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Polyclad 777 PL
PRODUCT DATA SHEET

S E L E C T I O N & S P E C I F I C AT I O N D ATA
Solvent-free aromatic polyurethane, ASTM D16
Generic Type
Type V

Polyclad 777 PL is a high performance 100% solids structural polyurethane designed to provide
superior corrosion protection for steel, ductile iron and concrete pipe. Typical uses include pipeline
exterior surfaces.
Description
Tenacious adhesion and high impact resistance allow its use in the harshest environments. It forms
a dense, long-term impermeable barrier that is ready for service moments after application through
a fast-set cure mechanism. No primer is required.

• Fast curing increases throughput

• Excellent abrasion resistance
• Superior wetting properties for outstanding adhesion
Features
• Mix ratio of 1:1 with easy application properties
• Can be topcoated with Carbothane series of products
• Unlimited film build with single or multi-pass coats

Color Standard colors are: Yellow (0600) and Medium Blue (0100)

Finish Gloss

Primer None needed - direct to steel

25 - 40 mils (635 - 1016 microns) For most applications on steel.

Dry Film Thickness
25 - 125 mils (635 - 3175 microns) For other applications on steel, depending on service conditions.

Steel pipeline exteriors, steel valves & fittings, steel pilings, steel poles (above & below ground),
Typical Uses buried tank exteriors, penstocks. Also other applications requiring high abrasion resistance, rapid
cure and superior corrosion protection for steel.

Solids Content By Volume 100% +/- 1%

Theoretical Coverage
Rates

1604 ft²/gal at 1.0 mils (39.4 m²/l at 25 microns)

Theoretical Coverage 64 ft²/gal at 25.0 mils (1.6 m²/l at 625 microns)
Rate 13 ft²/gal at 125.0 mils (0.3 m²/l at 3125 microns)
Allow for loss in mixing and application.

As Supplied : <0.04 lbs/gal (5 g/L)*

VOC Values
*Calculated value

Approvals Meets requirements of AWWA C222-08

Due to its aromatic composition Polyclad 777 PL will tend to yellow or darken in exterior UV
Limitations
exposure. This will not affect performance.

Topcoats Contact Carboline Technical Service for more information.

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Polyclad 777 PL
PRODUCT DATA SHEET

S U B S T R AT E S & S U R F A C E P R E PA R AT I O N
Prepare surface as noted below. Ensure dust/smut from blasting operation does not interfere with
General adhesion. Recommend using ISO 8502-3 to confirm low surface dust with a preferred rating of "1"
or "2". Apply coating prior to any flash rusting or contamination fallout.

Remove all contaminants in accordance with SSPC-SP 1. Near White Metal Blast clean in
Steel accordance with NACE No. 2/SSPC-SP 10 and create 3-5 mils, (75-125 microns), of dense angular
anchor profile.

Remove all contaminants in accordance with SSPC-SP 1. Abrasive blast clean in accordance with
Ductile or Cast Iron
National Association of Pipe Fabricators, Inc., NAPF 500-03-04.

P E R F O R M A N C E D ATA

All test data was generated under laboratory conditions. Field testing results may vary.

Test Method System Results

Abrasion Resistance ASTM D4060 1 Coat Polyclad 777 PL 27 mg loss
Adhesion to Steel ASTM D4541 1 Coat Polyclad 777 PL Minimum 1500 psi
Cathodic Disbondment ASTM G-95 1 Coat Polyclad 777 PL 4 mm
Chemical Resistance ATSM D543 1 Coat Polyclad 777 PL Pass 30 day immersion
Dielectric Strength D149 1 Coat Polyclad 777 PL > 500 V/mil
Flexibility ASTM D522 1 Coat Polyclad 777 PL Pass 3 inch 180 degrees
Hardness: ASTM D2240 Shore D 1 Coat Polyclad 777 PL > 70 Shore D
Impact Resistance ASTM G14 1 Coat Polyclad 777 PL 101 in-lbs
Tensile Strength ASTM D412 1 Coat Polyclad 777 PL > 4000 psi
Water Absorption ASTM D570 1 Coat Polyclad 777 PL < 1.6%

MIXING & THINNING

Power mix part B until the pigments are dispersed into a homogeneous liquid. Do not batch mix
Mixing
parts A & B. Do not thin.

A P P L I C AT I O N E Q U I P M E N T G U I D E L I N E S
Listed below are general equipment guidelines for the application of this product. Job site conditions may require modifications
to these guidelines to achieve the desired results.

Applicators must be knowledgeable with the proper safety guidelines, operation and maintenance
General
of the spray equipment (pumps, hoses, heaters and spray guns).

Use only heated plural component airless equipment with 1:1 mix ratio. The plural airless pump
must have a minimum capability of 1.25 gallons per minute with a fluid pressure of up to 3,000
psi. The recommended spray system is a Graco Reactor or WIWA PU 460 plural component
system utilizing typical transfer pumps to supply both the resin and catalyst to the spray system,
Airless Spray in-line heaters capable of heating the material up to 160 °F as needed, heated hose bundle, and a
Graco Fusion Plural Component Gun. Other equipment of equal capabilities may suffice. Contact
Carboline Technical Service Department for alternate spray equipment recommendations. We
recommend that the applicator perform a mock up prior to and after mobilizing to the jobsite to be
sure all equipment is performing properly.

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Polyclad 777 PL
PRODUCT DATA SHEET

A P P L I C AT I O N C O N D I T I O N S
Condition Material Surface Ambient Humidity
Minimum 125°F (52°C) 0°F (-18°C) 35°F (2°C) 0%
Maximum 160°F (71°C) 120°F (49°C) 120°F (49°C) 85%
Optimum 145°F (63°C) 70°F (21°C) 70°F (21°C) 35%

Industry standards are for substrate temperatures to be 5 °F(3 °C) above the dew point. Caution: this product in the liquid stage
is moisture sensitive and needs to be protected from high humidity, dew and direct moisture contact until cured to a firm state.
Application and/or curing in humidity above maximum, or exposure to moisture from rain or dew may result in a loss of gloss, micro
bubbling and/or blistering of the product.
Note: for applications on concrete, please contact your Carboline representative for proper application procedures.

CURING SCHEDULE
Surface Temp. Cure for Service Dry to Handle Dry to Touch
75°F (24°C) 1 Hour 15 Minutes 120 Seconds

Lower metal temperatures will slow the dry time and higher metal temperatures will speed up dry time. Polyclad 777 PL is ready for
holiday testing as soon as it reaches its dry-to-handle state. It is ready for service when the hardness reaches Shore D 70 (typically
1 hour)
Maximum recoat time with Carbothane series is 28 days. To topcoat past the maximum recoat time, the surface must be abraded
and cleaned. Maximum recoat with itself is two hours.

CLEANUP & SAFETY

Use Thinner 2 or 76. To clean lines, use Thinner 76 followed by Carboline's Polyclad Line Stabilizer
Cleanup for long term storage. Contact Carboline Technical Service for cleaning recommendations. In case
of spills, absorb and dispose of in accordance with local applicable regulations.

Read and follow all caution statements on this product data sheet and on the SDS for this product.
Safety Employ normal workmanlike safety precautions. Use adequate ventilation. Keep container closed
when not in use.

This product does not contain flammable solvents, however, clean-up solvents that may be used
do contain flammable solvents. Keep away from sparks and open flames. All electrical equipment
Caution and installations should be made and grounded in accordance with the National Electric Code. In
areas where explosion hazards exist, workers should be required to use non-ferrous tools and wear
conductive and non-sparking shoes.

PA C K A G I N G , H A N D L I N G & S T O R A G E
Packaging 10 gal., 110 gal., 528 gal. and dual cartridge kits

Part A: Min. 12 months at 75 °F (24 °C)

Part B: Min. 24 months at 75 °F (24 °C)
Shelf Life
When kept at recommended storage conditions and in original unopened containers.

Storage Temperature & 40-110 °F (4-43 °C)

Humidity 0-100% Relative Humidity

Store indoors and keep dry. Blanket all partial drums with nitrogen gas to prevent moisture
Storage
contamination. Do not allow Part A to freeze. Do not open until ready to use.

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Polyclad 777 PL
PRODUCT DATA SHEET

PA C K A G I N G , H A N D L I N G & S T O R A G E
Shipping Weight 9.8 lbs per kit gal (4.4 kg per gal)
(Approximate)

Part A 390 °F (199 °C)

Flash Point (Setaflash)
Part B >200 °F (93 °C)

WA R R A N T Y
To the best of our knowledge the technical data contained herein is true and accurate on the date of publication and is subject
to change without prior notice. User must contact Carboline Company to verify correctness before specifying or ordering. No
guarantee of accuracy is given or implied. We guarantee our products to conform to Carboline quality control. We assume no
responsibility for coverage, performance, injuries or damages resulting from use. Carbolines sole obligation, if any, is to replace
or refund the purchase price of the Carboline product(s) proven to be defective, at Carbolines option. Carboline shall not be liable
for any loss or damage. NO OTHER WARRANTY OR GUARANTEE OF ANY KIND IS MADE BY CARBOLINE, EXPRESS OR
IMPLIED, STATUTORY, BY OPERATION OF LAW, OR OTHERWISE, INCLUDING MERCHANTABILITY AND FITNESS FOR A
PARTICULAR PURPOSE. All of the trademarks referenced above are the property of Carboline International Corporation unless
otherwise indicated.

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