Amercoat

Amerlock 400AL/AL WN
High Solids Epoxy Coating

Product Data/
Application Instructions Physical Data
Finish ..................................... semi-gloss
• Amerlock 400AL is a surface tolerant maintenance coating Colour .................................... aluminium
which can be applied to mechanically cleaned surfaces
• Amerlock 400AL WN Wintergrade version can be applied at Components .......................... 2
temperatures down to 0°C
Mixing ratio (by volume)
• Gives performance superior to conventional coatings resin .................................... 1 part
when applied over mechanically cleaned surfaces cure ..................................... 1 part
• Contains special ingredients which wet the surface and
penetrate any traces of existing rust Curing mechanism ................ solvent release and chemical
• Can be applied over most existing coatings and can be reaction between components
topcoated with a wide range of topcoats
Volume solids
• High solids, VOC compliant 400AL ................................. 85% (ASTM-D2697 modified) *
• Compatible with prepared damp surfaces 400AL WN .......................... 79% (ASTM-D2697 modified) *

VOC**
Typical Uses 400 AL
Amerlock 400AL is most often used in those areas where blasting EC SED 1999/13/EC ........... 157 g/kg (196 g/l)
is impractical or impossible. Uses include steel structures in UK PG6/23(92) Appendix 3 . 150 g/l (1.3 lbs/gal)
industrial facilities, bridges, tanks, marine weathering, oil tanks,
piping, roofs, water towers and other exposures subject to high VOC**
humidity and moisture. Amerlock 400AL has good resistance to 400AL WN
splash/spillage and fumes of acids, alkalies. solvents and fresh and EC SED 1999/13/EC ........... 197 g/kg (240 g/l)
salt water. Amerlock 400AL can be applied over damp substrates. UK PG6/23(92) Appendix 3 . 145 g/l (1.2 lbs/gal)
For immersion in potable and seawater, abrasive blasting to Sa 2½
is required. For cold climates a special wintergrade version, Dry film thickness .................. 125 µm per coat
Amerlock 400AL WN is available for use in temperature between 0-
20°C (32-68ºF) Number of coats .................... 1-2

Calculated coverage
Outstanding Characteristics 400AL ................................. 6.8 m²/l at 125 µm
Amerlock 400AL is a high performance coating, which can be 400AL WN .......................... 6.3 m²/l at 125 µm
applied to mechanically cleaned surfaces. Adhesion is excellent to
Allow for application losses, surface irregularities, etc.
a wide variety of substrates. Amerlock 400AL has excellent
application characteristics. It can be applied by brush, roller, Specific gravity
conventional and airless spray equipment. 400AL ................................. 1.31 kg/l (mixed product)
400AL WN .......................... 1.23 kg/l (mixed product)
Approvals and Certificates Flash points (Closed Cup) ..... 400AL 400AL WN
Amerlock 400AL may be used for the transport of grain, as certified
by the North of England Industrial Health Service. ºC ºF ºC ºF
Complies with COT 16.75 and CCOT 17.09 (specifications for resin .................................... 51 124 23 73
epoxy primer and sealer). cure ..................................... 24 75 43 109
Amercoat 9HF ..................... 26 79 26 79
Amercoat 12 ....................... 24 75 24 75

* Volume solids is measured in accordance with ASTM D2697

modified. Slight variations ±3% may occur due to colour and testing
variances.

** VOC figures are quoted according to both the EC directive

1999/13/EC which are theoretically calculated figures and the UK
PG6/23(92) Appendix 3 which are practically determined figures.

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Amerlock 400AL/AL WN
Application Data Summary
Amerlock 400AL is a high solids epoxy coating for the
protection of steel surfaces.. To obtain the maximum
performance for which Amerlock 400AL is formulated, strict Application Data
adherence to all application instructions, precautions, Substrate .................................. tightly adhering existing coatings,
conditions and limitations is necessary. If conditions exist mechanically cleaned steel
that are not within the requirements or limitations described,
consult your PPG representative. Application methods ................. airless or conventional spray, brush
or roller

Environmental Conditions (during application and drying)

Surface Preparation Amerlock 400AL
Coatings performance in general, is proportional to the Air temperature: ...................... 5 - 50ºC 41-122ºF
degree of surface preparation. Abrasive blasting is usually Surface temperature: .............. 5 - 60°C 41-140ºF
the most effective and economical method. For Amerlock 400AL WN
Air temperature ....................... 0 to 20°C 32-68ºF
circumstances where this is impossible or impractical, Surface temperature ............... 0 to 40°C 32-104ºF
Amerlock 400AL has been developed.
Amerlock 400AL can be applied over mechanically cleaned To prevent moisture condensation during application, surface
surfaces. Amerlock 400AL may be used over most types of temperature must be at least 3°C/5ºF above dew point. Never apply
properly prepared and tightly adhering coatings, however a coatings under adverse environmental conditions. Ensure good
ventilation when applied in confined areas to assist evaporation and
test batch is recommended for use over existing coatings. elimination of solvents.
Remove all loose rust, dirt, oil and grease or other
contaminants from surface. Power tool clean in accordance For applications at high temperatures, a special 'X' cure is available.
with St 3 or SSPC-SP3 or hand tool clean in accordance See below for specific potlife, and specific drying times for the different
with St 2 or SSPC-SP2 Water blasting is also acceptable. If cure versions. Minimum temperature for full cure is 10°C/50ºF for
Amerlock 400AL.
possible, abrasive blasting is preferred. Amerlock 400AL
can be applied over damp substrates. Induction time (at 20ºC) ............. not applicable
For immersion in potable and sea water abrasive blasting is
required. Blast clean to Sa 2½ or SSPC-SP-10 (ISO 8501- Potlife (in hours, °C, °F) ......... 5/41 10/50 20/68 30/86
400AL 8 6 4 2
1). Note: Amerlock 400AL WN is not recommended for
400AL WN 4 2½ NR NR
immersion service. ‘X’ cure NR NR 8 4

Drying Times
Application Equipment (in hours) ºC/ºF 5/41 10/50 20/68 30/86
The following equipment is listed as a guide and suitable dry to touch
equipment from other manufacturers may be used. 400AL NR 16 6 4
400AL WN 9 7 2 NR
Adjustments of pressure and change of tip size may be ‘X’ cure NR NR 16 6
needed to obtain the proper spray characteristics. dry through
AIRLESS SPRAY - Standard airless spray equipment, such 400AL NR 72 24 10
as Graco, DeVilbiss, Nordson-Bede, Spee-Flo or others 400AL WN 18 14 4 NR
having a fluid tip with a 0.48 mm (0.019 inch) orifice or ‘X’ cure NR NR 36 16
dry to recoat/topcoat
larger. 400AL NR 24 16 8
CONVENTIONAL SPRAY - Industrial equipment such as 400AL WN 24 16 8 NR
DeVilbiss MBC or JGA gun with 78 or 765 air cap and "E" ‘X’ cure NR NR 24 16
fluid tip and heavy mastic spring or Binks No. 18 or 62 with NR = Not Recommended
a 66 x 63 PB nozzle setup. Separate air and fluid pressure
Maximum recoat time*............... extemded
regulators and a mechanical pot agitator are recommended.
A moisture and oil trap in the main air supply line is * Amerlock 400AL/WN has an extended maximum overcoating time.
essential. Surfaces to be overcoated must be clean and dry. Any contamination
MIXER - Use power mixer powered by an air motor or an must be identified and adequately removed. Particular attention must be
paid to surfaces that have been exposed to heat and/or sunlight and
explosion proof electric motor. where chalking may be present. A degree of surface cleaning will be
BRUSH/ROLLER - Use clean, short bristled brush or required. Your PPG representative can advise on suitable cleaning
medium nap roller. Brush or roller application may result in methods.
a duller or less uniform aluminium colour. Application by
brush or roller will require at least 2 coats to achieve the NOTE: potlife and drying times are dependent on air and steel
temperature, applied film thickness, ventilation and other environmental
specified 125 µm dry film thickness. conditions. Times are proportionally shorter at higher temperature and
longer at lower temperatures. Prior to recoating/topcoating ensure the
surface is clean. Maximum recoating/topcoating time intervals are
Repair dependent on temperature, degree of weathering, type of topcoat, and
Spot blast or power tool clean bare substrate to the service conditions of the complete coating system. Consult your PPG
requirements shown under surface preparation. Feather representative for specific recommendations.
edges of intact coating. Remove dust, dirt and
Thinner ..................................... Amercoat 9HF
contamination before recoating.
Cleaner ..................................... Amercoat 12

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Amerlock 400AL/AL WN

Application Procedure
Amerlock 400AL is packaged in the proper mixing Shipping Data
proportions of resin and cure.
Packaging (400AL and 400AL WN) 20 l
Resin 10 l in 20 l can
resin ............................... 10 l in 20 l can
Cure 10 l in 10 l can
cure ................................ 10 l in 10 l can
1. Flush equipment with recommended cleaner before use. Shipping weight ................ 400AL 400AL WN
2. Stir each of the components prior to mixing to an even resin ............................... ± 13.9 kg 13.3 kg
consistency with a power mixer. cure ................................ ± 15.7 kg 14.5 kg
3. Add cure to resin, and continue stirring for 10 minutes.
NOTE: since the potlife is limited and shortened by high
temperatures, do not mix more material than will be Packaging (400AL and 400AL WN) 5 l
used within the potlife period. resin ............................... 2.5 l in 5 l can
4. For conventional spray, thin only as needed for cure ................................ 2.5 l in 2.5 l can
workability with no more than 10% of recommended
thinner. Thinning is normally not needed for airless Shipping weight ................ 400AL 400AL WN
spray. resin ............................... ± 3.6 kg 3.4 kg
NOTE: for Amerlock 400AL WN a maximum of 20 % cure ................................ ± 3.5 kg 3.3 kg
thinning is allowed when necessary for workability.
5. Stir during application to maintain uniformity of material.
Apply a wet coat by even, parallel passes. Overlap each
pass 50% to avoid bare areas, pinholes or holidays. Shelf life 1 year from shipment date when
6. Double coat all welds, rough spots, sharp edges and stored indoors in unopened, original containers at 5- 40°C
corners, rivets, bolts, etc. (41-104ºF)
7. Application at 150 µm of Amerlock 400AL wet film
thickness will normally provide 125 µm dry film. With
Amerlock 400AL WN a wet film thickness of 160 µm is
required to provide a dry film thickness of 125 µm.
Maximum dft per coat -when measured- should not
exceed 250 µm per coat.
8. Check thickness of dry coating with a non-destructive
dry film thickness gauge, such as Mikrotest or
Elcometer. If less than specified thickness, apply
additional material as needed.
9. Small damaged or bare areas and random pinholes or
holidays can be touched up by brush. Repair larger
areas by spray.
10. In confined areas ventilate with clean air during
application and drying until all solvents are removed.
Temperature and humidity of ventilating air must be
such that moisture condensation will not form on
surface.
11. Clean all equipment with recommended cleaner
immediately after use or at least at the end of each
working day or shift. When left in spray equipment,
Amerlock 400AL will cure and cause clogging.

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Amerlock 400AL/AL WN

Caution Any recommendations or suggestion relating to the

This product is flammable. Keep away from heat and
use of the products made by PPG, whether in its
open flame. Keep container closed. Use with technical literature, or response to specific enquiry, or
adequate ventilation. Avoid prolonged and repeated otherwise, is based on data believed to be reliable;
contact with skin. If used in confined areas, observe however, the products and information are intended
the following precautions to prevent hazards of fire or for use by Buyer’s having requisite skill and know-
explosion or damage to health:
how in the industry, and therefore it is Buyer to satisfy
1. circulate adequate fresh air continuously during itself of the suitability of the products for its own
application and drying; particular use and it shall be deemed that Buyer has
2. use fresh air masks and explosion proof
done so, as its sole discretion and risk. Variation in
equipment; environment, changes in procedures of use, or
3. prohibit all flames, sparks, welding and smoking.
extrapolation of data may cause unsatisfactory
Do not empty into drains. Take precautionary
results.
measures
against static discharges. For specific information on
hazardous ingredients, required ventilation, possible Limitation of Liability
consequences of contact, exposure and safety PPG’s liability on any claim of any kind, including
measures claims based upon PPG’s negligence or strict liability,
see Safety Data Sheet for any loss or damage arising out of, connected with,
or resulting from the use of the products, shall in no
case exceed the purchase price allocable to the
Safety products or part thereof which give rise to the claim.
Since improper use and handling can be hazardous In no event shall PPG be liable for consequential or
to health and cause of fire or explosion, safety
incidental damages.
precautions included with Product Data/Application
Instruction and Material Safety Data Sheet must be Due to PPG’s policy of continuous product
observed during all storage, handling, use and drying improvement, the information contained in this
periods. Product Data/Application Instructions sheet is subject
to change without notice. It is the Buyer’s
Warranty responsibility to check that this issue is current prior to
PPG warrants its products to be free from defects in using the product. For the most up-to-date Product
material and workmanship. PPG’s sole obligations Data/Application Instructions always refer to the
and Buyer’s exclusive remedy in connection with the PPG Protective & Marine Coatings website at
products shall be limited, at PPG’s option, to either www.ppgpmc.com
replacement of products not conforming this warranty
or credit to Buyer’s account in the invoiced amount of To avoid any confusion that may arise through
the non-conforming products. Any claim under this translation into other languages, the English version
warranty must be made by Buyer to PPG in writing of the Product Data/Application Instructions will be the
within five (5) days of Buyer’s discovery of the governing literature and must be referred to in case of
claimed defect, but in no event later than the deviations with product literature in other languages.
expiration of the applicable shelf life, or one year from
the delivery date, whichever is earlier. Buyer’s failure
Condition of Sale
to notify PPG of such non-conformance as required All our transactions are subject to our Terms and
herein shall bar Buyer from recovery under this Conditions of Sale.
warranty.

PPG makes no other warranties concerning the

product. No other warranties, whether express,
implied or statutory, such as warranties of
merchantability or fitness particular purpose,
shall apply. In no event shall PPG be liable for
consequential or incidental damages.

PPG Industries Netherlands BV

Tel +(31) 345 587 200
www.ppgpmc.com

Page 4 of 4 Revision date: 15-04-2008