Directions For Use

Directions for Use — Copaltite Sealant

To use Copaltite, apply a thin coat to both clean, dry mating surfaces, assemble the joint, and allow heat of at least 212°F to set the sealant — approximately 30 minutes at 300°F. For steam applications, tighten the joint and bring the system to low pressure steam for six hours before full pressure operation. Full turbine horizontal joint instructions are detailed below.

Before You Begin — Surface Preparation

Proper surface preparation is the most important step in achieving a long-lasting Copaltite seal. Before applying either Copaltite Liquid Form or Copaltite Cement Form, ensure the following:

• Both mating surfaces must be clean and completely dry
• Remove all dirt, oil, grease, rust, and moisture from both surfaces
• Use gasoline or an appropriate solvent to degrease the surface thoroughly
• Wipe clean and allow to dry completely before application
• Copaltite has no affinity to foreign matter — it must bond directly to the metal surface to achieve a reliable seal
• Do not apply Copaltite over old sealant, oil film, or contaminated surfaces

Which Product to Use

Copaltite Liquid Form — smooth paste for precision machined surfaces, threaded connections, and flanged joints with close tolerances. Also used as a gasket dressing.

Copaltite Cement Form — thick, coarse-texture paste for rough surfaces, warped flanges, scored mating surfaces, and unfinished parts. Also used in turbine groove pumping and as a gun grooving compound.

If Copaltite Cement Form needs to be thinned, use Copaltite Liquid Form to thin it. To thin Copaltite Liquid Form itself, pure alcohol can be used.

General Application Instructions

Follow these steps for all standard pipe thread, flange, and joint sealing applications:

Step 1 — Clean Both Surfaces Remove all dirt, oil, grease, and moisture using gasoline or solvent. Wipe clean and dry. Both surfaces must be free of all foreign matter before application.

Step 2 — Apply Copaltite to Both Surfaces Apply a thin, even coat of Copaltite to both surfaces to be sealed — not just one side. For threaded connections, apply to the male thread. For flange and machined surface joints, apply evenly across the full joint face on both mating surfaces.

Step 3 — Assemble the Joint Bring the joint together and tighten to the specified torque immediately after application.

Step 4 — Apply Heat to Set Heat of at least 212°F must be applied to set Copaltite:

• At 212°F — set-up time can take up to 4 hours
• At 300°F — set-up time is approximately 30 minutes

Important: If the joint is required to hold high pressure at elevated temperature, apply heat without pressure until Copaltite has fully set before pressurising the system.

Application Instructions for Steam Joints

For steam line connections, boiler joints, and all steam system applications:

Step 1 — Clean both mating surfaces thoroughly with gasoline or solvent. Wipe dry.

Step 2 — Apply a thin coat of Copaltite Liquid Form to both surfaces. For rough or damaged surfaces, use Copaltite Cement Form.

Step 3 — Assemble and tighten the joint.

Step 4 — Turn on steam at little or no pressure and allow the joint to heat for approximately six hours — preferably overnight.

Step 5 — Once Copaltite has set under low-pressure steam conditions, the sealed joint will withstand full high temperature and high pressure steam service.

This cure procedure ensures Copaltite achieves maximum sealing strength before the system is brought to full operating pressure — the standard approach for boiler, turbine, and process steam line applications.

Instructions for Sealing Turbine Horizontal Joints

Turbine horizontal joint sealing requires a specific application procedure depending on whether the flange surfaces are smooth or scored. Follow the procedure below for both types.

Step 1 — Prepare the Flange Surfaces

After the casing has been lifted:

• Clean the upper and lower flange surfaces of all foreign matter
• Ensure the surface area is completely clean, dry, and free of all oil
• Use gasoline or a suitable solvent to clean the full surface
• Wipe clean and allow to dry fully before application

For Grooved Turbines with Smooth Surface Flanges

Applying Copaltite Liquid Form to the Flange Faces:

1. Apply a thin film of Copaltite Liquid Form to the upper and lower flange surfaces — do not apply into the grooves at this stage
2. Allow the material to become tacky
3. Lower the casing and bolt down — this creates a tight joint seal across the smooth flange faces independently of the grooves

Pumping Copaltite Cement Form into the Grooves:

Groove filling is performed while the turbine is hot — during warm-up before the turbine is placed in full operation:

1. Use a pressure gun capable of producing at least 4,000 PSI to dispense Copaltite Cement Form into the grooves
2. Work around the entire turbine in sequence to secure a uniform, permanent joint — this creates the Copaltite Cement key
3. Pumping sequence: When dispensing into any one groove outlet, remove the plug from the next outlet in the direction of pumping (Plug No. 1). When Copaltite begins to flow from the No. 1 opening, close it and start pumping into the next opening (No. 2), while removing the plug from the No. 3 opening. Continue this sequence until all plugged openings have been pumped around the full turbine circumference

For Grooved Turbines with Scored Surface Flanges

When the flange surfaces are scored or damaged:

1. Substitute Copaltite Cement Form in place of Copaltite Liquid Form for making the flange joint — the thicker paste fills the surface imperfections that Liquid Form cannot bridge on scored surfaces
2. Use Copaltite Cement Form for pumping the grooves using the same sequential pumping procedure described above

Removing Copaltite

If Copaltite has hardened on a surface and needs to be removed:

• Use a wire brush and alcohol to remove hardened Copaltite from joint faces
• Clean the surface thoroughly before reapplication of fresh Copaltite

Thinning Copaltite

If either product needs to be thinned:

• To thin Copaltite Cement Form: use Copaltite Liquid Form as the thinning agent
• To thin Copaltite Liquid Form: use pure alcohol

Storage Instructions

• Store Copaltite in a cool, dry place
• Shelf life is one year from the date of manufacture when stored at 72°F (22°C)
• Do not expose to extreme heat or freezing conditions during storage

Quick Reference — Application Summary

Shop Copaltite Sealants

• Copaltite Liquid Form Sealant — 5oz Tube
• Copaltite Liquid Form Sealant — 1 Quart Can
• Copaltite Cement Form Sealant — 5oz Tube
• Copaltite Cement Form Sealant — 1 Quart Can

Browse the full range: Copaltite Liquid Form → | Copaltite Cement Form →

Frequently Asked Questions — How to Use Copaltite

Q: How do I apply Copaltite sealant correctly? Apply a thin, even coat of Copaltite to both mating surfaces after cleaning them thoroughly with gasoline or solvent. Assemble and tighten the joint, then apply heat of at least 212°F to set the sealant. At 300°F, set time is approximately 30 minutes.

Q: What temperature is required to cure Copaltite? Copaltite requires heat of at least 212°F to begin setting. At 212°F, set time can take up to 4 hours. At 300°F, the set time is approximately 30 minutes. For steam applications, the recommended approach is to run low-pressure steam through the joint for approximately six hours before bringing the system to full operating pressure.

Q: Do I apply Copaltite to one surface or both? Both surfaces must be coated. Apply a thin coat of Copaltite to both mating surfaces — not just one. This ensures full surface contact and a complete seal across the joint interface.

Q: Can I use Copaltite on surfaces that are not perfectly clean? No. Copaltite must bond directly to the metal surface. It has no affinity to foreign matter — oil, grease, moisture, or dirt will prevent adhesion and cause the seal to fail. Always clean and dry both surfaces thoroughly before application.

Q: What is the difference between Copaltite Liquid Form and Cement Form, and when should I use each? Copaltite Liquid Form is a smooth paste for precision machined surfaces, threaded connections, and close-tolerance flanged joints. Copaltite Cement Form is a thicker, coarser paste for rough, scored, or warped surfaces that require gap-filling. For turbine horizontal joints, Liquid Form is used on smooth flange faces and Cement Form is used for groove pumping and scored surfaces.

Q: How do I seal a turbine horizontal joint with Copaltite? Clean both upper and lower flange surfaces with solvent and dry completely. For smooth flanges, apply Copaltite Liquid Form to both faces, allow to become tacky, then lower the casing and bolt down. While the turbine warms up, use a pressure gun at minimum 4,000 PSI to pump Copaltite Cement Form sequentially into all groove outlets around the full turbine circumference. For scored flanges, use Copaltite Cement Form on the flange faces and for groove pumping.

Q: How do I remove hardened Copaltite from a joint face? Use a wire brush and alcohol to remove hardened Copaltite. Clean the surface thoroughly before applying fresh Copaltite for reassembly.

Q: Can Copaltite be thinned? Yes. To thin Copaltite Cement Form, use Copaltite Liquid Form as the thinning agent. To thin Copaltite Liquid Form, use pure alcohol.

Q: What is the shelf life of Copaltite? Copaltite has a shelf life of one year from the date of manufacture when stored in a cool, dry place at 72°F (22°C).

Q: Where can I get technical support for Copaltite application in the UAE or GCC? Copaltite MENA is the authorised Copaltite distributor for the Middle East and provides full technical support for all application questions. Email [email protected] or visit copaltitemena.com. We support customers across UAE, Saudi Arabia, Qatar, Oman, Kuwait, and Bahrain.

Need Technical Support or a Quote?

Our team at Copaltite MENA is available to assist with product selection, application guidance, Safety Data Sheets, and bulk pricing across the UAE and GCC.

Email: [email protected] | Website: copaltitemena.com

We supply across UAE, Saudi Arabia, Qatar, Oman, Kuwait, and Bahrain.