Monokote Field App Manual_LR

To Our Valued Customers,

We at Grace would like to welcome you to the most recent edition of the Monokote Field Application Manual. The first edition of the Application Manual was published in 1975 with

the goal of compiling, in one document, recommendations that provided for the most efficient

application of Monokote Fireproofing products. While much has changed since the first edition,

the goal remains the same; to provide a comprehensive resource dedicated to helping our customers succeed.

This Application Manual contains many ideas and practices that will be of value to your

business. Some ideas may appear new while others will serve as reminders that could improve

both safety and profitability. Most importantly, the information will serve as a guide for

improving the overall performance of your field operations. We encourage you to review the

contents of the manual and adapt the information to your operations. Furthermore, we suggest you view the manual as a reference tool that would remain on each of your job sites.

We are honored to be of service to you and the fireproofing industry. We trust the information

contained in this updated edition of the Monokote Field Application Manual will be of value to

your company.

Best Regards,

Grace Construction Products

IndexSection 1 Product Information Data Submittal sheets Monokote MK-6 (MK/6HY MK-6s) Monokote MK-6 GF Monokote MK 10/HB Monokote Spattercoat Type SK-3 Retro-guard Type RG Monokote Z106 and Z106HY Monokote Z106/G Monokote Z146 and Z156 Monokote Type Z-3306 Thermal Barrier Monokote MK-6/HY Extended SetSection 2 Planning Pre set-up Planning Preparation and Clean Up Heat and Ventilation Material Storage

Section 3 Set Up Station Set Up Pump Station Location Pump Station Set Up Pump Station Requirements Conveying Systems Delivery Systems Floor Hose Reduction Whips Delivery System Winter Procedures

Section 4 Application Mixing Mixing Procedures Measuring Mix Water Benefits Nozzle set up & adjustments Nozzle Components Orifice Selection Nozzle Air Pressure Air Stem Adjustment Hand Held Nozzles Ridged and Rubber Nozzle Assemblies Nozzle Swivels Pole Gun Assemblies

Monokote, Topkrete, Retro-Guard and Zonolite are registered trademarks and Spatterkote is a trademark of Grace Construction Products, W. R. Grace & Co. Conn., 62 Whittemore Ave., Cambridge, MA 02140. We hope the information given here will be helpful. It is based on data and knowledge considered to be true and accurate and is offered for the users consideration, investigation and verification but we do not warrant the results to be obtained. Please read all statements, recommendations or suggestions in conjunction with our conditions of sale which applyu to all goods suppled by us. No statement, recommendation or suggestion is intended for any use which would infringe any patent or copyright.

Section 4 Application (continued) Pumping and Spraying Pump In and Pump Out Procedures Spraying Basics Beam Application Column Application Bar Joist Application With Scrim Bar Joist Application Without Scrim Pole guns High Production Pole Gun Spray Technique Injection Introduction to Injection Inline Injection Injection System Troubleshooting Guide Deluxe Yield Kit Yield Charts Winter Procedures Miscellaneous Fire Bond Application Spatterkote Application

Section 5 Equipment General Equipment Safety Pumps and Mixers Super Pumps High Production Pumps Patch Pumps Continuous Mixers Conventional Batch Mixers Injectors/Injection Injection Units Injection Pumps Scaffolding Scaffolding Recommendations Equipment Water Meter systems Timers/Temp gaugesSection 6 Miscellaneous Testing and Inspection ASTM Technical Manual 12A Third Edition Frequently Asked Questions Filling Flutes Misc. Steel Application Hand Patching 1/2 Flange Tip Application Painted deck Steel Columns at Walls Dissimilar Materials Estimating Introduction to Estimating Color Coded Drawings

Monokote, Topkrete, Retro-Guard and Zonolite are registered trademarks and Spatterkote is a trademark of Grace Construction Products, W. R. Grace & Co. Conn., 62 Whittemore Ave., Cambridge, MA 02140. We hope the information given here will be helpful. It is based on data and knowledge considered to be true and accurate and is offered for the users consideration, investigation and verification but we do not warrant the results to be obtained. Please read all statements, recommendations or suggestions in conjunction with our conditions of sale which applyu to all goods suppled by us. No statement, recommendation or suggestion is intended for any use which would infringe any patent or copyright.

Monokote Field Application Manual

January 2013 | 2013 W. R. Grace & Co. Conn. Section 1: Product Information | 1

Grace Fireproofing Products

MONOKOTE MK-6, MK-6/HY and MK-6sProduct data and application instructions

Product DescriptionMonokote MK-6/HY and MK-6s are singlecomponent, spray applied, mill-mixed fire resistiveplasters. MK-6/HY and MK-6s have approval for useon structural steel members and fluted decking toprovide up to four hours of fire protection, and onflat plate cellular decking for up to three hours withSpatterkote SK-3.Note: Monokote MK-6/HY and MK-6s afford thesame level of the fire protection at identical protec-tion thicknesses. By simply specifying MonokoteMK-6, the fireproofing subcontractor can select theproduct that will provide the most efficient fireprotection for the specific project conditions.

Features & BenefitsMonokote cementitious fireproofing offers manysignificant advantages to the architect, owner, appli-cator and building occupant. These include: Proven in-place performance Low in-place cost Fast, efficient application UL fire tested and factory inspected Building Code compliant(ICBO, SBCCI, BOCA, ICC)

Delivery & Storagea. All material to be used for fireproofing shall bedelivered in original unopened packages bearingthe name of the manufacturer, the brand andproper UL labels for fire hazard and fire resistanceclassifications.

b. The material shall be kept dry until ready for use.Packages of material shall be kept off the ground,under cover and away from sweating walls and

other damp surfaces. All bags that have beenexposed to water before use shall be discarded.Stock of material is to be rotated and used beforeits expiration date.

Steel & Concrete Surfacesa. Prior to the application of Monokote MK-6, aninspection shall be made to determine that all steelsurfaces are acceptable to receive fireproofing. Thesteel shall be free of oil, grease, rolling compoundsor lubricants, loose mill scale, excess rust,noncompatible primer, lock down agent or anyother substance that will impair proper adhesion.Where necessary, the cleaning of steel surfaces toreceive fireproofing shall be the responsibility ofthe general contractor.

b. The project architect shall determine if thepainted/primed structural steel to receive fireproof-ing has been tested in accordance with ASTME119, to provide the required fire resistance rating.

c. Many Fire Resistance Designs allow the use ofpainted metal floor or roof-deck in place of galva-nized decking. Painted decking must be UL listedin the specific fire resistance designs and mustcarry the UL classification marking. Consult yourlocal Grace sales representative for details.

d. Prior to application of Monokote MK-6, a bondingagent, approved by the fireproofing manufacturer,shall be applied to all concrete substrates toreceive MK-6.

e. Fireproofing to the underside of roof deck assem-blies shall be done only after roofing application iscomplete and roof traffic has ceased.

f. No fireproofing shall be applied prior to comple-tion of concrete work on steel decking.

Performance CharacteristicsPhysical Properties Recommended Specification Typical Values Test MethodDry density, minimum average 15 pcf (240 kg/m3) 15 pcf (240 kg/m3) ASTM E605Bond strength 200 psf (9.6 KPa) 339 psf (16.2 KPa) ASTM E736Compression, 10% deformation 1,200 psf (51 KPa) 1,483 psf (71.0 KPa) ASTM E761Air erosion Max 0.000 g/ft2 (0.00 g/m2) 0.000 g/ft2 (0.00 g/m2) ASTM E859High velocity air erosion No continued erosion after 4 hours No continued erosion after 4 hours ASTM E859Corrosion Does not contribute to corrosion Does not contribute to corrosion ASTM E937Bond impact No cracking, spalling or delamination No cracking, spalling or delamination ASTM E760Deflection No cracking, spalling or delamination No cracking, spalling or delamination ASTM E759Resistance to mold growth No growth after 28 days No growth after 28 days ASTM G21Surface burning characteristics Flame spread = 0 Flame spread = 0 ASTM E84

Smoke developed = 0 Smoke developed = 0Combustibility Less than 5 MJ/m2 total, Less than 5 MJ/m2 total, ASTM E1354

20 kw/m2 peak heat release 20 kw/m2 peak heat releaseImpact penetration Max 6 cm3 abraded 3.9 cm3 City of San FranciscoAbrasion resistance Max 15 cm3 abraded 8.3 cm3 City of San Francisco



g. Other trades shall not install ducts, piping, equip-ment, or other suspended items until thefireproofing is completed and inspected.

h. Other trades shall install clips, hangers, supportsleeves, and other attachments that penetrate thefireproofing, prior to application of the fireproofing.

Mixinga. Monokote Fireproofing shall be mixed by machinein a conventional, plaster-type mixer or a continu-ous mixer specifically modified for cementitiousfireproofing. The mixer shall be kept clean andfree of all previously mixed material. The mixerspeed in a conventional mixer shall be adjusted tothe lowest speed which gives adequate blending ofthe material and a mixer density of 4045 pcf(640720 kg/m3) of material.

b. Using a suitable metering device and a conven-tional mixer, all water shall be first added to themixer as the blades turn. Mixing shall continueuntil the mix is lump-free, with a creamy texture.All material is to be thoroughly wet. Target densityof 43 1 pcf (688 16 kg/m3) is most desirable.Overmixing Monokote will reduce pumping rate.

Applicationa. Application of Monokote Fireproofing can bemade in the following sequence:1. For thicknesses of approximately 12 in. (13 mm)or less, apply in one pass.

2. For thicknesses of 58 in. (16 mm) or greater, applysubsequent passes after the first coat has set.

b. Spatterkote SK-3 shall be applied to all cellularsteel floor units with flat plate on the bottom andto roof decking where required prior to applicationof Monokote. Spatterkote shall be applied inaccordance with manufacturers applicationinstructions.

c. Monokote Fireproofing material shall not be usedif it contains partially set, frozen or caked material.

d. The minimum average density shall be thatrequired by the manufacturer, listed in the UL FireResistance Directory for each rating indicated,ICBO Evaluation Report, as required by theauthority having jurisdiction, or minimum average15 lbs/ft3 (240 kg/m3), whichever is greater.

e. Monokote shall be mixed with water at the job site.f. Monokote Accelerator is to be used withMonokote Fireproofing* to enhance set character-istics and product yield. The MonokoteAccelerator is injected into the Monokote Fire-proofing at the spray gun. Monokote Acceleratorshall be mixed and used according to manufactur-ers recommendations.

g. Monokote is applied directly to the steel, at variousrates of application which will be job dependent,using standard plastering type equipment orcontinuous mixer/pump units. A spray gun, with aproperly sized orifice and spray shield and airpressure at the nozzle of approximately 20 psi(38 KPa), will provide the correct hangability,density and appearance. NOTE: If freshly sprayedMonokote does not adhere properly, it is probablydue to a too wet mix, poor thickness control, or animproperly cleaned substrate.

Temperature & Ventilationa. An air and substrate temperature of 40F (4.4C)minimum shall be maintained for 24 hours prior toapplication, during application and for a minimumof 24 hours after application of Monokote.

b. Provisions shall be made for ventilation to properlydry the fireproofing after application. In enclosedareas lacking natural ventilation, air circulationand ventilation must be provided to achieve aminimum total fresh air exchange rate of 4 timesper hour until the material is substantially dry.

Field Testsa. The architect will select an independent testinglaboratory (for which the owner will pay) tosample and verify the thickness and density of thefireproofing in accordance with the provisions ofASTM E605, Standard Test Method for Thicknessand Density of Sprayed Fire-Resistive MaterialApplied to Structural Members or Uniform Build-ing Code Standard No. 7-6 Thickness and DensityDetermination for Spray Applied Fireproofing.

b. The architect will select an independent testinglaboratory (for which the owner will pay) torandomly sample and verify the bond strength ofthe fireproofing in accordance with the provisionsof ASTM E736.

c. Results of the above tests will be made available toall parties at the completion of pre-designatedareas which shall have been determined at a pre-job conference.

Safetya. Monokote is slippery when wet. The generalcontractor and applicator shall be responsible forposting appropriate cautionary SLIPPERYWHENWET signs. Signs should be posted in all areas incontact with wet fireproofing material. Anti-slipsurfaces should be used on all working surfaces.

b. Material Safety Data Sheets for MonokoteMK-6/HY and MK-6s are available on our website at www.graceconstruction.com or by calling866-333-3SBM.

* Use of accelerator with MK-6s will provide rapid set but will notresult in yield increase.

www.graceconstruction.comFor technical assistance call toll free at 866-333-3SBM (3726)

Monokote, MK-6, HY and Spatterkote are registered trademarks of W. R. Grace & Co.Conn.

We hope the information here will be helpful. It is based on data and knowledge considered to be true and accurate and is offered for the usersconsideration, investigation and verification, but we do not warrant the results to be obtained. Please read all statements, recommendations orsuggestions in conjunction with our conditions of sale, which apply to all goods supplied by us. No statement, recommendation or suggestion isintended for any use which would infringe any patent or copyright. W. R. Grace & Co.Conn., 62 Whittemore Avenue, Cambridge, MA 02140.In Canada, Grace Canada, Inc., 294 Clements Road, West, Ajax, Ontario, Canada L1S 3C6.

This product may be covered by patents or patents pending. Copyright 2010. W. R. Grace & Co.Conn.MK-515G Printed in U.S.A. 06/10 FA/PDF




MONOKOTE MK-6GFProduct data and application instructions

Product DescriptionMonokote MK-6 GF is single component, sprayapplied, mill-mixed fire resistive plasters. MK-6 GFhas approval for use on structural steel members andfluted decking to provide up to four hours of fireprotection, and on flat plate cellular decking for upto three hours with Spatterkote SK-3.

Features & BenefitsMonokote cementitious fireproofing offers manysignificant advantages to the architect, owner, appli-cator and building occupant. These include: Proven in-place performance Low in-place cost Fast, efficient application UL fire tested and factory inspected Building Code compliant(ICBO, SBCCI, BOCA, ICC)


b. The material shall be kept dry until ready for use.Packages of material shall be kept off the ground,under cover and away from sweating walls andother damp surfaces. All bags that have beenexposed to water before use shall be discarded.Stock of material is to be rotated and used beforeits expiration date.

Steel & Concrete Surfacesa. Prior to the application of Monokote MK-6 GF, aninspection shall be made to determine that all steelsurfaces are acceptable to receive fireproofing. Thesteel shall be free of oil, grease, rolling compoundsor lubricants, loose mill scale, excess rust,noncompatible primer, lock down agent or anyother substance that will impair proper adhesion.Where necessary, the cleaning of steel surfaces toreceive fireproofing shall be the responsibility ofthe general contractor.



d. Prior to application of Monokote MK-6 GF, abonding agent, approved by the fireproofing manu-facturer, shall be applied to all concrete substratesto receive MK-6 GF.



g. Other trades shall not install ducts, piping,equipment, or other suspended items until thefireproofing is completed and inspected.














e. Monokote shall be mixed with water at the job site.f. Monokote Accelerator is to be used withMonokote Fireproofing* to enhance set character-istics and product yield. The MonokoteAccelerator is injected into the Monokote Fire-proofing at the spray gun. Monokote Acceleratorshall be mixed and used according to manufactur-ers recommendations.

g. Monokote is applied directly to the steel, at variousrates of application which will be job dependent,using standard plastering type equipment orcontinuous mixer/pump units. A spray gun, with aproperly sized orifice and spray shield and airpressure at the nozzle of approximately 20 psi(38 KPa), will provide the correct hangability,density and appearance. NOTE: If freshly sprayedMonokote does not adhere properly, it is probablydue to a too wet mix, poor thickness control, or animproperly cleaned substrate.






Safetya. Monokote is slippery when wet. The generalcontractor and applicator shall be responsible forposting appropriate cautionary SLIPPERYWHENWET signs. Signs should be posted in all areas incontact with wet fireproofing material. Anti-slipsurfaces should be used on all working surfaces.

b. Material Safety Data Sheets for MonokoteMK-6 GF is available on our web site atwww.graceconstruction.com or by calling866-333-3SBM.

* Use of accelerator with MK-6 GF will provide rapid set butwill not result in yield increase.


Monokote, MK-6 and Spatterkote are registered trademarks of W. R. Grace & Co.Conn.We hope the information here will be helpful. It is based on data and knowledge considered to be true and accurate and is offered for the usersconsideration, investigation and verification, but we do not warrant the results to be obtained. Please read all statements, recommendations orsuggestions in conjunction with our conditions of sale, which apply to all goods supplied by us. No statement, recommendation or suggestion isintended for any use which would infringe any patent or copyright. W. R. Grace & Co.Conn., 62 Whittemore Avenue, Cambridge, MA 02140.In Canada, Grace Canada, Inc., 294 Clements Road, West, Ajax, Ontario, Canada L1S 3C6.This product may be covered by patents or patents pending. Copyright 2011. W. R. Grace & Co.Conn.MK-515I Printed in U.S.A. 01/11 FA/PDF




MONOKOTE MK-10HBProduct data and application instructions

Product DescriptionMonokote MK-10 HB is single component, sprayapplied, mill-mixed fire resistive plasters. MK-10HB has approval for use on structural steel membersand fluted decking to provide up to four hours of fireprotection, and on flat plate cellular decking for up tothree hours with Spatterkote SK-3. It has been designed to obtain bond strengths inexcess of 430 psf making it an attractive material for meeting the 2006 IBC building requirements forbond strength for buildings in excess of 75 tall butless than 420 feet tall. The capability of meeting thebond strength requirements with a high yieldingspray applied fire resistant material makes MonokoteMK-10 HB a cost effective option.

Features & BenefitsMonokote cementitious fireproofing offers manysignificant advantages to the architect, owner, applicator and building occupant. These include: Proven in-place performance Low in-place cost Fast, efficient application UL fire tested and factory inspected Building Code compliant



Steel & Concrete Surfacesa. Prior to the application of Monokote MK-10 HB,an inspection shall be made to determine that allsteel surfaces are acceptable to receive fireproof-ing. The steel shall be free of oil, grease, rollingcompounds or lubricants, loose mill scale, excessrust, noncompatible primer, lock down agent orany other substance that will impair proper adhe-sion. Where necessary, the cleaning of steelsurfaces to receive fireproofing shall be theresponsibility of the general contractor.



d. Prior to application of Monokote MK-10 HB, abonding agent, approved by the fireproofing manu-facturer, shall be applied to all concrete substratesto receive MK-10 HB.


Performance CharacteristicsPhysical Properties Recommended Specification Laboratory Test* Values Test MethodDry density, minimum average 15 pcf (240 kg/m3) 15 pcf (240 kg/m3) ASTM E605Bond strength 600 psf (28.7 KPa) 1,337 psf (63.9 KPa) ASTM E736Compression, 10% deformation 4,500 psf (215 KPa) 5,601 psf (267.7 KPa) ASTM E761Air erosion Max 0.000 g/ft2 (0.00 g/m2) 0.000 g/ft2 (0.00 g/m2) ASTM E859High velocity air erosion No continued erosion after 4 hours No continued erosion after 4 hours ASTM E859Corrosion Does not contribute to corrosion Does not contribute to corrosion ASTM E937Bond impact No cracking, spalling or delamination No cracking, spalling or delamination ASTM E760Deflection No cracking, spalling or delamination No cracking, spalling or delamination ASTM E759Resistance to mold growth No growth after 28 days No growth after 28 days ASTM G21Surface burning characteristics Flame spread = 0 Flame spread = 0 ASTM E84


20 kw/m2 peak heat release 20 kw/m2 peak heat release

*Actual laboratory tested values meet or exceed Graces recommended value. Test reports are available on request from your Grace sales representative.




g. Other trades shall not install ducts, piping, equipment, or other suspended items until the fireproofing is completed and inspected.









e. Monokote shall be mixed with water at the job site.f. Monokote Accelerator is to be used with MonokoteFireproofing to enhance set characteristics andproduct yield. The Monokote Accelerator isinjected into the Monokote Fireproofing at thespray gun. Monokote Accelerator shall be mixedand used according to manufacturers recommenda-tions.

g. Monokote is applied directly to the steel, at variousrates of application which will be job dependent,using standard plastering type equipment orcontinuous mixer/pump units. A spray gun, with aproperly sized orifice and spray shield and airpressure at the nozzle of approximately 20 psi (38 KPa), will provide the correct hangability,density and appearance. NOTE: If freshly sprayedMonokote does not adhere properly, it is probablydue to a too wet mix, poor thickness control, or animproperly cleaned substrate.






Safetya. Monokote is slippery when wet. The generalcontractor and applicator shall be responsible forposting appropriate cautionary SLIPPERY WHENWET signs. Signs should be posted in all areas incontact with wet fireproofing material. Anti-slipsurfaces should be used on all working surfaces.

b. Material Safety Data Sheets for Monokote MK-10 HB is available on our web site atwww.graceconstruction.com or by calling 866-333-3SBM.

www.graceconstruction.comFor technical assistance call toll free at 866-333-3SBM (3726)Monokote, and Spatterkote are registered trademarks of W. R. Grace & Co.Conn.We hope the information here will be helpful. It is based on data and knowledge considered to be true and accurate and is offered forthe users consideration, investigation and verification, but we do not warrant the results to be obtained. Please read all statements,recommendations or suggestions in conjunction with our conditions of sale, which apply to all goods supplied by us. No statement, recommendation or suggestion is intended for any use which would infringe any patent or copyright.W. R. Grace & Co.Conn., 62 Whittemore Avenue, Cambridge, MA 02140.In Canada, Grace Canada, Inc., 294 Clements Road, West, Ajax, Ontario, Canada L1S 3C6.This product may be covered by patents or patents pending. Copyright 2012 . W. R. Grace & Co.Conn.MK-660 Printed in U.S.A. 07/12 FA/PDF




MONOKOTE SPATTERKOTE SK-3

Product InformationDescriptionMonokote Spatterkote SK-3 is a mill-mixedPortland cement based cementitious spray appliedfireproofing accessory product. It is designed tobe used with Monokote MK-6, Z-106/G andRetro-Guard RG Replacement Fireproofing oncellular steel decking with flat plate on the bottomand some roof-ceiling designs. Cement basedSpatterkote bonds tenaciously to flexiblegalvanized flat plate steel surfaces used in manyof todays most advanced structural steel deckdesigns. When used in conjunction with MonokoteMK-6, Z-106/G and/or Retro-Guard Fireproofing,Spatterkote provides the most reliable fireproofingsystems available to the spray fireproofing industry.

UsesSpatterkote SK-3 shall be applied to all cellularsteel floor units with flat plate on the bottom beforethe application of Monokote MK-6, Z106/G orRetro-Guard Replacement Fireproofing. Spatterkoteis also required in some roof-ceiling and concretefloor-ceiling designs and is optional on other steelsurfaces. The thickness of Spatterkote is includedin the total final fireproofing thickness.

Materialsa. Material shall be Spatterkote, UnderwritersLaboratories designation Type SK-3, asmanufactured by Grace Construction Products,W. R. Grace & Co.Conn. or its processingdistributors.

b.Mixing water shall be clean, fresh and suitablefor domestic consumption and free from suchamounts of minerals or organic substances aswould affect the set of the fireproofing.

c. Retarder material shall be Red Top PlasterRetarder as manufactured by United StatesGypsum or approved equal.

ApplicationApplication procedure shall conform to the mate-rial manufacturers application instructions.Spatterkote shall be spray applied at the approxi-mate rate of 1 lb/20 ft2 (1 kg/4.9 m2) [nominal960 ft2/46 lbs (100 m2/21 kg) bag]. Spatterkote

should be sprayed as its name suggests. Afterapplication, the deck areas should look lightlytextured and when viewed directly from below,1030% of the galvanized surface should remainexposed. A continuous coverage with no deckshowing through is NOT acceptable.

Surface PreparationAll surfaces to receive Spatterkote shall be free ofoil, grease, paints/primers, loose mill scale, dirt orother foreign substances which may impair properadhesion of the fireproofing to the substrate.Spatterkote is not intended for application overalkali sensitive primers.

Job Set-Up, Equipment &Spray InstructionsGeneralSpatterkote can be pumped through the mainsystem directly from the main pump to a smallerpump on the floor or can be applied using a separatemixer/pump set up on the floor. The use of only amain system is considered most cost effective.

For simplest application, start with Spatterkotefirst thing in the morning before application ofMonokote has begun. Pumping will begin withSpatterkote and be immediately followed withretarded Monokote (see caution for sandwichMonokote-Spatterkote-Monokote alternate).Predetermine the number of bags of Spatterkoteneeded to spray the entire floor and place near themixer. UL requires a minimum waiting period of30 minutes after Spatterkote application beforeoverspraying with Monokote or Retro-Guard. Asingle floor or several floors may be sprayed withSpatterkote at one time.

Job Set-UpSet-up detailed below is based on pumpingthrough the main Monokote system to an FM-9(2L4 Rotor Stator) pump on the floor.

A large plaster pump, TM-30, A-3.75 or other(presently being used for Monokote application) isused to pump Spatterkote through main system tothe hopper of a small pump (FM-9 or other 2L4Rotor Stator Pump) placed on spray floor. FM-9 isfitted with 100 ft (30.5 m) max of 114 in. (31 mm)



plaster hose with 6 ft (1.8 m) pole gun. Pole gun tobe 1 or 114 in. by 5 ft (25 or 31 mm by 1.5 m)aluminum pipe with hose swivel and nozzle fittedwith 38 in. (10 mm) tough boy orifice. The 38 in.(10 mm) tough boy orifice is essential to obtainbest pattern and throw to the steel surface, FM-9to be fitted with front wheel to increase floormobility. Monokote floor (main system) hose to befitted with 2 in. (50 mm) KamLoc Brass (quick fit)fitting at the 2 in. x 112 in. (50 mm x 38 mm)reducer. 2 in. (50 mm) hose to be disconnectedand placed near hopper of FM-9. Large pumpmust be able to be shut off from spray floor, 10 gal(38 L) of water should be brought to the sprayfloor to allow for cleanout of the floor pump.

Mixing ProceduresSpatterkote is formulated to be mixed with waterin a mechanical plaster mixer to form a cohesive,uniform slurry of 4455 lb/ft3 (700880 kg/m3).Water nominal 814834 gal (31.233.1 L) per bagshould be added to the mixer followed by additionof Spatterkote. Mixing should continue and wateradjusted to create a wet, creamy mix with theconsistency of medium thick tomato/rice soup.Mixing a wet mix at 35 rpm for a period of1123 minutes will produce proper consistency.Mix will be significantly wetter than Monokote.

Pumpinga. Large plaster pump (TM-30, A3.75 or equal)and hoses should be primed with a small amountof water. Pump should be placed in a low gearand when the hopper is empty the mixer can bedumped and Spatterkote pumping begun. Whenall the Spatterkote has been mixed and dumpedinto the pump hopper, the mixer must bedumped and allowed to empty completely. Thefirst 3 bag batch of Monokote MK-6 can then bemixed with the addition of 2.5 oz (74 mL)[one half of a 5 oz (148 mL) dixie cup] ofplaster retarder. Retarder must be added or fastsetting will occur. When all the Spatterkote hasbeen pumped and the hopper is empty, theretarded Monokote can be dumped and regularMonokote mixing/pumping can continue.

b.On the spray floor the 2 in. (50 mm) hose(open mouth with quick fit) should be held inthe hopper of the FM-9 and the Spatterkote

allowed to flow into the hopper. The FM-9(soap the night before, see section c, whichfollows) should be placed in third gear. Whenthe hopper of the FM-9 is approximately 12 full,start the pump and immediately begin Spat-terkote application. Experience will dictate theproper speed of the large main pump to matchthe output of the FM-9 floor pump.

c. When Monokote appears at the mouth of the 2 in.(50 mm) hose, the main pump can be shut offand the 112 in. (38 mm) Monokote floor hoseattached with the quick fit and laid aside untilcompletion of Spatterkote application. When allthe Spatterkote has been pumped, 5 gal (19 L)of water can be used to wash down the pumpand clean the hoses. When this is complete, anadditional 5 gal (19 L) of water pumped throughthe system will complete the cleanout. When thesystem is clean, a small amount of liquid dishsoap can be dribbled over the end of theturning stator tube in hopper. This will lubricatethe stator and prevent sticking of the tube androtor during start up at a later date.

Cautions1. If Spatterkote is sandwiched between MonokoteMK-6, Z-106/G or Retro-Guard (i.e., Monokotepumping-change to Spatterkote-change back toMonokote) the Monokote batches in front of andfollowing Spatterkote MUST BE RETARDED.One half of a 5 oz (148 mL) dixie cup of plasterretarder added to the mixing water of a 3 bagbatch of Monokote MK-6 or Retro-Guard issufficient.

2.Whenever changing products, the pump hoppershould be allowed to completely empty and thesides scraped clean. Where mixing blades do notclean the mixer, a small amount of water shouldbe added to the mixer and dumped into the fullpump hopper to help empty the mixer completely.

3.Caution: Spatterkote is cement-based. It willstain aluminum curtain walls, car finishes, andother surfaces which are attacked by alkali (lime).

4.Always review the information on the bag and inthe MSDS before using the product. This productis manufactured for professional use only.


Monokote, MK-6, Retro-Guard and Spatterkote are registered trademarks of W. R. Grace & Co.Conn.


This product may be covered by patents or patents pending. Copyright 2007. W. R. Grace & Co.Conn.MK-513G Printed in U.S.A. 12/07 FA/LI/1M




RETRO-GUARD RGReplacement fireproofing

Product DescriptionRetro-Guard RG replacement fireproofing is a singlecomponent, mill-mixed gypsum plaster based productwhich requires only the addition of water on the job siteto form a consistent, pumpable slurry. RG can be usedon structural steel columns, beams, joists, trusses, flatplate cellular and fluted decking.

Features & BenefitsRetro-Guard Cementitious Fireproofing has been specif-ically developed by Grace Construction Products tomeet the needs of the fireproofing respray contractor.Retro-Guard offers the following advantages: Quick setin 7 to 10 minutes with the use ofMonokote Accelerator and Injection System

Low water ratioreduced drying time Less overspraywork close to steel, less cleanup No noxious fumes or irritating particulates releasedduring or after application

Hard durable surface Extra-strength bags for handling and storage ease Fully UL fire tested and classified for use with themost post-removal lock downs in the industry

Dries to a light blue coloreasily identified anddifferentiated

Materialsa. Material shall be Retro-Guard RG replacementfireproofing as manufactured by Grace ConstructionProducts.

b. Mixing water shall be clean, fresh and suitable fordomestic consumption, and free from such amountsof mineral or organic substances as would affect theset of the fireproofing material.

c. Lock down agents shall be UL Classified for use withRetro-Guard RG. Refer to the ULI Fire ResistanceDirectory current edition for products listed withRetro-Guard under Classification Category CBUI.

Delivery & Storagea. All material to be used for fireproofing shall be deliv-ered in original unopened packages bearing the nameof the manufacturer, the brand and the proper Under-writers Laboratories Inc. identification.

Mixinga. Retro-Guard shall be mixed by machine in a conven-tional plaster type mixer or a continuous mixerspecifically modified for cementitious fireproofing.The mixer shall be kept clean and free of all previouslymixed material. The mixer speed in a conventionalmixer shall be adjusted to the lowest speed whichgives adequate blending of the material and a mixerdensity of 4045 pcf (640720 kg/m3) of material.

b. Using a suitable metering device and a conventionalmixer, all water shall be first added to the mixer asthe blades turn. Where possible, the mixer bladesshall then be stopped and all the Retro-Guard fire-proofing added. The mixer blades shall then berestarted. If the mixer blades are left running, Retro-Guard should be added to the mixer as quickly aspossible. Mixing shall continue only until all materialis thoroughly wet and no lumps remain. Targetdensity of 43 1 pcf (688 16 kg/m3) is most desir-able. Overmixing Retro-Guard will reduce pumpingrate and will adversely affect final in-place densityand hangability. Undermixing Retro-Guard will nega-tively affect in-place density and yield.

Steel Surfacesa. Prior to the application of Retro-Guard an inspectionshall be made to determine that all steel surfaces areacceptable to receive fireproofing. The steel to be






fireproofed shall be free of oil, grease, excess rollingcompounds or lubricants, loose mill scale, rust or anyother substance that will impair proper adhesion.Where necessary, the cleaning of steel surfaces toreceive fireproofing shall be the responsibility of theabatement contractor, or general contractor.

b. The project architect shall determine if the painted/primed steel or lock down agent on the steel to receivefireproofing have been tested in accordance withASTME119, to provide the required fire resistance rating.

c. Many Fire Resistance Designs allow the use ofpainted metal floor or roof deck in place of galva-nized decking. Painted decking must be UL listed inthe specific fire resistance designs and must carry theUL classification marking. Consult your local Gracesales representative for details.

d. Prior to application of Retro-Guard, a bonding agent,approved by the fireproofing manufacturer, shall beapplied to all concrete substrates to receive Retro-Guard.

e. In advance of the application of the fireproofing, abond test shall be conducted on all painted/primedsteel surfaces or steel that has been covered with alock down agent to determine if the paint or lock downagent will impair the ambient bond of the fireproofing.

f. Where cellular steel decking is present, both cellularand fluted decking requires the application of Spat-terkote SK-3 before application of Retro-Guard RG.The thickness of SK-3 is incorporated into the totalfireproofing thickness.

g. Fireproofing to the underside of steel roof deckassemblies shall be done only after roofing applica-tion is complete and roof traffic has ceased.

Applicationa. Application of Retro-Guard Fireproofing can be madein the following sequence:1. For thicknesses of approximately 12 in. (13 mm) orless, apply in one pass.

2. For thicknesses of 58 in. (16 mm) or greater, applysecond passes after the first coat has set.The use of the Monokote Accelerator InjectionSystem is required to obtain optimal job site appli-cation performance. The use of the MonokoteAccelerator Injection System will provide quick setmaterial (usually seven to ten minutes after appli-cation), greater in-place yield, and the ability tospray an area in essentially one continuous opera-tion. Second coat can be applied as soon as firstmaterial applied has set.

b. Prior to application of Retro-Guard, a bonding agent,approved by the fireproofing manufacturer, shall beapplied to all concrete substrates to receive Retro-Guard.

c. Spatterkote SK-3 shall be applied to all deck areaswhen flat plate cellular steel decking is present, andas specified in some roof deck designs. Consultcurrent UL Directory for specific use. Spatterkoteshall be applied in accordance with manufacturersapplication instructions.

d. Retro-Guard Fireproofing material shall not be usedif it contains partially set, frozen or caked material.

e. Retro-Guard shall have a minimum average dryin-place density of 15 lbs/ft3 (240 kg/m3).

f. Retro-Guard shall be mixed with water at the job site.g. Monokote Accelerator when used shall be mixed andused according to the manufacturers recommendations.

h. Retro-Guard is applied directly to the steel, at variousrates of application which will be job dependent,using standard plastering type equipment or continu-ous mixer/pump units. A spray gun, with a properlysized orifice and spray shield and air pressure at thenozzle of approximately 20 psi (38 KPa), will providethe correct hangability, density and appearance.NOTE: If freshly sprayed Retro-Guard does not adhereproperly, it is probably due to a too wet mix, poorthickness control, or an improperly cleaned substrate.

Temperature & Ventilationa. An air and substrate temperature of 40F (4.5C)minimum shall be maintained for 24 hours prior toapplication, during application and for a minimum or24 hours after application of Retro-Guard.

b. Provisions shall be made for ventilation to properlydry the fireproofing after application. In enclosedareas lacking natural ventilation, air circulation andventilation must be provided to achieve a minimumtotal fresh air exchange rate of 4 times per hour untilthe material is dry.

Field Testsa. The architect will select an independent testing labo-ratory (for which the owner will pay) to sample andverify the thickness and density of the fireproofing inaccordance with the provisions of ASTM E605-93,Standard Test Method for Thickness and Density ofSprayed Fire-Resistive Material Applied to StructuralMembers or Uniform Building Code StandardNo. 7-6, Thickness and Density Determination forSpray Applied Fireproofing.

b. The architect will select an independent testing labo-ratory (for which the owner will pay) to randomlysample and verify the bond strength of the fireproof-ing in accordance with the provisions of ASTM E736.

c. Results of the above tests will be made available to allparties at the completion of pre-designated areas whichshall have been determined at a pre-job conference.

Safetya. Retro-Guard is SLIPPERYWHENWET.The General Contractor and Applicator shall beresponsible for posting appropriate cautionarySLIPPERYWHENWET signs.

b. AMaterial Safety Data Sheet for Retro-Guard isavailable on our web site at www.graceconstruction.comor call toll free at 866-333-3SBM.


Retro-Guard, Monokote and Spatterkote are registered trademarks of W. R. Grace & Co.Conn.We hope the information here will be helpful. It is based on data and knowledge considered to be true and accurate and is offered for the usersconsideration, investigation and verification, but we do not warrant the results to be obtained. Please read all statements, recommendations orsuggestions in conjunction with our conditions of sale, which apply to all goods supplied by us. No statement, recommendation or suggestion isintended for any use which would infringe any patent or copyright. W. R. Grace & Co.Conn., 62 Whittemore Avenue, Cambridge, MA 02140.In Canada, Grace Canada, Inc., 294 Clements Road, West, Ajax, Ontario, Canada L1S 3C6.This product may be covered by patents or patents pending. Copyright 2007. W. R. Grace & Co.Conn.RG-121K Printed in U.S.A. 12/07 FA/LI/1M




MONOKOTE Z-106 AND Z-106/HY

Portland cement based, medium density,cementitious fireproofing

Product InformationMonokote Z-106 and Z-106/HY are Portland cementbased cementitious fireproofing designed to meetspecific commercial and industrial fire protectionrequirements on structural steel members, floor/ceilingand roof/ceiling assemblies.Monokote Z-106 and Z-106/HY are hard, moistureresistant and suitable for interior areas where resistanceto moisture and abrasion is needed. Formulated for usewith Graces patented Injection System, MonokoteZ-106/HY offers high-yield and improved applicationcharacteristics while providing resistance to repeatedphysical contact and/or high humidity.Note:Monokote Z-106 and Z-106/HY afford the samelevel of fire protection and physical performance.Specifying both Monokote Z-106 and Z-106/HY allowsalternatives to provide the most cost effective installa-tion while assuring the specifier of the same highin-place performance characteristics.

ApplicationsMonokote Z-106 and Z-106/HY can be used for interior,exposed applications where abrasion, high humidity anddamage resistance are desired such as: Special use areas in commercial buildings Transportation terminals Convention centers Stairwells Parking garages Elevator shafts Light manufacturing areas and facilities Mechanical rooms Gymnasiums and pool areas Correctional facilities

BenefitsMonokote Z-106 and Z-106/HY offer the followingadvantages to the architect, owner, applicator and build-ing occupant. Durability100% Portland cement binder providesincreased durability in interior environments wherehigh-traffic resistance to physical abuse is required.

Moisture resistantProvides excellent resistance tohigh humidity and condensation.

Quick setHY formulation allows use with Gracepatented Injection System for high-yield and quick set.

Applicator friendlyLow pumping pressures allowuse of small diameter hoses for increased maneuver-ability and greater pumping distances.

Non-toxicThe factory-mixed blend of commonPortland cement and inert materials require only theaddition of water for mixing and application.

Delivery and Storagea. All material to be used for fireproofing shall be deliv-ered in original unopened packages bearing the nameof the manufacturer, the brand and proper Underwrit-ers Laboratories Inc. labels for fire hazard and fireresistance classifications.

b. The material shall be kept dry until ready for use.Packages of material shall be kept off the ground,under cover and away from sweating walls and otherdamp surfaces. All bags that have been exposed towater before use shall be discarded. Stock of materialis to be rotated and used before its expiration date.

Steel and Concrete Surfacesa. Prior to the application of Monokote Z-106 orZ-106/HY Fireproofing, an inspection shall be madeto determine that all steel and concrete surfaces areacceptable to receive fireproofing. The steel to befireproofed shall be free of oil, grease, excess rollingcompounds or lubricants, loose mill scale, excessrust, non-compatible primer, lock down agent or anyother substance that will impair proper adhesion.

Recommended SpecificationsMedium Density ProductsPhysical Properties Z-106 Z-106/HY Test Method Laboratory Test* ValueMinimum density 22 pcf (350 kg/m3) 22 pcf (350 kg/m3) ASTM E605 See note below**Minimum bond strength 2,000 psf (94.5 kN/m2) 2,000 psf (94.5 kN/m2) ASTM E736 Greater than 2,000 psf

(94.5 kN/m2)Minimum compressive 100 psi (680 kPa) 100 psi (680 kPa) ASTM E761 Greater than 100 psistrength @ 10% deformation (680 kPa)Deflection and No cracking No cracking ASTM E759 Passbond impact No delamination No delamination ASTM E760 PassAir erosion 0.000 gr/ft2 (0.000 gr/m2) 0.000 gr/ft2 (0.000 gr/m2) ASTM E859 0.000 gr/ft2 (0.000 gr/m2)Mold inhibitor Yes Yes ASTM G21 Pass/No growthStandard color Gray Gray NA

* Actual laboratory tested values meet or exceed Graces recommended value. Test reports are available on request from yourGrace sales representative.

** ASTM test methods modified where required, for high density, high performance products.



Where necessary, the cleaning of steel surfaces toreceive fireproofing shall be the responsibility of thegeneral contractor.

b. Prior to application of Monokote Z-106, a bondingagent approved by the manufacturer shall be appliedto all concrete surfaces to receive Z-106.

c. Prior to application of Monokote Z-106/HY, a bondingagent approved by the fireproofing manufacturer shallbe applied to all substrates to receive Z-106/HY.

d. The project architect shall determine if thepainted/primed structural steel to receive fireproofinghas been tested in accordance with ASTM E119, toprovide the required fire resistance rating.

e. No fireproofing shall be applied prior to completionof concrete work on steel decking.

f. Fireproofing to the underside of roof deck assembliesshall be done only after roofing application iscomplete and roof traffic has ceased.

Mixinga. Monokote Z-106 and Z-106/HY Fireproofing shall bemixed by machine in a conventional, plaster-typemixer or a continuous mixer specifically modified forcementitious fireproofing. The mixer shall be keptclean and free of all previously mixed material. Themixer speed in a conventional mixer shall be adjustedto the lowest speed which gives adequate blending ofthe material and a mixer density of 3843 pcf(610690 kg/m3).

b. Using a suitable metering device and a conventionalmixer, all water shall be first added to the mixer asthe blades turn. Mixing shall continue until the mix islump-free, with a creamy texture. All material is tobe thoroughly wet. Target density of 3843 pcf(610690 kg/m3) is most desirable. OvermixingMonokote Z-106 or Z-106/HY will reduce pumpingrate and will negatively effect in-place density andmechanical properties.

Applicationa. Application of Monokote Z-106 or Z-106/HY Fire-proofing can be made in the following sequence:1. Required fire rating thickness will determine if amulti-pass operation is required. If the first pass canbe applied at a thickness sufficient to obtain therequired rating a second pass will not be required.

2. Where the full required thickness can not beapplied in a single pass, subsequent passes can beapplied only after the first coat has set.

b. Monokote Z-106 and Z-106/HY Fireproofing mate-rial shall not be used if they contain partially set,frozen or caked material.

c. Monokote Z-106 and Z-106/HY shall have a minimumaverage dry, in-place density of 22 pcf (350 kg/m3).

d. Monokote Z-106 and Z-106/HY are formulated to bemixed with water at the job site.

e. Monokote Accelerator may be used with MonokoteZ-106/HY to enhance set characteristics and productyield. The Monokote Accelerator is injected into the

Monokote Z-106/HY at the nozzle of the spray gun.Monokote Accelerator shall be mixed and usedaccording to manufacturers recommendations.

f. Monokote Z-106 and Z-106/HY are applied directlyto the steel, at various rates of application which willbe job dependent, using standard plastering typeequipment or continuous mixer/ pump units. A spraygun, with a properly sized orifice and spray shieldand air pressure at the nozzle of approximately 20 psi(0.14 MPa), will provide the correct hangability,density and appearance.

Temperature and Ventilationa. An air and substrate temperature of 40F (4.4C)minimum shall be maintained for 24 hours prior toapplication, during application and for a minimum of24 hours after application of Monokote Z-106 orZ-106/HY.

b. Provisions shall be made for ventilation to properlydry the fireproofing after application. In enclosedareas lacking natural ventilation, air circulation andventilation must be provided to achieve a minimumtotal air exchange rate of 4 times per hour until mate-rial is substantially dry.

Field Testsa. The architect will select an independent testing labo-ratory (for which the owner will pay) to sample andverify the thickness and density of the fireproofing inaccordance with the provisions of ASTM E605(current edition), Standard Test Method for Thicknessand Density of Sprayed Fire-Resistive MaterialApplied to Structural Members or Uniform BuildingCode Standard No. 7-6 Thickness and Density Deter-mination for Spray Applied Fireproofing. Wheresamples are of irregular shape (or sprayed texture),the displacement method (ASTM E605 published inAWCI Technical Manual 12-A) shall be used to deter-mine in-place fireproofing density.

b. The architect will select an independent testing labo-ratory (for which the owner will pay) to randomlysample and verify the bond strength of the fireproof-ing in accordance with the provisions of ASTM E736.

c. Results of the above tests will be made available to allparties at the completion of pre-designated areas whichshall have been determined at a pre-job conference.

Safetya. Monokote Z-106 and Z-106/HY are slippery when wet.The general contractor and applicator shall be respon-sible for posting appropriate cautionary SLIPPERYWHENWET signs. Signs should be posted in allareas in contact with wet fireproofing material. Anti-slip surfaces should be used on all working surfaces.

b. Material Safety Data Sheets for Monokote Z-106 andZ-106/HY are available upon request by writing:Grace Construction Products, Attn: EnvironmentalHealth & Safety Dept., 62 Whittemore Ave.Cambridge, MA 02140.


Monokote and HY are registered trademarks of W. R. Grace & Co.Conn.


This product may be covered by patents or patents pending. Copyright 2007. W. R. Grace & Co.Conn.Z106-13N Printed in U.S.A. 3/07 FA/LI/2M




MONOKOTE Z-106/GGypsum based, medium density, cementitiousfireproofingProduct DescriptionMonokote Z-106/G is a gypsum based cementitiousfireproofing designed to meet commercial and industrial fire protection requirements on structuralsteel members, floor/ceiling and roof/ceiling, andwall assemblies. Z-106/G is designed to meet interior exposed productrequirements where the superior durability and waterresistance of Portland cement based products is not required.

ApplicationsZ-106/G can be used for interior, exposed applica-tions where light abrasion, and damage resistance are desired: Elevator shafts High bay light manufacturing areas High bay mechanical rooms

BenefitsMonokote Z-106/G offers the following advantages tothe architect, owner, applicator and building occupant. Low costZ-106/G is a low cost, medium densityproduct for interior, dry environments subject tointermittent traffic and physical contact.

DurabilityHigher gypsum binder contentimproves damage resistance and helps maintain thefire resistance for the design life of the building.

Quick setMay be used with our patented Injec-tion System for quick set and fast double onmultiple pass applications.

Applicator friendlyLow pumping pressuresallow use of small diameter hoses for increasedmaneuverability and greater pumping distances.

AestheticsCan be spray applied to a fine texture finish.

Non-toxicThe factory-mixed blend of commongypsum, Portland cement and inert materialsrequires only the addition of water for mixing andapplication.

Delivery & Storagea. All material to be used for fireproofing shall bedelivered in original unopened packages bearingthe name of the manufacturer, the brand andproper Underwriters Laboratories Inc. labels forfire hazard and fire resistance classifications.


Steel & Concrete Surfacesa. Prior to the application of Monokote Z-106/G Fire-proofing, an inspection shall be made to determinethat all steel and concrete surfaces are acceptableto receive fireproofing. The steel to be fireproofedshall be free of oil, grease, excess rollingcompounds or lubricants, loose mill scale, excessrust, noncompatible primer, lock down agent orany other substance that will impair proper adhe-sion. Where necessary, the cleaning of steelsurfaces to receive fireproofing shall be theresponsibility of the general contractor.

b. Prior to application of Monokote Z-106/G, abonding agent approved by the manufacturer shallbe applied to all concrete surfaces to receive Z-106/G.

Performance CharacteristicsPhysical Properties Recommended Specifications Test Method/Notes Laboratory Tested* ValueDry density Min. 22 pcf (350 kg/m3) ASTM E605 See note below**Bond strength Min. 500 psf (23.6 kN/m2) ASTM E736 797 psf (37.6 kN/m2)Compressive strength 50 psi (340 KPa) ASTM E761 60.8 psi (413.6 KPa)@ 10% deformationDeflection and No cracking or ASTM E759 Passbond impact delamination ASTM E760 PassAir erosion 0.000 gr/ft2 (0.000 gr/m2) ASTM E859 0.000 gr/ft2 (0.000 gr/m2)Resistance to mold growth No mold growth after 28 days ASTM G21 Pass/No growth

* Independent laboratory tested value. Report available upon request.** All in-place performance tests should be conducted at or below the minimum recommended specification density.

Test reports here were conducted at 22 pcf (350 kg/m3) or below.



c. The project architect shall determine if thepainted/primed structural steel to receive fireproof-ing has been tested in accordance with ASTME119, to provide the required fire resistance rating.

d. No fireproofing shall be applied prior to comple-tion of concrete work on steel decking.


Mixinga. Monokote Z-106/G Fireproofing shall be mixed bymachine in a conventional, plaster-type mixer or acontinuous mixer specifically modified for cemen-titious fireproofing. The mixer shall be kept cleanand free of all previously mixed material. Themixer speed in a conventional mixer shall beadjusted to the lowest speed which gives adequateblending of the material and a mixer density of3843 pcf (610690 kg/m3).

b. Using a suitable metering device and a conven-tional mixer, all water shall be first added to themixer as the blades turn. Mixing shall continueuntil the mix is lump-free, with a creamy texture.All material is to be thoroughly wet. Target densityof 3843 pcf (610690 kg/m3) is most desirable.Overmixing Z-106/G will reduce pumping rate andwill negatively effect in-place density and mechan-ical properties.

Applicationa. Application of Z-106/G Fireproofing can be madein the following sequence:1. For thicknesses of approximately 12 in. (13 mm)or less, apply in one pass.

2. For thicknesses of 58 in. (16 mm) or greater,apply subsequent passes after the first coat has set.

b. Z-106/G Fireproofing material shall not be used ifit contains partially set, frozen or caked material.

c. Z-106/G shall have a minimum average dry, in-place density of 22 pcf (350 kg/m3).

d. Z-106/G is formulated to be mixed with water atthe job site.

e. Monokote Accelerator may be used withMonokote Z-106/G to attain fast set and speedmultiple pass application. The Monokote Accelera-tor is injected into the Monokote Z-106/G at thenozzle of the spray gun. Monokote Acceleratorshall be mixed and used according to manufactur-ers recommendations.

f. Z-106/G is applied directly to the steel, at variousrates of application which will be job dependent,using standard plastering type equipment or

continuous mixer/ pump units. A spray gun, with aproperly sized orifice and spray shield and airpressure at the nozzle of approximately 20 psi(0.14 MPa), will provide the correct hangability,density and appearance.

Temperature & Ventilationa. An air and substrate temperature of 40F (4.4C)minimum shall be maintained for 24 hours prior toapplication, during application and for a minimumof 24 hours after application of Z-106/G.

b. Provisions shall be made for ventilation to prop-erly dry the fireproofing after application. Inenclosed areas lacking natural ventilation, aircirculation and ventilation must be provided toachieve a minimum total air exchange rate of 4 times per hour until material is substantially dry.

Field Testsa. The architect will select an independent testinglaboratory (for which the owner will pay) tosample and verify the thickness and density of thefireproofing in accordance with the provisions ofASTM E605 (current edition), Standard TestMethod for Thickness and Density of SprayedFire-Resistive Material Applied to StructuralMembers or Uniform Building Code Standard No. 7-6 Thickness and Density Determination forSpray Applied Fireproofing. Where samples are ofirregular shape (or sprayed texture), the displace-ment method (ASTM E605 published in AWCITechnical Manual 12-A) shall be used to determinein-place fireproofing density.



Safetya. Z-106/G is slippery when wet. The general contrac-tor and applicator shall be responsible for postingappropriate cautionary SLIPPERY WHEN WETsigns. Signs should be posted in all areas in contactwith wet fireproofing material. Anti-slip surfacesshould be used on all working surfaces.

b. A Material Safety Data Sheet for Monokote Z-106/G is available upon request by writing:Grace Construction Products, Attn: EnvironmentalHealth & Safety Dept., 62 Whittemore Ave.Cambridge, MA 02140

www.graceconstruction.comFor technical assistance call toll free at 866-333-3SBM (3726)Monokote is a registered trademark of W. R. Grace & Co.Conn.We hope the information here will be helpful. It is based on data and knowledge considered to be true and accurateand is offered for the users consideration, investigation and verification, but we do not warrant the results to beobtained. Please read all statements, recommendations or suggestions in conjunction with our conditions of sale, whichapply to all goods supplied by us. No statement, recommendation or suggestion is intended for any use which wouldinfringe any patent or copyright. W. R. Grace & Co.Conn., 62 Whittemore Avenue, Cambridge, MA 02140. In Canada, Grace Canada, Inc., 294 Clements Road, West, Ajax, Ontario, Canada L1S 3C6.This product may be covered by patents or patents pending. Copyright 2007. W. R. Grace & Co.Conn.Z106-19E Printed in U.S.A. 12/07 FA/PDF




MONOKOTE Z-146High density, cementitious fireproofing

Product DescriptionMonokote Z-146 high density cementitious fire-proofing has been developed by Grace ConstructionProducts to meet specialty, commercial and industrialfireproofing requirements.Z-146 is a Portland cement-based, factory-mixedmaterial requiring only the addition of water on thejob for application. It is spray applied directly tostructural steel (beams and columns), providing up to4 hours of fire resistance. Its physical characteristicsare excellent for areas exposed to environmental orclimatic conditions.Z-146 may be used in areas where high durability isrequired such as parking garages. This product isideal for use in clean room environments where issuessuch as particle emissions and off gassing are criticalto the interior environment within the building.

Features & BenefitsZ-146 offers the following advantages to architects,engineers, and applicators: Factory pre-mixedReady to use. No job siteproportioning required. Simply add water in astandard paddle-type plaster mixer and apply withconventional plastering equipment.

Non-toxicThe factory-mixed blend of commonPortland cement and other inert materials requiresonly the addition of water for mixing and application.

Attractive finishesZ-146 may be sprayed orhand troweled after spraying to achieve a lightlytextured appearance.

Equipment versatilityZ-146 can be mixed instandard plaster mixer. After mixing, Z-146 maybe spray-applied with commonly availablepumping and spraying equipment.

Moisture resistantThe Portland cement baseaffords excellent fire protection characteristics inareas subjected to high humidity.

DurableHardness and durability help resistaccidental physical damage.

WeatherableAble to withstand freeze/thaw,wind, rain and other climatic conditions.

UsesZ-146 may be used in parking garages, exteriorareas, mechanical rooms and other areas where ahighly durable product is required.

Delivery & Storagea. All material to be used for fireproofing should bedelivered in original unopened packages bearingthe name of the manufacturer, the brand andproper Underwriters Laboratories Inc. labels forfire hazard and fire resistance classifications.

b. The material should be kept dry until ready foruse. Keep packages of material off the ground,under cover and away from sweating walls and

Performance CharacteristicsPhysical Recommended* Test Method/Notes**Properties SpecificationsDry density Min. 40 pcf (640 kg/m3) ASTM E605Bond strength Min. 10,000 psf (478 kN/m2) ASTM E736Compressive strength 500 psi (3.45 MPa) ASTM E761@ 10% deformationHardness 40 ASTM D2240Yield Theoretical maximum

Color Natural concrete grayVolatile Organic Content Less than 1 PPMW Dynamic headspace(off gassing) at 122F (50C) (part per million by weight) (Thermal desorbtion gas chroma-organic compounds C6-C28 tographymass spectrometry)Leachable ammonia Less than 50 PPB, Leachable ion

50 nanograms/mg by ion chromatography

* Independent test values exceed recommended specification limits. Report available upon request** ASTM International test methods modified for Bond Strength and Compressive Strength, where required,

for high density, high performance products.



other damp surfaces. All bags that have beenexposed to water before use should be discarded.Stock of material is to be rotated and used beforeits expiration date.

Steel & Concrete Surfacesa. Prior to the application of Z-146, an inspectionshould be made to determine that all steel surfacesare acceptable to receive fireproofing. The steel tobe fireproofed should be free of oil, grease, excessrolling compounds or lubricants, loose mill scale,excess rust, noncompatible primer, lock downagent or any other substance that will impairproper adhesion. Where necessary, the cleaning ofsteel surfaces to receive fireproofing will be theresponsibility of the general contractor.

b. Prior to application of Z-146, a bonding agent,approved by the fireproofing manufacturer, shouldbe applied to all concrete substrates to receiveZ-146.

c. The project architect will determine if thepainted/primed steel to receive fireproofing hasbeen tested in accordance with ASTM E119, toprovide the required fire resistance rating.

Mixinga. Z-146 should be mixed by machine in a conven-tional, plaster-type mixer or a continuous mixerspecifically modified for cementitious fireproof-ing. The mixer should be kept clean and free of allpreviously mixed material. Adjust the mixer speedin a conventional mixer to the lowest speed whichgives adequate blending of the material and amixer density of 50 to 60 pcf (800 to 961 kg/m3)of material.

b. Using a suitable metering device and a conven-tional mixer, add all water to the mixer as theblades turn. Mixing should continue until the mixis lump-free, with a creamy texture. All material isto be thoroughly wet. Overmixing Z-146 willreduce pumping rate and will negatively effectin-place density and mechanical properties.

Applicationa. Z-146 material should not be used if it containspartially set, frozen or caked material.

b. Z-146 should have a minimum average dry,in-place density of 40 lbs/ft3 (640 kg/m3).

c. Z-146 is formulated to be mixed with water atthe job site.

d. Z-146 is applied directly to the steel, at variousrates of application which will be job dependent,using standard plastering type equipment orcontinuous mixer/pump units. A spray gun, with aproperly sized orifice and spray shield and airpressure at the nozzle of approximately 20 psi(0.138 MPa), will provide the correct hangability,density and appearance.

Note: If freshly sprayed Z-146 does not adhere prop-erly, it is most likely due to a too wet mix, poorthickness control, or an improperly cleaned substrate.

Temperaturea. An air and substrate temperature of 40F (4.5C)minimum should be maintained for 24 hours priorto application, during application and for aminimum of 72 hours after application of Z-146.

Field Testsa. The architect will select an independent testinglaboratory (for which the owner will pay) tosample and verify the thickness and density of thefireproofing in accordance with the provisions ofASTM E605-77, Standard Test Method forThickness and Density of Sprayed Fire-ResistiveMaterial Applied to Structural Members orUniform Building Code Standard No. 438,Thickness and Density Determination for SprayApplied Fireproofing.

Note: No recognized field bond strength test proce-dure exists for sprayed fireproofing materials withbond strengths greater than 1,000 psf (4,882 kg/m2)such as Monokote Z-146. Where bond strengthspecifications exceed 1,000 psf (4,882 kg/m2) it isrecommended that independent laboratory test databased upon a modified version of ASTM E736 besubmitted to verify specification compliance.

Safetya. Z-146 is slippery when wet. Signs readingSLIPPERYWHENWET should be posted inall areas in contact with wet fireproofing material.Anti-slip surfaces should be used on allworking surfaces.

b. AMaterial Safety Data Sheet for MonokoteZ-146 is available on our web site atwww.graceconstruction.com or call toll free at866-333-3SBM.


Monokote is a registered trademark of W. R. Grace & Co.Conn.


This product may be covered by patents or patents pending. Copyright 2007. W. R. Grace & Co.Conn.Z146-2R Printed in U.S.A. 3/10 FA/DSG/1M




MONOKOTE Z-156Ultra high density, cementitious fireproofing

Product DescriptionMonokote Z-156 ultra high density cementitiousfireproofing has been developed by Grace Construc-tion Products to meet specialty, commercial andindustrial fireproofing requirements.Z-156 is a Portland cement-based, factory-mixedmaterial requiring only the addition of water on thejob for application. It is spray applied directly tostructural steel (beams and columns), providing up to4 hours of fire resistance. Its physical characteristicsare excellent for areas exposed to environmental orclimatic conditions.Z-156 may be used in areas where superior durabilityis required such as parking garages. This product isideal for use in clean room environments where issuessuch as particle emissions and off gassing are criticalto the interior environment within the building.

Features & BenefitsZ-156 offers the following advantages to architects,engineers, and applicators: Factory pre-mixedReady to use. No job siteproportioning required. Simply add water in astandard paddle-type plaster mixer and apply withconventional plastering equipment.

Non-toxicThe factory-mixed blend of commonPortland cement and other inert materials requiresonly the addition of water for mixing and application.

Attractive finishesZ-156 may be sprayed orhand troweled after spraying to achieve a lightlytextured appearance.

Equipment versatilityZ-156 can be mixed instandard plaster mixers. After mixing, Z-156 maybe spray-applied with commonly availablepumping and spraying equipment.

Moisture resistantThe Portland cement baseaffords excellent fire protection characteristics inareas subjected to high humidity.

DurableHardness and maximum durability helpresist accidental physical damage even in thetoughest exposures.

WeatherableAble to withstand freeze/thaw,wind, rain and other climatic conditions.

UsesZ-156 may be used in parking garages, exteriorareas, mechanical rooms and other areas where asuperior durable product is required.

Delivery & Storagea. All material to be used for fireproofing should bedelivered in original unopened packages bearingthe name of the manufacturer, the brand andproper Underwriters Laboratories Inc. labels forfire hazard and fire resistance classifications.

b. The material should be kept dry until ready foruse. Keep packages of material off the ground,under cover and away from sweating walls andother damp surfaces. All bags that have beenexposed to water before use should be discarded.Stock of material is to be rotated and used beforeits expiration date.

Performance CharacteristicsPhysical Recommended Test Method/Notes** Laboratory Tested*Properties Specifications ValueDry density Min. 50 pcf (800 kg/m3) ASTM E605 See note below***Bond strength Min. 10,000 psf (478 kN/m2) ASTM E736 >26,536 psf (>1265 kN/m2)Compressive strength 850 psi (5.86 MPa) ASTM E761 1059 psi (7.32 MPa)@ 10% deformationHardness 40 ASTM D2240 91Yield Theoretical maximum 13.3 board feet

(Target 12.0 bdf per bag) (1.24 m2 at 25 mm) per bagColor Natural concrete grayVolatile Organic Content Less than 1 PPMW Dynamic headspace Less than 1 PPMW(off gassing) at 122F (50C) (part per million by weight) (Thermal desorbtion gas chroma- (Below detectable limits)organic compounds C6-C28 tographymass spectrometry)Leachable ammonia Less than 50 PPB, Leachable ion Less than 50 PPB

50 nanograms/mg by ion chromatography (Below detectable limits)

* Independent laboratory tested value. Report available upon request.** ASTM International test methods modified for Bond Strength and Compressive Strength, where required, for high density,

high performance products.*** All in-place performance tests should be conducted at or below the minimum recommended specification density.



Steel & Concrete Surfacesa. Prior to the application of Z-156, an inspectionshould be made to determine that all steel surfacesare acceptable to receive fireproofing. The steel tobe fireproofed should be free of oil, grease, excessrolling compounds or lubricants, loose mill scale,excess rust, noncompatible primer, lock downagent or any other substance that will impairproper adhesion. Where necessary, the cleaning ofsteel surfaces to receive fireproofing will be theresponsibility of the general contractor.

b. Prior to application of Z-156, a bonding agent,approved by the fireproofing manufacturer, shouldbe applied to all concrete substrates to receiveZ-156.

c. The project architect will determine if thepainted/primed steel to receive fireproofing hasbeen tested in accordance with ASTM E119, toprovide the required fire resistance rating.

Mixinga. Z-156 should be mixed by machine in a conven-tional, plaster-type mi

Documents

Monokote Field App Manual_LR