ESTIMATION GUIDE
Why Sell By Weight And Not By The Gallon?
The reason Pyroclad X1 is sold by weight is because the actual spray applied coverage is better than theoretical 1604 ft2/mil (I liter per mm/m2) with 100% solid calculations. This is due to entrained air that is trapped in the film during application. The entrained air reduces the applied density, making the material go farther and increasing the material’s coverage. Selling by weight makes sense with this material because it avoids the customer paying for air and allows for more realistic coverage rates. Actual coverage is up to 27% higher than theoretical. All competitors also sell by weight.
- Wet density in the can: 1.30 g/cm3
(This is the theoretical density that would be used for traditional 1604 ft2/mil estimates).
- Spray applied density: 1.03 g/cm3
(This is the estimated sprayed film density which is a 27% reduction in density and equates to 27% higher coverage rate).
The density of these types of materials can vary with application methods and parameters ranging between 1.03 – 1.20 g/cm3. An applied density of 1.03 g/cm3 can be achieved by using Carboline approved plural component equipment and application procedures.
Typical Densities:
- 100% solids plural application: 1.03-1.10 g/cm3
- Batch mix single component application
(thinned up to 5%): 1.10-1.20 g/cm3
- Trowel application (thinned 2%):1.10-1.20 g/cm3
As with loss factors, density is variable with application techniques. The contractor will ultimately have to decide what density/spread rate will be used depending on application methods.
Packaging
Pyroclad X1 is supplied in 40 kg (full) and 20 kg (half) kits for simplified estimation. The full kits shall be used for plural application and the half kits shall be used for batch mix and trowel applications.
Kit Sizes:
Full Kit: 40 kg (88.1 lbs) / 7.88 gal (29.8 L)
Half Kit: 20 kg (44.1 lbs) / 3.94 gal (14.9 L)
Steps To Estimate Material Thickness And Quantity
1. Determine fire rating type and duration: (e.g. J30/H30) J: jet fire, H: hydrocarbon fire
2. Add jet and hydrocarbon fire rating to obtain total rating duration: (e.g. J30 + H30 = 60 minute total duration). This is the total duration that is used to obtain thicknesses from the appropriate hydrocarbon certification tables
3. Verify certification requirement for project (Lloyd’s Register, Det Norske Veritas, American Bureau of Shipping)
4. Verify limiting temperature for project (e.g. 400°C)
5. Verify type of structure (I-section, hollow section, bulkhead, deck)
6. List all steel sizes to be fireproofed in Hp/A: (heated perimeter/cross section area) or W/D: (weight per linear foot/dimensional area) and list total m2 or ft2 of each steel size
7. Verify total project size in m2 or ft2
8. For hydrocarbon protection only, find Pyroclad X1 thickness required for hydrocarbon protection of structural member type at specified rating and limiting temperature using Hp/A charts in product certification
For combination hydrocarbon and jet fire ratings, add the two ratings together to establish overall fire duration. Find Pyroclad X1 thickness required for hydrocarbon protection of structural member type at specified rating for this total duration and limiting temperature using Hp/A charts in product certification
9. If required, find jet fire erosion factor for structural member type at specified rating and limiting temperature using Hp/A charts in product certification.
10. If combination rating, add jet fire erosion factor to hydrocarbon thickness to calculate total thickness in mm
11. Multiply required PFP thickness (mm) x density (g/cm³) to calculate weight of PFP per unit area in (kg/m²) @ specified thickness
12. Multiply weight of PFP per unit area x total m² of project or steel, to generate total material needed in kilograms
13. Divide weight of total material required by kit weight (40 kg or 20 kg kit) to determine number of kits required for project
14. Multiply weight of PFP per unit area x price per kg to calculate material cost per m²
15. Estimate High Temp Mesh required for project with overlaps (typically 1.2 m2 of mesh is required per 1 m2 of steel surface area (150 mm overlaps at all seams without waste)
16. Add total PFP cost and mesh cost to calculate total cost for project
17. Always require the applicator or buyer establishes their own overspray / waste factors
18. Always contact a Carboline Fireproofing Technical Service representative to assist in generating Pyroclad X1 thicknesses and to establish selling price for all thickness estimates
Conversion Units
In order to estimate projects using density instead of gallon coverage, the project must be estimated in metric units. Items should be converted to or from metric using the following conversion tables below.
PYROCLAD X1 WEIGHT/VOLUME CONVERSIONSkg / lbs / gallon / liter
1.0 / 2.205 / 0.197 / 0.746
0.454 / 1.0 / 0.089 / 0.339
5.071 / 11.180 / 1.0 / 3.785
0.153 / 0.338 / 0.264 / 1.0
PYROCLAD X1 KIT CONVERSIONS
kg / lbs / gallon / liter
40 / 88.1 / 7.88 / 29.8
20 / 44.1 / 3.94 / 14.9
LENGTH
From / To / Multiplier
inches / centimeters / 2.54
centimeters / inches / 0.04
feet / centimeters / 30.48
feet / meters / 0.3048
centimeters / feet / 0.03281
meters / feet / 3.2808
mils / microns / 25.0
microns / mils / 0.04
AREA
From / To / Multiplier
ft2 / m2 / 0.0929
m2 / ft2 / 10.764
VOLUME
From / To / Multiplier
US gallon / liter / 3.785
US gallon / UK gallon / 0.833
liter / US gallon / 0.264
liter / UK gallon / 0.22
UK gallon / US gallon / 1.20
UK gallon / liter / 4.55
AREA/VOLUME
From / To / Multiplier
ft2/US gal / m2/liter / 0.0245
ft2/US gal / m2/UK gal / 0.112
m2/liter / ft2/US gal / 40.76
m2/liter / ft2/UK gal / 48.93
m2/UK gal / m2/liter / 0.2197
WEIGHT
From / To / Multiplier
lbs / kg / 0.4536
kg / lbs / 2.2046
PRESSURE
From / To / Multiplier
psi / Kg/cm2 / 0.0703
Kg/cm2 / psi / 14.223
TEMPERATURE
From / To / Multiplier
°C / °F / °F = (°Cx9)/5 +32
°F / °C / °C = (°F–32x5)/9
Steel Conversion Table
W/D: Weight per linear foot / Dimensional Perimeter
A/P: cross sectional Area / cross sectional Perimeter
M/D: Mass / Dimensional Perimeter
HP/A: Heated Perimeter / cross sectional Area
HP/A / W/D / A/P / M/D / HP/A / W/D / A/P / M/D / HP/A / W/D / A/P / M/D
m ^ -1 / lb/in/ft / sq in/in / kg/sqm / m ^ -1 / lb/in/ft / sq in/in / kg/sqm / m ^ -1 / lb/in/ft / sq in/in / kg/sqm
400 / 0.33 / 0.098 / 19.6 / 212 / 0.63 / 0.186 / 36.9 / 88 / 1.15 / 0.447 / 89.0
395 / 0.34 / 0.100 / 19.8 / 208 / 0.64 / 0.189 / 37.7 / 86 / 1.56 / 0.458 / 91.1
390 / 0.34 / 0.101 / 20.1 / 204 / 0.66 / 0.193 / 38.4 / 84 / 1.59 / 0.469 / 93.3
386 / 0.35 / 0.102 / 20.3 / 200 / 0.67 / 0.197 / 39.2 / 82 / 1.63 / 0.480 / 95.5
380 / 0.35 / 0.104 / 20.6 / 197 / 0.68 / 0.200 / 39.8 / 80 / 1.67 / 0.492 / 97.9
375 / 0.36 / 0.105 / 20.9 / 194 / 0.69 / 0.203 / 40.4 / 78 / 1.71 / 0.505 / 100.4
370 / 0.36 / 0.106 / 21.2 / 191 / 0.70 / 0.206 / 41.0 / 76 / 1.76 / 0.518 / 103.1
365 / 0.37 / 0.108 / 21.5 / 188 / 0.71 / 0.209 / 41.7 / 74 / 1.81 / 0.532 / 105.9
360 / 0.37 / 0.109 / 21.8 / 185 / 0.72 / 0.213 / 42.3 / 72 / 1.86 / 0.547 / 108.8
355 / 0.38 / 0.111 / 22.1 / 182 / 0.74 / 0.216 / 43.0 / 70 / 1.91 / 0.562 / 111.9
350 / 0.38 / 0.112 / 22.4 / 179 / 0.75 / 0.220 / 43.8 / 68 / 1.97 / 0.579 / 115.2
345 / 0.39 / 0.114 / 22.7 / 176 / 0.76 / 0.224 / 44.5 / 66 / 2.03 / 0.597 / 118.7
340 / 0.39 / 0.116 / 23.0 / 173 / 0.77 / 0.228 / 45.3 / 64 / 2.09 / 0.615 / 122.4
335 / 0.40 / 0.118 / 23.4 / 170 / 0.79 / 0.232 / 46.1 / 62 / 2.16 / 0.635 / 126.3
330 / 0.41 / 0.119 / 23.7 / 167 / 0.80 / 0.236 / 46.9 / 60 / 2.23 / 0.656 / 130.6
325 / 0.41 / 0.121 / 24.1 / 164 / 0.82 / 0.240 / 47.8 / 58 / 2.31 / 0.679 / 135.1
320 / 0.42 / 0.123 / 24.5 / 161 / 0.83 / 0.245 / 48.7 / 56 / 2.39 / 0.703 / 139.9
315 / 0.24 / 0.125 / 24.9 / 158 / 0.85 / 0.249 / 49.6 / 54 / 2.48 / 0.729 / 145.1
310 / 0.43 / 0.127 / 25.3 / 155 / 0.86 / 0.254 / 50.5 / 52 / 2.57 / 0.757 / 150.6
305 / 0.44 / 0.129 / 25.7 / 152 / 0.88 / 0.259 / 51.5 / 50 / 2.67 / 0.787 / 156.7
300 / 0.45 / 0.131 / 26.1 / 149 / 0.90 / 0.264 / 52.6 / 48 / 2.79 / 0.820 / 163.2
296 / 0.45 / 0.133 / 26.5 / 146 / 0.92 / 0.270 / 53.7 / 46 / 2.91 / 0.856 / 170.3
292 / 0.46 / 0.135 / 26.8 / 143 / 0.94 / 0.275 / 54.8 / 44 / 3.04 / 0.895 / 178.0
288 / 0.46 / 0.137 / 27.2 / 140 / 0.96 / 0.281 / 56.0 / 42 / 3.18 / 0.937 / 186.5
284 / 0.47 / 0.139 / 27.6 / 137 / 0.98 / 0.287 / 57.2 / 40 / 3.34 / 0.984 / 195.8
280 / 0.48 / 0.141 / 28.0 / 134 / 1.00 / 0.294 / 58.5 / 38 / 3.52 / 1.036 / 206.1
276 / 0.48 / 0.143 / 28.4 / 131 / 1.02 / 0.301 / 59.8 / 36 / 3.71 / 1.094 / 217.6
272 / 0.49 / 0.145 / 28.8 / 128 / 1.04 / 0.308 / 61.2 / 34 / 3.93 / 1.158 / 230.4
268 / 0.50 / 0.147 / 29.2 / 125 / 1.07 / 0.315 / 62.7 / 32 / 4.18 / 1.230 / 244.8
264 / 0.51 / 0.149 / 29.7 / 122 / 1.10 / 0.323 / 64.2 / 30 / 4.46 / 1.312 / 261.1
260 / 0.51 / 0.151 / 30.1 / 119 / 1.12 / 0.331 / 65.8 / 28 / 4.78 / 1.406 / 279.8
256 / 0.52 / 0.154 / 30.6 / 116 / 1.15 / 0.339 / 67.5 / 26 / 5.14 / 1.514 / 301.3
252 / 0.53 / 0.156 / 31.1 / 113 / 1.18 / 0.348 / 69.3 / 24 / 5.57 / 1.640 / 326.4
248 / 0.54 / 0.159 / 31.6 / 110 / 1.22 / 0.358 / 71.2 / 22 / 6.08 / 1.790 / 356.1
244 / 0.55 / 0.161 / 32.1 / 107 / 1.25 / 0.368 / 73.2 / 20 / 6.69 / 1.969 / 391.7
240 / 0.56 / 0.164 / 32.6 / 104 / 1.29 / 0.379 / 75.3 / 19 / 7.04 / 2.072 / 412.3
236 / 0.57 / 0.167 / 33.2 / 102 / 1.31 / 0.386 / 76.8 / 18 / 7.43 / 2.187 / 435.2
232 / 0.58 / 0.170 / 33.8 / 100 / 1.34 / 0.394 / 78.3 / 17 / 7.86 / 2.316 / 460.8
228 / 0.59 / 0.173 / 34.4 / 98 / 1.36 / 0.402 / 79.9 / 16 / 8.36 / 2.461 / 489.6
224 / 0.60 / 0.176 / 35.0 / 96 / 1.39 / 0.410 / 81.6 / 15 / 8.91 / 2.625 / 522.2
220 / 0.61 / 0.179 / 35.6 / 94 / 1.42 / 0.419 / 83.3 / 14 / 9.55 / 2.812 / 559.5
216 / 0.62 / 0.182 / 36.3 / 92 / 1.45 / 0.428 / 85.1 / 13 / 10.28 / 3.028 / 602.5
212 / 0.63 / 0.186 / 36.9 / 90 / 1.49 / 0.437 / 87.0 / 12 / 11.14 / 3.281 / 652.8
Pyroclad X1 Estimation Worksheet (Example)
Project Information (*Required)
*Project Name / XYZ Platform / Date / 4-1-13*Location / Singapore / Prepared By / Sean Younger
*Client / Chevron / *Carboline Representative / Mike Ogles
Fire Rating Information (*Required)
*Jet FireRating / 30 minutes / *Hydrocarbon Rating / 90 minutes / *Total
Duration / 120 minutes
*Certification (Circle one) / *Limiting Temperature (Circle one)
LR / DNV / ABS / 300°C / 350°C / 400°C / 450°C / 500°C / 550°C / 600°C
*1. List steel type:
I-Section
Hollow Section
Bulkhead
Deck
*2. List Hp/A for each member
*3. List m2 of each steel size for project
*4. For bulkheads and decks list H or J rating and steel thickness
Certificate No.
1. SAS F120374 (I-Section)
2. SASF120373/M1 (Hollow)
3. SASF120361 (Bulkhead)
4. SAS F130013 (Jet Fire)
*Structure Type
Project Estimation
Structure Type / Hp/A / m2 / Hydrocarbon Thickness
(mm) / Erosion
Factor
(mm) / Total
Thickness
(mm) / Weight per Unit Area
(kg/m2) / Total Weight
(kg)
Thickness x density
(mm) x (g/cm3) / Weight per area x m2
(kg/m2) x (m2)
I-Section / 40 / 1000 / 5.6 / 1.8 / 7.4 / 7.4 x 1.03 = 7.62 kg/m2 / 7.62 x 1000 = 7,622 kg
I-Section / 60 / 500 / 6.9 / 1.8 / 8.7 / 8.96 / 4,480
I-Section / 80 / 500 / 9.0 / 1.8 / 10.8 / 11.12 / 5,560
Hollow Section / 100 / 1000 / 10.6 / 1.3 / 11.9 / 12.25 / 12,250
Hollow Section / 120 / 1000 / 12.4 / 1.3 / 13.7 / 14.11 / 14,110
Bulkhead / 8.0 mm
J30 / H90 / 1000 / 17.5 / 1.8 / 19.3 / 19.88 / 19,880
Total m2 for project / 5000 / Total Pyroclad X1 weight for project (kg) / 63,902 kg
Total kits required
(total weight/kit weight) / 63,902 kg / 40 kg = 1,598 full kits
Pyroclad X1 Cost / 63,902 kg x $16.00/kg = $1,022,432.00
Project Estimation For Each Member Size (*Required)
Pyroclad X1 / High Temp Mesh (HTM)Member Type / I-Section / Member Type / I-Section
Member Size (Hp/A) / 40 / Member size (Hp/A) / 40
*Area (m2) / 1000 / *Project Size (m2) / 1000
Pyroclad X1 Thickness (mm) / 7.4 / Overlap / 1.2 m2 per m2 of steel
*Assumed Density / 1.03 g/cm3 / HTM Requirement (m2) / 1,200 m2
*Spread Rate / 7.62 kg/m2
Pyroclad X1 Unit Price / $16.00/kg
Pyroclad X1 Price per m2 / 7.62 x 16.00 = $121.92 / HTM Price per m2 / 17.50/m2
Total Pyroclad X1 Cost / $121.92 x 1000 = $121,920.00 / Total HTM Cost / 17.50 x 1200 = $21,000.00
Notes:
1. Does not include loss or overspray for Pyroclad X1
2. Does not include loss for High Temp Mesh (only overlap requirement)
3. Does not include surface prep, primer, topcoat, or labor
4. Pyroclad X1 spread rate: 1.03 kg for 1 mm per m2 (based on 1.03 g/cm3)
Cost Summary