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Application Guide - Above Waterline Application Systems

Priming - Aluminum

Detailed information on surface preparation of aluminum substrates and blister repairs, prior to priming, can be found earlier in this guide.

Non-Anodized Aluminum

  1. Apply Max Cor CF to the prepared aluminum in areas with an increased corrosion risk for maximum protection. Spray apply Max Cor CF in one full wet coat to approximately 0.8–1.4 mils (20–34 microns) wet film thickness to achieve 0.6–1.0 mils (15–25 microns) dry film thickness.

Important

Allow to cure for a minimum 17 hours.

Caution

Do not use a roller to apply the primer in Step 1. Products in Step 2 must be applied within 72 hours of the completion of Step 1 or the surface must be removed and Step 1 repeated.

  1. Apply Hullgard Extra by roller or spray. NOTE: Only apply Hullgard Extra by roller if applying over Max Cor CF due to risk of snagging roller fibers.

    For spray application, apply 9 mils (220 microns) wet film thickness to achieve 4 mils (100 microns) dry film thickness. Allow a minimum drying time of 3 hours at 68°F (20ºC) before proceeding.

    Roller application will require at least two coats to achieve 4 mils (100 microns) dry film thickness. Allow a drying time of 3 hours at 68°F (20ºC) between coats.

  2. Fill and fair as necessary with Awlfair LW. Allow to cure 12+ hours. Note: Apply Awlfair LW within 6 months of application of Hullgard Extra. Alternatively, sand Hullgard Extra prior to application of Awlfair LW if more than 6 months has passed.

    Caution

    If polyester putties are used they should be kept to an absolute minimum. Only use polyester putties for pinholes and very slight scratches or dents (1mm deep x 1mm wide maximum use). Polyester putties shrink and distort rapidly. Epoxy fillers are much more stable.

  3. Block and machine sand with 36-80 grit paper. Remove air pockets and chamfer the edges prior to refilling as appropriate.
  4. Remove sanding dust and residue before applying more Awlfair LW. Stop when the faired surface meets the fairing quality specified for the project.
  5. Prime the entire surface with High Build. Allow to cure 12 hours or overnight.

    Other alternative schemes, such as replacing High Build with Ultra Build, are available. Contact your local Technical Service Representative for more information.


  6. High Build must always be sanded with 120 - 220 grit paper before overcoating.
  7. Blow off the surface with clean, dry compressed air while dry wiping with clean rags to remove sanding dust and residue. Wipe surface with Awlgrip Wipe-­Down Solvent (NA/AP: Awlprep T0008; EU: Surface Cleaner T0340) using the Two Cloth Method.
  8. Prime the entire surface with 545 Epoxy Primer (Spray). Allow to dry 12+ hours.


  9. Alternatively you can also use Awlquik (Brush & Roll) in place of 545 Epoxy Primer.

    Tip

    The application of the 545 Epoxy Primer in the step above (provided sufficient DFT is applied and the sanded finish is acceptably smooth) can be seen as the final priming coat. Further application of 545 Epoxy Primer prior to topcoating would not be necessary.

Following sanding, if necessary, surface is now ready for final prime and topcoat.

Aluminum Blister Repair

Important

Following removal of the blistered material and the aluminum being suitably prepared, the first coat of primer must be applied within 8 hours, ideally within 4 hours. Products in Step 1 must be applied within 72 hours of the completion of Max Cor CF application or the surface must be removed and Max Cor CF re-applied.

Tip

For the ultimate anti­-corrosive scheme, first prime the prepared aluminum with Max Cor CF.
NOTE: This must be during the same work shift, preferably within 4 hours after the final surface preparation. Spray apply Max Cor CF in one full wet coat to approximately 0.8–1.4 mils (20–34 microns) wet film thickness to achieve 0.6–1.0 mils (15–25 microns) dry film thickness.

Important

Allow to cure for a minimum 17 hours.

Caution

Do not use a roller to apply Max Cor CF. See previous caution regarding wicks. Products in Step 1 must be applied within 72 hours of the completion of Max Cor CF application or the surface must be removed and Max Cor CF re-applied.

  1. Apply Hullgard Extra by roller or spray.
    NOTE: Only apply Hullgard Extra by roller if applying over Max Cor CF due to risk of snagging roller fibers. For spray application apply 9 mils (220 microns) wet film thickness to achieve 4 mils (100 microns) dry film thickness. Allow a minimum drying time of 3 hours at 68°F (20ºC) before proceeding.

    Roller application will require at least two coats to achieve 4 mils (100 microns) dry film thickness. Allow a drying time of 3 hours at 68°F (20ºC) between coats.


  2. Fill and fair as necessary with Awlfair LW. Allow to cure 12+ hours.

    Caution

    If polyester putties are used they should be kept to an absolute minimum. Only use polyester putties for pinholes and very slight scratches or dents (1mm deep x 1mm wide maximum use). Polyester putties shrink and distort rapidly. Epoxy fillers are much more stable.


  3. Block and machine sand with 36-80 grit paper. Remove air pockets and chamfer the edges prior to refilling as appropriate. Remove sanding dust and residue before applying more Awlfair LW. Stop when the faired surface meets the fairing quality specified for the project.


  4. a: Faired Systems

    Prime the entire surface with High Build. Allow to cure 12 hours or overnight.

    Other alternatives schemes, such as replacing High Build with Ultra Build, are available. Contact your local Technical Sales Representative for more information.


    Sand the entire surface smooth with 120–220 grit paper.

    Blow off the surface with clean, dry compressed air while dry wiping with clean rags to remove sanding dust and residue. Wipe surface with Awlgrip Wipe-­Down Solvent (NA/AP: Awlprep T0008; EU: Surface Cleaner T0340) using the Two Cloth Method. Prime the entire surface with 545 Epoxy Primer (Spray). Allow to dry 12+ hours.

    Tip

    The application of the 545 Epoxy Primer in the step above (provided sufficient DFT is applied and the sanded finish is acceptably smooth) can be seen as the final priming coat. Further application of 545 Epoxy Primer prior to topcoating would not be necessary.

    Following sanding, if necessary, surface is now ready for final prime and topcoat.

    b: Thin film unfaired systems

    Max Cor CF must be primed with either Hullgard Extra or High Build before application of 545 Epoxy Primer (spray). Allow 12+ hours.

    Alternatively, you can use Awlquik (Brush & Roll) in place of 545 Epoxy Primer.

    Tip

    Use care when applying this primer. If smoothly applied and all surfaces are adequately covered, it may be used as the final prime step.

Following sanding, if necessary, surface is now ready for final prime and topcoat.

Anodized Aluminum (pre–treated with Wash Primer CF)

  1. Prime the entire surface with 545 Epoxy Primer (Spray). Allow to dry 12+ hours.

    Alternatively, you can use Awlquik (Brush & Roll) in place of 545 Epoxy Primer.

    Tip

    Use care when applying this primer. If smoothly applied and all surfaces are adequately covered, it may be used as the final prime step.

Following sanding, if necessary, surface is now ready for final prime and topcoat.