1. Surface Preparation (Critical)

Correct preparation directly affects adhesion and performance.

• Substrate condition: Sound, dry, and structurally stable
• Clean: Remove dust, dirt, chalking, oil, mould, salt, and loose paint
• Repairs: Fill cracks, repair defects, and allow to cure

Priming:
• Bare metal: Approved anti-corrosive primer
• Masonry/concrete: Suitable masonry sealer or primer
• Previously painted surfaces: Ensure compatibility and sound adhesion

Surface moisture content must be within acceptable limits for coating application.

2. Mixing the Insultec Paint

Insultec contains specialised insulating solids and must be mixed correctly.

• Use a low-speed mechanical mixer
• Mix until fully homogeneous, scraping sides and base of pail
• Do not over-mix (avoid aeration)
• Do not strain the product
• Thinning is generally not required
• If absolutely necessary for spraying: max 2–5% clean water, subject to ambient conditions and equipment

3. Spray Equipment (Recommended)

Insultec is a high-build coating. Standard domestic sprayers are not suitable.

Airless Spray (Preferred)

• Pump: Minimum 3.8–5.5 L/min output
• Pressure: 2,500–3,000 psi (adjust to achieve even fan)
• Hose: 3/8" internal diameter (minimise length)
• Gun: Heavy-duty airless gun

Tip Size

• 0.021" – 0.027"
• Most common: 0.023" or 0.025"

Larger tips may be required in hot conditions or on textured substrates.

4. Application Technique

• Apply in multiple coats, not one heavy pass

Typical system:
• 2–3 coats, depending on specification
• Spray in a cross-hatch pattern for even coverage

Maintain consistent:
• Gun distance
• Spray speed
• Overlap (50% overlap recommended)
• Target specified dry film thickness (DFT) per coat
(DFT is critical to thermal performance)

Do not attempt to “stretch” the product.

5. Drying & Recoat Times (Indicative)

Actual times vary with temperature, humidity, and airflow.

• Touch dry: ~30–60 minutes
• Recoat: 2–4 hours
• Full cure: 7 days

Avoid application:
• Below manufacturer’s minimum temperature
• In rain, fog, or heavy dew
• On hot substrates in direct sun

6. Clean-Up

• Clean spray equipment immediately after use
• Use clean water before product begins to set
• Do not allow material to dry inside hoses or gun

7. Common Application Errors to Avoid

• Using under-powered sprayers
• Over-thinning
• Applying too thin to meet DFT
• Poor surface preparation
• Spraying in extreme heat or wind

These issues reduce both durability and thermal performance.

8. Practical Tip for Installers