Marathon 500 AG
Marathon 500 AG
Marathon 500 AG
UK
Marathon 500
Product description
This is a two component polyamine cured epoxy coating. It is a surface tolerant, high solids, high build product.
Will continue to cure when immersed in water. The product has high abrasion resistance. Suitable for
environments with very high corrosivity, such as areas in the splash or tidal zone. Can be used as primer, mid
coat, finish coat or as single coat system in atmospheric and immersed environments. Suitable for properly
prepared carbon steel, galvanised steel, stainless steel, aluminium and concrete substrates.
Scope
The Application Guide offers product details and recommended practices for the use of the product.
The data and information provided are not definite requirements. They are guidelines to assist with efficient and
safe use, and optimum service of the product. Adherence to the guidelines does not relieve the applicator of
responsibility for ensuring that the work meets specification requirements.
Jotuns liability is in accordance with general product liability rules.
The Application Guide (AG) must be read in conjunction with the relevant specification, Technical Data Sheet
(TDS) and Safety Data Sheet (SDS) for all the products used as part of the coating system.
Referred standards
Reference is generally made to ISO Standards. When using standards from other regions it is recommended to
reference only one corresponding standard for the substrate being treated.
Surface preparation
The required quality of surface preparation can vary depending on the area of use, expected durability and if
applicable, project specification.
When preparing new surfaces, maintaining already coated surfaces or aged coatings it is necessary to remove all
contamination that can interfere with coating adhesion, and prepare a sound substrate for the subsequent
product.
Inspect the surface for hydrocarbon and other contamination and if present, remove with an alkaline detergent.
Agitate the surface to activate the cleaner and before it dries, wash the treated area using fresh water. Paint
solvents (thinners) shall not be used for general degreasing or preparation of the surface for painting due to the
risk of spreading dissolved hydrocarbon contamination. Paint thinners can be used to treat small localized areas
of contamination such as marks from marker pens. Use clean, white cotton cloths that are turned and replaced
often. Do not bundle used solvent saturated cloths. Place used cloths into water. When the surface is an existing
coating, verify with technical data sheet and application guide of the involved products, both over coatability and
the given maximum over coating interval.
Process sequence
Surface preparation and coating should normally be commenced only after all welding, degreasing, removal of
sharp edges, weld spatter and treatment of welds is complete. It is important that all hot work is completed
before coating commences.
FOR FREE ADVICE AND TRADE PRICES CONTACT SML MARINE PAINTS
SUPPLIED BY SML MARINE PAINTS - TEL: 01285 862 132 - WEB: WWW.SMLMARINEPAINTS.CO.UK
Application Guide
Marathon 500
Carbon steel
Initial rust grade
The steel shall preferably be Rust Grade A or B (ISO 8501-1). It is technically possible to apply the coating to
rust grades C and D, but it is practically challenging to ensure specified film thickness on such a rough surface,
hence risk of reduced lifetime of the coating system. When steel of Rust Grade C or D is coated, the frequency of
inspection and testing should be increased.
Metal finishing
For areas in corrosivity category C1 to C4 (ISO 12944-2) all irregularities, burrs, slivers, slag and spatter on
welds, sharp edges and corners shall conform to minimum grade P2 (ISO 8501-3) Table 1, or as specified. All
edges shall have a rounded radius of minimum 2 mm subjected to three pass grinding or equally effective
method.
For areas in corrosivity category C5, Im1-3 the requirement are for the steel to conform to grade P2 (ISO
8501-3) Table 1. All edges shall have a rounded radius of minimum 2 mm subjected to three pass grinding or
equally effective method. One may use a mechanical grinder fitted with a suitable abrasive disc. All sharp
irregularities, burrs, slivers, slag and spatter on welds, whether apparent before or after blast cleaning, shall be
removed before coating application. It is recommended that welding smoke should be removed by low-pressure
Water Cleaning LP WC method (ISO 8501-4) Wa 1 using fresh water. Welding smoke residues are water soluble
and could cause blistering if not removed by washing before blasting.
Defective welds shall be replaced and treated to an acceptable finish before painting. Temporary welds and
brackets shall be ground to a flat finish after removal from the parent metal.
Surface preparation and coating should normally be commenced only after all metal finishing and degreasing of
a specific area is complete. It is important as much hot work as possible is completed before coating commences.
Pitting repair
Pittings in steel can be difficult to cover fully with most coatings. In some areas it is practically feasible to use
filler to fill pittings. This should then be done either after the initial surface preparation or after application of
first coat.
Cleanliness
After pre-treatment is complete, the surface shall be dry abrasive blast cleaned to Sa 2½ (ISO 8501-1) using
abrasive media suitable to achieve a sharp and angular surface profile.
Surface profile
Recommended surface profile 75-150 μm, grade Medium to Coarser than coarse G (ISO 8503-2). Measure the
achieved profile with surface replication tape (Testex) to ISO 8503-5 or by a surface roughness stylus instrument
(ISO 8503-4).
The selected abrasive must be compatible with both the surface to be blast cleaned and the specified coating
system. The abrasive shall meet specifications as per relevant parts of ISO 11124 (Specification for metallic
blast-cleaning abrasives), or ISO 11126 (Specification for non-metallic blast-cleaning abrasives). It should be
sampled and tested as per relevant parts of ISO 11125 (metallic abrasives) or ISO 11127 (non-metallic
abrasives). Dry storage of abrasive and shelter for blasting pots is necessary to prevent equipment becoming
clogged with damp abrasive.
All abrasive blast media used should be new and not recirculated, with the exception of Steel Grit. If this is
utilized the circulation process must include a cleaning process.
The supply of clean air to blasting pots must be secured to avoid contamination of abrasive and thereby of blast
cleaned surfaces. Compressors must be fitted with sufficient traps for oil and water. It is also recommended to fit
two water separators at the blasting machine to ensure a supply of moisture-free air to the abrasive chamber.
FOR FREE ADVICE AND TRADE PRICES CONTACT SML MARINE PAINTS
SUPPLIED BY SML MARINE PAINTS - TEL: 01285 862 132 - WEB: WWW.SMLMARINEPAINTS.CO.UK
Application Guide
Marathon 500
Dust contamination
At the completion of abrasive blasting the prepared surface shall be cleaned to remove residues of corrosion
products and abrasive media, and inspected for surface particulate contamination. Maximum contamination level
is rating 1 (ISO 8502-3) as per Figure 1. Dust size no greater than class 2.
Minor damage of the coating may be prepared to St 3 (ISO 8501-1). Suitable method is disc grinding with rough
discs only. Ensure the surface is free from mill scale, residual corrosion, failed coating and is suitable for painting.
The surface should appear rough and mat.
Overlapping zones to intact coating shall have all leading edges feathered back by sanding methods to remove
all sharp leading edges and establish a smooth transition from the exposed substrate to the surrounding coating.
Consecutive layers of coating shall be feathered to expose each layer and new coating shall always overlap to an
abraded existing layer. Abrade intact coatings around the damaged areas for a minimum 100 mm to ensure a
mat, rough surface profile, suitable for over coating.
Water jetting
High pressure water jetting surface preparation refers to ISO 8501-4, for substrates previously coated either
with a full coating system (surface DC A, DC B, DC C) or shop primer (surface DP I and DP Z). The surface
definition for existing coating (DC) refers to the degree of coating breakdown according to ISO 4628.
It is important before considering hydro jetting, to ensure that the specified coating system is compatible with
the existing coating system. High pressure water jetting does not remove mill scale or create surface roughness,
and is only useful for surfaces with an initial roughness suitable for the subsequent coat.
Optimum performance is achieved with preparation grade Wa 2 (ISO 8501-4). Minimum preparation grade is Wa
1. For DP I and DP Z surface Wa 2 is accepted.
Maximum accepted grade of flash rust for any preparation is FR M (ISO 8501-4).
Alternatively minimum approved preparation grade is SSPC-SP WJ-2/ NACE WJ-2, Very thorough cleaning.
Maximum accepted flash rust grade is Moderate (M).
Galvanised steel
The galvanised finish shall be smooth as is consistent for a protective coating and shall have no sharp fins, sharp
edges, dross or zinc ash on the surface. If present, remove by mechanical cleaning methods.
After removal of excess zinc and surface defects the area to be coated shall be degreased to ISO 12944-4, Part
6.1.4 Alkaline Cleaning. The galvanised surface shall be dry abrasive brush off blast cleaned with the nozzle
angle at 45-60° from perpendicular at reduced nozzle pressure to create a sharp and angular surface profile
using approved non-metallic abrasive media. As a guide, a surface profile 25-55 µm, grade Fine G; Ry5 (ISO
8503-2) should be achieved.
After removal of excess zinc and surface defects the area to be coated shall be degreased with an alkaline
detergent, washed by Low-Pressure Water Cleaning (LPWC) to a grade corresponding to the description of Wa 1
(ISO 8501-4) or higher standard and the surface abraded using mechanical or hand sanding methods using non-
metallic abrasives or bonded fibre abrasive pads to remove all polish and to impart a scratch pattern to the
surface. Do not use high speed rotational sanders.
Water jetting
Inspect the surface for process residues, hydrocarbon contamination and zinc corrosion by-products. If present,
remove with an alkaline detergent. Agitate the surface to activate the detergent and before it dries, wash the
treated area by Low-Pressure Water Cleaning (LPWC) to a grade corresponding to the description of Wa 1 (ISO
8501-4) or higher standard using fresh water.
Optimum performance is achieved with preparation to a grade corresponding to the description of Wa 2½.
Minimum preparation grade is Wa 1.
Aluminium
Abrasive blast cleaning
FOR FREE ADVICE AND TRADE PRICES CONTACT SML MARINE PAINTS
SUPPLIED BY SML MARINE PAINTS - TEL: 01285 862 132 - WEB: WWW.SMLMARINEPAINTS.CO.UK
Application Guide
Marathon 500
After pre-treatment of welds, sharp edges, removal of weld spatter and other surface contamination the surface
shall be degreased using an alkaline detergent which is agitated with non-metallic brushes and removed by Low-
pressure Water Cleaning (LPWC) to a grade corresponding to the description of Wa 1 (ISO 8501-4) or higher
standard with fresh water. The surface shall be then dry abrasive blast cleaned with an approved non-metallic
abrasive media to create a sharp and angular surface profile. As a guide, a surface profile between 25-55 µm,
grade Fine G; Ry5 (ISO 8503-2) should be achieved.
After pre-treatment of welds, sharp edges, removal of weld spatter and other surface contamination the surface
shall be degreased using an alkaline detergent which is agitated with non-metallic brushes and then fresh water
rinsed. The cleaned surface shall be then hand or machine abraded with non-metallic abrasives or bonded fibre
machine or hand abrasive pads to remove all surface polish and to impart a scratch pattern to the surface. Do
not use high speed rotational sanders.
Water jetting
Surfaces not contaminated with hydrocarbon deposits shall be cleaned by Low-pressure Water Cleaning (LPWC)
to a grade corresponding to the description of Wa 1 (ISO 8501-4) or higher standard using fresh water to
remove all dusts, chloride and non-visible contamination.
Optimum performance is achieved with preparation to a grade corresponding to the description of Wa 2½.
Minimum preparation grade is Wa 1.
Stainless steel
The surface to be coated shall be dry abrasive blast cleaned as required for the specified surface profile using
approved non-metallic abrasive media which is suitable to achieve a sharp and angular surface profile. As a
guide, a surface profile corresponding to 25-55 µm, grade Fine G; Ry5 (ISO 8503-2) should be achieved.
Examples of recommended abrasives are:
• Ferrite free almandite garnet grade 30/60 and 80 grade (US Mesh size)
• Aluminium oxide grade G24
Chlorinated or chlorine containing solvents or detergents must not be used on stainless steel.
Concrete
Sand sweeping
Dry abrasive blast cleaning to SSPC-SP 13/NACE No. 6. Where the concrete has become contaminated with oils,
grease, or fuels, alkaline detergent may be used to remove the contaminants. It is important to only clean an
area that can be fully washed down after degreasing before the cleaner can dry on the surface. Where the
contamination has penetrated deep in to the substrate it may be necessary to use Flame/ Thermal cleaning. All
prepared surfaces should then have all “blow holes” and other surface defects filled with suitable filler that is
compatible with the primer and finish coat system to ensure that the coating can be applied over a smooth and
regular substrate.
Diamond grind the surface to remove all laitance and expose the aggregates.
Coated surfaces
Shop primers
Shop primers are accepted as temporary protection of steel plates and profiles. However the shop primer should
be completely removed through blast cleaning to minimum Sa 2½ (ISO 8501-1) using abrasive media suitable
to achieve a sharp and angular surface profile 50-85 µm, grade Medium G; Ry5 (ISO 8503- 2).
FOR FREE ADVICE AND TRADE PRICES CONTACT SML MARINE PAINTS
SUPPLIED BY SML MARINE PAINTS - TEL: 01285 862 132 - WEB: WWW.SMLMARINEPAINTS.CO.UK
Application Guide
Marathon 500
Application
Acceptable environmental conditions - before and during application
Before application, test the atmospheric conditions in the vicinity of the substrate for the dew formation
according to ISO 8502-4.
Air temperature 10 - 60 °C
Substrate temperature 10 - 50 °C
Relative Humidity (RH) 10 - 85 %
• Only apply the coating when the substrate temperature is at least 3 °C (5 °F) above the dew point
• Do not apply the coating if the substrate is wet or likely to become wet
• Do not apply the coating if the weather is clearly deteriorating or unfavourable for application or curing
• Do not apply the coating in high wind conditions
Product mixing
Paint temperature 23 °C
The temperature of base and curing agent is recommended to be 18 °C or higher when the product is mixed.
Thinner/Cleaning solvent
Thinner: Jotun Thinner No. 17
Application data
Spray application
FOR FREE ADVICE AND TRADE PRICES CONTACT SML MARINE PAINTS
SUPPLIED BY SML MARINE PAINTS - TEL: 01285 862 132 - WEB: WWW.SMLMARINEPAINTS.CO.UK
Application Guide
Marathon 500
Several factors influence, and need to be observed to maintain the recommended pressure at the nozzle. Among
factors causing pressure drop are:
- extended hoses or hose bundles
- extended hose whip-end line
- small internal diameter hoses
- high paint viscosity
- large spray nozzle size
- inadequate air capacity from compressor
- incorrect or clogged filters
This product can be applied up to 50 % higher than maximum specified film thickness without loss of technical
properties.
To ensure correct film thickness, it is recommended to measure the wet film thickness continuously during
application using a painter's wet film comb (ISO 2808 Method 1A). The measurements should be done as soon
as possible after application.
Fast drying paints may give incorrect (too low) readings resulting in excessive dry film thickness. For multi layer
physically drying (resoluble) coating systems the wet film thickness comb may give too high readings resulting
in too low dry film thickness of the intermediate and top coats.
Use a wet-to-dry film calculation table (available on the Jotun Web site) to calculate the required wet film
thickness per coat.
When the coating has cured to hard dry state the dry film thickness can be checked to SSPC PA 2 or equivalent
standard using statistical sampling to verify the actual dry film thickness. Measurement and control of the WFT
and DFT on welds is done by measuring the wet and dry film thickness adjacent to and no further than 15 cm
from the weld.
Ventilation
Stripe coating
It is important to pay special attention to edges, openings, rear sides of stiffeners, scallops etc. and to apply a
stripe coat to these areas where the spray fan may not reach or deposit an even film.
When applying a stripe coat to bare metal use only a stiff, round stripe coating brush to ensure surface wetting
and filling of pits in the surface.
Stripe coating shall be of a different colour to the main primer coat and the topcoat colour and should be applied
FOR FREE ADVICE AND TRADE PRICES CONTACT SML MARINE PAINTS
SUPPLIED BY SML MARINE PAINTS - TEL: 01285 862 132 - WEB: WWW.SMLMARINEPAINTS.CO.UK
Application Guide
Marathon 500
in an even film thickness, avoiding excessive brush marks in order to avoid entrapped air. Care should be taken
to avoid excessive film thickness. Pay additional attention to pot life during application of stripe coats.
Jotun recommends a minimum of one stripe coat. However, in extremely aggressive exposure conditions there
may be good reason to specify two stripe coats.
Coating loss
The consumption of paint should be controlled carefully, with thorough planning and a practical approach to
reducing loss. Application of liquid coatings will result in some material loss. Understanding the ways that
coating can be lost during the application process, and making appropriate changes, can help reducing material
loss.
Some of the factors that can influence the loss of coating material are:
- type of spray gun/unit used
- air pressure used for airless pump or for atomization
- orifice size of the spray tip or nozzle
- fan width of the spray tip or nozzle
- the amount of thinner added
- the distance between spray gun and substrate
- the profile or surface roughness of the substrate. Higher profiles will lead to a higher "dead volume"
- the shape of the substrate target
- environmental conditions such as wind and air temperature
Drying and curing times are determined under controlled temperatures and relative humidity below 85 %, and
at average of the DFT range for the product.
If the product is applied during the tidal zone on piles and jetties, it can be immersed after 1 hour. Early
immersion will lead to a whitening of colours, most visible on darker colours. The corrosion performance is
however not affected.
Surface (touch) dry: The state of drying when slight pressure with a finger does not leave an imprint or reveal
tackiness.
Walk-on-dry: Minimum time before the coating can tolerate normal foot traffic without permanent marks,
imprints or other physical damage.
Dry to over coat, minimum: The recommended shortest time before the next coat can be applied.
Dried/cured for immersion: Minimum time before the coating can be permanently immersed in sea water.
FOR FREE ADVICE AND TRADE PRICES CONTACT SML MARINE PAINTS
SUPPLIED BY SML MARINE PAINTS - TEL: 01285 862 132 - WEB: WWW.SMLMARINEPAINTS.CO.UK
Application Guide
Marathon 500
If maximum over coating interval is exceeded the surface should in addition be carefully roughened to ensure
good inter coat adhesion.
Itself 14 d 10 d 7d 3d
polyurethane 7d 5d 3d 2d
polysiloxane 7d 5d 3d 2d
epoxy 14 d 10 d 7d 3d
vinyl epoxy 7d 5d 3d 2d
Itself 5d 5d 3d 2d
epoxy 5d 5d 3d 2d
vinyl epoxy 5d 5d 3d 2d
Anti skid aggregate should only be added in the final coat, and should not be used in single coat systems.
Spread the aggregate evenly on the surface before half of time to Surface dry. For coatings applied in 400 to
800 µm DFT use Jotun Anti-skid, coarse particle size (700 - 1000 µm). The recommended usage is 3.0 - 3.5 kg
per 10 litres of paint.
For coatings applied in 800 to 1500 µm DFT use Jotun Anti-skid, extra coarse particle size (1200 - 1600 µm).
The recommended usage is 3.5 - 4.0 kg per 10 litres of paint.
FOR FREE ADVICE AND TRADE PRICES CONTACT SML MARINE PAINTS
SUPPLIED BY SML MARINE PAINTS - TEL: 01285 862 132 - WEB: WWW.SMLMARINEPAINTS.CO.UK
Application Guide
Marathon 500
Sags and runs can be caused by too high wet film thickness, too much thinner added or the spray gun used too
close to the surface.
Repair by using a paint brush to smooth the film when still wet.
Sand down to a rough, even surface and re-coat if the coating is cured.
Orange peel can be caused by poor flow/levelling properties of the paint, poor atomization of the paint, thinner
evaporating too fast or the spray gun held too close to the surface.
This can be rectified by abrading the surface and applying an additional coat after having adjusted the
application properties or the application technique.
Dry spray can be caused by poor atomization of the paint, spray gun held too far from the surface, high air
temperature, thinner evaporating too fast or coating applied in windy conditions.
Sand down to a rough even surface and re-coat.
Pinholes can be caused by entrapped solvents in the film or by incorrect application technique. Pinholes can be
repaired as per procedure for damages to the coating layer or to the substrate, ref. above.
When required by the specification, the coating shall be tested for film discontinuity according to ASTM D 5162,
test method A or B as appropriate for the actual dry film thickness.
All recorded defects shall be repaired by best practical means.
Quality assurance
The following information is the minimum required. The specification may have additional requirements.
- Confirm that all welding and other metal work has been completed before commencing pre-treatment and
surface preparation
- Confirm that installed ventilation is balanced and has the capacity to deliver and maintain the RAQ
- Confirm that the required surface preparation standard has been achieved and is held prior to coating
application
- Confirm that the climatic conditions are within recommendations in the AG, and are held during the application
- Confirm that the required number of stripe coats have been applied
- Confirm that each coat meets the DFT requirements in the specification
- Confirm that the coating has not been adversely affected by rain or other factors during curing
- Observe that adequate coverage has been achieved on corners, crevices, edges and surfaces where the spray
gun cannot be positioned so that its spray impinges on the surface at 90° angle
- Observe that the coating is free from defects, discontinuities, insects, abrasive media and other contamination
- Observe that the coating is free from misses, sags, runs, wrinkles, fat edges, mud cracking, blistering, obvious
pinholes, excessive dry spray, heavy brush marks and excessive film build
- Observe that the uniformity and colour are satisfactory
All noted defects shall be fully repaired to conform to the coating specification.
Caution
This product is for professional use only. The applicators and operators shall be trained, experienced and have
the capability and equipment to mix/stir and apply the coatings correctly and according to Jotun's technical
documentation. Applicators and operators shall use appropriate personal protection equipment when using this
product. This guideline is given based on the current knowledge of the product. Any suggested deviation to suit
the site conditions shall be forwarded to the responsible Jotun representative for approval before commencing
the work.
For further advice please contact your local Jotun office.
Accuracy of information
Always refer to and use the current (last issued) version of the TDS, SDS and if available, the AG for this
product. Always refer to and use the current (last issued) version of all International and Local Authority
Standards referred to in the TDS, AG & SDS for this product.
Colour variation
FOR FREE ADVICE AND TRADE PRICES CONTACT SML MARINE PAINTS
SUPPLIED BY SML MARINE PAINTS - TEL: 01285 862 132 - WEB: WWW.SMLMARINEPAINTS.CO.UK
Application Guide
Marathon 500
Some coatings used as the final coat may fade and chalk in time when exposed to sunlight and weathering
effects. Coatings designed for high temperature service can undergo colour changes without affecting
performance. Some slight colour variation can occur from batch to batch. When long term colour and gloss
retention is required, please seek advice from your local Jotun office for assistance in selection of the most
suitable top coat for the exposure conditions and durability requirements.
When applicable, refer to the separate application procedure for Jotun products that are approved to
classification societies such as PSPC, IMO etc.
Disclaimer
The information in this document is given to the best of Jotun's knowledge, based on laboratory testing and
practical experience. Jotun's products are considered as semi-finished goods and as such, products are often
used under conditions beyond Jotun's control. Jotun cannot guarantee anything but the quality of the product
itself. Minor product variations may be implemented in order to comply with local requirements. Jotun reserves
the right to change the given data without further notice.
Users should always consult Jotun for specific guidance on the general suitability of this product for their needs
and specific application practices.
If there is any inconsistency between different language issues of this document, the English (United Kingdom)
version will prevail.
FOR FREE ADVICE AND TRADE PRICES CONTACT SML MARINE PAINTS