer

Firefilm
III

Water-based
Intumescentfireproofing

Carbothane
133 SeriesHigh gloss
weatherable acrylicurethane

Up to 4 hours
UL 1709

Carboguard
890

Chemicallyresistant epoxy
primerPyrocrete
241 Series

Cementitious,
durable fireproofing

Carboguard 1340
andCarbothane
133 HBEpoxy sealer
andHigh build satin
urethane

Up to 4 hours
UL 1709

Carboguard
893

Chemicallyresistant epoxy
primer

Thermo-Lag
3000

Epoxy based
intumescentfireproofing

Carboguard 1340
andCarbothane
133 HB

Epoxy sealer
andHigh build satin
urethaneCable and Cable Tray Protection
Applications – Electrical cables and cable tray raceways.
Factory Mutual
Certification

Intumastic
285

4 | POWER SYSTEM GUIDE

Water-based
intumescentcable mastic

Concrete Flooring and Secondary
Containment
PREP

PRIMER

PRIMERDESCRIPTIONTOPCOATTOPCOATDESCRIPTIONOPTIONAL
TOPCOATOPTIONAL TOPCOATDESCRIPTION

Floors – Concrete
Applications – Control rooms, aisleways, corridors, mechanical rooms, turbine decks, shower rooms, locker rooms, battery room,laboratory, warehouses.
SSPCSP 13
NACE 6

Carboguard
1340 WB

Water borne epoxy
concrete sealer

Sanitile 555

High performancewater-based epoxy

Sanitile 555

Thin-film floor for lighttraffic use

SSPCSP 13
NACE 6

Semstone
110

High build epoxy
concrete sealer

Sanitile 945 SL

Self-leveling, chemical
resistant epoxy

Sanitile 945 SL

Self-leveling floor for lightto moderate duty use

SSPCSP 13
NACE 6

Carboguard
1340 WB

Water borne epoxy
concrete sealer

Sanitile 985 PA

High solids
polyaspartic

Sanitile 985 PA

High solids polyaspartic

Secondary Containment – Concrete
Applications – Containment areas for acid/caustic storage, fuel storage, aggressive chemical storage, wastewater containment,
sumps, trenches, demin and cooling water treatment area, cooling tower basins, neutralization pits.

ASTM
D4259

Semstone
110

High build epoxy
Concrete sealer

Semstone140 (AFRC)-orSemstone
145 (AFRC)-orSemstone
870 (AFRC)

ASTM
D4259

Carboguard 1340
WB

Water-based epoxy
primer/sealer forconcrete

ReactamineET

Chemicallyresistant epoxy-orExtreme performance
epoxy-novolac-orVinyl-ester for
hypochlorite exposure

Chemical resistant linings
with optional aggregatefilled and/or reinforcement
options for severe abuse/heavy duty service

Elastomeric
polyurea

High abrasion resistant,
350% elongation membrane
to bridge cracks for coolingwater basin and others

Interior
Walls
Concrete, Concrete Masonry Units, and Drywall
SUBSTRATEPRIMER

PRIMERDESCRIPTIONTOPCOATTOPCOATDESCRIPTIONOPTIONAL
THIRD COAT

THIRD COATDESCRIPTION

Poured Concrete, Concrete Masonry Units, Drywall – Occasional to Frequent Washdown
Applications – Hallways, shower rooms, control rooms, storage rooms, etc.

Drywall

Sanitile 120

Drywall sealer

Sanitile 155-orSanitile 555

Satin acrylic finish-orHigh performancewater-based epoxy

Sanitile 155-orSanitile 555

Satin acrylic finish-orHigh performancewater-based epoxy

ConcreteorCMU

Sanitile 100-orSanitile 500

Water-based
acrylic block filler-orWater-based
epoxy block filler

Sanitile 155-orSanitile 555

Satin acrylic finish-orHigh performancewater-based epoxy

Sanitile 155-orSanitile 555Satin acrylic finish-orHigh performancewater-based epoxy

POWER SYSTEM GUIDE | 5

Specialty Applications
PREP

PRIMER

PRIMERDESCRIPTIONTOPCOATTOPCOATDESCRIPTIONOPTIONAL
THIRD COAT

THIRD COATDESCRIPTION

Galvanized Steel – Structural, Ductwork, Cable Trays
Applications – Over-coating galvanized steel or other surfaces to provide color coordination and UV protection may also be used on
stainless, bronze, brass, fiberglass

SP 1-orSP 7

Galoseal WB-orCarboguard 60

Acrylic bonding primer
for SP1 prep
-orEpoxy polyamide forgeneral purpose forSP7 prepCarbocrylic 3359
-orCarbothane
134 Series-orCarbothane
133 Series

Industrial, weatherable
acrylic finish-orHigh gloss
weatherable acrylic
urethane-orSatin finish; high build
urethane hybrid

Galvanized Steel – Transmission Towers and Substations
Applications – Over-coating weathered galvanized steel or other surfaces to provide color coordination and UV protection
SP 1

Carbocoat 2600

Metallic-filled
long-oil alkyd fortransmission towers

SP 1

Carbocoat2900 Primer

Epoxy ester alkyd
primer for substations

Carbocoat 2901

Metallic-filled
epoxy ester

SP 1

Carbocoat2900 Primer

Epoxy ester alkyd
primer for substations

Carbocoat2900 Primer

Epoxy ester
alkyd primer

Interior Steel – (less than 200°F, 93°C)
Applications – Structural steel. Turbines, piping, pumps, motors, electrical equipment

SP 3

Carboguard
890 Series-orCarbomastic 94

High chemical
resistant epoxy-orSurface tolerant
mastic in colors

Carboguard
890 Series-orCarbomastic 94

High chemical
resistant epoxy-orSurface tolerant
mastic in colors

SP 3

Carbocoat 8215

Direct-to-metal,
fast dry alkyd

Carbocoat
8215

Direct-to-metal,
fast dry alkyd

Buried Piping – SteelApplications – External surface of buried pipelines, valves, manifolds, girth weld repair, etc.

SP 10

Bitumastic 300M
-orPolyclad 975-orPolyclad 975 H

6 | POWER SYSTEM GUIDEHigh build,epoxy coal-tar-orHybrid epoxy pipeline
coating-orHand applied hybrid
epoxy pipeline coating

Carbocoat30

Weatherable silicone(30%)-modified
alkyd finish

Linings for Storage Tanks and Vessels

All tank lining recommendations must be reconfirmed through Carboline Technical Service Department.
GENERIC TYPEPRODUCT# OF COATS

Mils (µm)
TOTAL

Epoxy Novolac

Plasite 4550

140-50(1000-1250)

Epoxy Novolac

Plasite 4550 S

140-50(1000-1250)

Epoxy

Phenoline 353

212-15(300-375)

100% Solids
Epoxy Novolac

Plasite 4550 Series

125-30(625-750)

100% Solids Elastomeric
Polyurethane Hybrid

Reactamine 760

130-40(750-1000)

More caustic

Flake Pigment Vinyl Ester

Plasite 4100

235-45(875-1125)

More acidic

Flake Pigment Vinyl Ester

Plasite 4300

235-45(875-1125)

Demin water
up to 210°F

Epoxy Phenolic

Plasite 7159

210-12(250-300)

Demin water less than150°F

Cycloaliphatic Epoxy

Plasite 9133

212-15(300-375)

Raw water

Epoxy

Carboguard 891 HS

212-15(300-375)

Circulating water;water screens

Coal-tar Epoxy

Bitumastic 300M

1-224(600)

Water boxes,
circulating water pipe,
penstocks, dam gates

Epoxy-orPolyurethane Hybrid

Plasite 4500 Series-orReactamine 760

1-or140-50(1000-1250)-or30-40(750-1000)

High Abrasion Resistant
Epoxy Phenolic

Plasite 7122 VAR

212-14(300-350)

High Abrasion ResistantVinyl Ester

Plasite 4110

235-45(875-1125)

Gypsum Tanks

Epoxy Novolac

Plasite 4550 Series

240-80(1000-2000)

Absorber Towers (Scrubbers)
Outlet Ductwork and Stacks

Abrasion-Resistant
Flake Pigment Vinyl Ester

Plasite 4310

235-45(875-1125)

Cycloaliphatic Amine Epoxy

Phenoline 385

212-14(300-350)

Epoxy Phenalkamine

Phenoline 341

112-14(300-350)

Epoxy

Plasite 4500 Series

125-30(625-750)

SERVICE CONDITIONS

98% Sulfuric Acid

50% Caustic(Sodium Hydroxide)

Fly Ash or Coal Silos

Neutralization Tanks

Water Storage orExposure

Lime Slurry Tanks

Diesel Fuel, Oil,
Gasoline Storage

POWER SYSTEM GUIDE | 7

NOTES:
1. Carbozinc 11 Series consists of four inorganic zinc products designed to meet every need:››Carbozinc 11: Standard high performance inorganic zinc silicate.

››Carbozinc 11 VOC: High performance inorganic zinc silicate designed to meet local VOC limits of 3.2 lbs./gal. (389 g/l)››

Carbozinc 11 HS: High performance inorganic zinc silicate designed to meet local VOC limits of 2.4 lbs./gal. (288 g/l)››

Carbozinc 11 WB: A water-based inorganic zinc with a VOC of zero.

2. Carbothane 134 Series include several choices of high gloss acrylic urethanes to meet your needs:››Carbothane 134 HG: Superior performance polyurethane exceeding the requirements of SSPC Paint 36 Level 3.

››Carbothane 134 VOC: Same performance as 134 HG but with a VOC limit of <200 g/l.

››Carbothane 134 MC: Same performance as 134 HG but with a VOC limit of <100 g/l.

››Carbothane 134 WB: A water-borne urethane exceeding the requirements of SSPC Paint 36; Level 3 and VOC <100 g/l.

3. Carbothane 133 Series may be used in lieu of 134 Series when a satin finish and higher film build characteristics are desired. Carbothane 133 Seriesincludes 133 HB, 133 VOC, 133 MC, 133 LH and 133 LV used where VOC regulations dictate.
4. Thermaline 4900 VOC and Thermaline 4700 VOC may be substituted for Thermaline 4900 and Thermaline 4700, respectively, as local VOC regulations
dictate.
5. Heavily pitted steel can make coating application more complicated. Please consult your Carboline Sales Representative for specific advice.
6. The application technique of stripe coating edges and weld lines will improve coating system performance.
7. Surface Cleaner 3 is a water based cleaner that is effective in cleaning and degreasing surfaces prior to painting.
8. Where surface preparation designations of SSPC SP 10, SP 6, SP 7, SP 3, and SP 2 are used the ISO designations of Sa 2 ½, Sa 2, Sa 1, St 3, and St 2
(respectively) are also applicable.
9. Plasite 4500 Series and 4550 Series includes versions that can be sprayed using standard airless equipment or plural-component equipment. Always
check with Carboline’s Technical Service Department for the most appropriate version for the specific application.

CA R B O L I N E CO M PA N YG LO BA L H E A D Q U A RT E R S
2150 S C H U E T Z R O A D
S T. LO U I S , M O 63146 U S A
P H : +1-314-644-1000
W W W. CA R B O L I N E . CO M

8 | POWER SYSTEM GUIDE

12-46-0815-583