Copyright is vested with FIRELAB cc Reg no: 2005/087037/23

The use of this report is subject to the condition that it will only be published in full or an abridged version approved by FIRELAB

FIRELAB cc, Building 28, CSIR Campus, Meiring Naudé Road, Brummeria, Pretoria, SA. (T) +27 12 349 2929, (F) +27 12 349 1519

Kobus Strydom, kobus@firelab.co.za, +27 82 892 4565. Peet Strydom, peet@firelab.co.za, +27 82 321 4269

TITLE : Report on the Large-scale Fire Resistance Properties of the CAPCO Fireshield Gypsum Board when tested in accordance with the SANS 10177 – 2 Horizontal test protocol

REQUESTED BY : CAPCO cc

PO Box 4203 RIVERHORSE VALLEY EAST 4017

CONTRACT No : FTC 18/157

ISSUE No :

2 (18/10/2018)

DATE : 2 October 2018

SANS 10177 – 2 CONFIDENTIAL 2 October 2018 CAPCO cc Page 1 of 25 CAPCO Fireshield Gypsum Board FTC 18/157 (2)

The Test Report and results only relate to the product(s) and/or sample(s) submitted for testing as identified in Section 1 and Annexures and do not apply to any similar product(s) or sample(s) that has not been tested. This Test Report is only valid for 5 years or until there is a change to the product composition, manufacturing process or previously approved supplier(s). The validity of this report may be extended by a validation certificate issued by FIRELAB upon verification of the product(s) or sample(s).

TABLE OF CONTENTS

LIST OF FIGURES AND TABLES ....................................................................................... 2

1. SAMPLE DESCRIPTION..................................................................................................... 3

2. FIRE RESISTANCE: SANS 10177 – PART 2:2005 ............................................................ 5

2.1. TEST PROCEDURE ........................................................................................................... 5

2.2. TEST EQUIPMENT ............................................................................................................. 5

3. TEST RESULTS .................................................................................................................. 6

4. DISCUSSION OF RESULTS ............................................................................................. 18

5. CONCLUSION .................................................................................................................. 19

ANNEXURE “A” ................................................................................................................. 20

ANNEXURE “B” ................................................................................................................. 21

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The Test Report and results only relate to the product(s) and/or sample(s) submitted for testing as identified in Section 1 and Annexures and do not apply to any similar product(s) or sample(s) that has not been tested. This Test Report is only valid for 5 years or until there is a change to the product composition, manufacturing process or previously approved supplier(s). The validity of this report may be extended by a validation certificate issued by FIRELAB upon verification of the product(s) or sample(s).

LIST OF FIGURES AND TABLES

Figure 1.1: The CAPCO Fireshield from the exposed side prior to the test ............................. 4

Figure 1.2: The CAPCO Fireshield with thermocouples from the unexposed side .................. 4

Table 3.1: Observations recorded during the SANS 10177 – 2 test ........................................ 6

Figure 3.1: Furnace temperatures recorded during the large-scale FR test ............................. 7

Figure 3.2: Temperatures recorded on the specimen ............................................................... 8

Figure 3.3: Smoke release ....................................................................................................... 9

Figure 3.4: Joint opening ......................................................................................................... 9

Figure 3.5: Draping ................................................................................................................ 10

Figure 3.6: Smoke release increase at front .......................................................................... 10

Figure 3.7: 2nd layer collapsing............................................................................................... 11

Figure 3.8: Strip glowing red .................................................................................................. 11

Figure 3.9: 3rd Layer collapsing .............................................................................................. 12

Figure 3.10: Smoke release from TC 6 .................................................................................... 12

Figure 3.11: Smoke release at back ........................................................................................ 13

Figure 3.12: Glowing at left perimeter ...................................................................................... 13

Figure 3.13: Glowing at right perimeter .................................................................................... 14

Figure 3.14: Discolouration at TC 3 (middle section) ............................................................... 14

Figure 3.15: Joint starting to open............................................................................................ 15

Figure 3.16: Exposed side of specimen at test termination ...................................................... 15

Figure 3.17: Flaming visible ..................................................................................................... 16

Figure 3.18: Gap enlarged ....................................................................................................... 16

Figure 3.19: The specimen from the exposed side the day after the test ................................. 17

SANS 10177 – 2 CONFIDENTIAL 2 October 2018 CAPCO cc Page 3 of 25 CAPCO Fireshield Gypsum Board FTC 18/157 (2)

The Test Report and results only relate to the product(s) and/or sample(s) submitted for testing as identified in Section 1 and Annexures and do not apply to any similar product(s) or sample(s) that has not been tested. This Test Report is only valid for 5 years or until there is a change to the product composition, manufacturing process or previously approved supplier(s). The validity of this report may be extended by a validation certificate issued by FIRELAB upon verification of the product(s) or sample(s).

1. SAMPLE DESCRIPTION

CAPCO installed the CAPCO Fireshield Gypsum Board ceiling into the FIRELAB’s Horizontal SANS 10177 – 2 test facility. Description of product below: System: CAPCO Fireshield Gypsum Board System Abbr. name: CAPCO Fireshield System Type: Fire Resistant Plasterboard Proposed Application: FR120 Escape route

System make up; Board: 4 layers of Fireshield boards Plaster: CAPCO Jointing compound Length (per board): 3 m Width (per board): 1.2 m Overall thickness: 120 mm

Product Composition; Layer 1: Fireshield Gypsum Board 15 mm Layer 2: Fireshield Gypsum Board 15 mm Layer 3: Fireshield Gypsum Board 15 mm Layer 4: Fireshield Gypsum Board 15 mm

Support; T’s: Fire rated T38/35G Galvanized Hangers: Galvanized angles Fixing: Drywall screws

Annexure “A”: Company detail

Annexure “B”: Specimen information and drawing The test specimen is shown from the exposed and unexposed sides in Figures 1.1 and 1.2 prior to commencement of the test.

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The Test Report and results only relate to the product(s) and/or sample(s) submitted for testing as identified in Section 1 and Annexures and do not apply to any similar product(s) or sample(s) that has not been tested. This Test Report is only valid for 5 years or until there is a change to the product composition, manufacturing process or previously approved supplier(s). The validity of this report may be extended by a validation certificate issued by FIRELAB upon verification of the product(s) or sample(s).

Figure 1.1: The CAPCO Fireshield from the exposed side prior to the test

Figure 1.2: The CAPCO Fireshield with thermocouples from the unexposed side

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The Test Report and results only relate to the product(s) and/or sample(s) submitted for testing as identified in Section 1 and Annexures and do not apply to any similar product(s) or sample(s) that has not been tested. This Test Report is only valid for 5 years or until there is a change to the product composition, manufacturing process or previously approved supplier(s). The validity of this report may be extended by a validation certificate issued by FIRELAB upon verification of the product(s) or sample(s).

2. FIRE RESISTANCE: SANS 10177 – PART 2:2005

2.1. TEST PROCEDURE

The nominal 3 meter wide by 6 meter long system was tested for fire resistance in a large-scale air-aspirated diesel furnace. The furnace temperature was controlled to follow the ISO standard time-temperature curve as stipulated in SANS 10177 – 2. The Fire Resistance Rating (FRR) of the system is determined based on the following criteria:

Integrity (E): The system is deemed to have failed should flames be observed on the unexposed side or an opening larger than 6 mm wide or 150 mm long is noted.

Stability (R): The system may not collapse or fail structurally during the test.

Insulation (I): The temperature on the unexposed surface may not exceed 140 °C plus ambient temperature on average or 180 °C plus ambient maximum at any of the measured surface positions.

The Insulation criteria of the specimen wall were measured using 5 thermocouples (TC 1 – TC 5) placed in a grid of equal area with an additional two thermocouples used to measure the joints (TC 6 & TC 7) as shown in Figure 1.2. The furnace was operated within the tolerable limits applicable to the ISO Time-Temperature Curve and is shown in Figure 3.1. The temperatures recorded by the thermocouples (TC) used to determine compliance to the Integrity, Stability and Insulation criteria are depicted graphically in Figures 3.2. Events observed and during the SANS 10177 – 2 test, are shown in Table 3.1. The CAPCO Fireshield Gypsum Board after conclusion of the test is shown from the exposed and unexposed sides in Figures 3.16 and 3.19. 2.2. TEST EQUIPMENT

Data logging equipment c/w controller Stopwatch Type K thermocouples SANS 10177 – 2 Horizontal Testing Facility

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The Test Report and results only relate to the product(s) and/or sample(s) submitted for testing as identified in Section 1 and Annexures and do not apply to any similar product(s) or sample(s) that has not been tested. This Test Report is only valid for 5 years or until there is a change to the product composition, manufacturing process or previously approved supplier(s). The validity of this report may be extended by a validation certificate issued by FIRELAB upon verification of the product(s) or sample(s).

3. TEST RESULTS

Table 3.1 contains all observations made during the SANS 10177 – 2 test conducted on 3 August 2018.

CAPCO Fireshield

OBSERVATIONS DURING THE SANS 10177 – 2 TEST

EVENT TIME (hh:mm:ss) DESCRIPTION

0 00:00:00 – Test Started –

1 00:03:45 Smoke release from perimeter

2 00:24:50 Joint opening

3 00:25:50 Joint opening enlarging

4 00:27:15 Board deforming (middle section)

5 00:31:30 Boards warping (back section)

6 00:32:40 2nd joint opening

7 00:39:40 1st layer starting to collapse (board fell off)

8 00:40:15 Boards draping (middle section)

9 00:43:05 Boards continue to drape

10 00:50:25 Joint at front section opening

11 00:52:50 Increase of smoke release at front

12 00:55:10 Boards falling off from 1st layer

13 01:06:40 2nd layer draping

14 01:10:50 Strips glowing

15 01:20:30 Smoke release from TC 6

16 01:26:10 Smoke release at back

17 01:30:00 Angle (right side) glowing red and deforming

18 01:32:20 3rd layer joint opening

19 01:33:00 3rd layer starting to collapse (middle section)

20 01:38:25 Discoloration at TC 3 (middle section)

21 01:38:50 TC 3 exceeds limitations » Fails Insulation

22 01:40:20 TC 6 exceeds limitations » Fails Insulation

23 01:40:40 Average exceeds limitations » Fails Insulation

24 01:39:30 Joint starting to open

25 01:40:50 – Test Terminated –

Table 3.1: Observations recorded during the SANS 10177 – 2 test

Note: Average Ambient Temperature during test = 24.2 °C

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The Test Report and results only relate to the product(s) and/or sample(s) submitted for testing as identified in Section 1 and Annexures and do not apply to any similar product(s) or sample(s) that has not been tested. This Test Report is only valid for 5 years or until there is a change to the product composition, manufacturing process or previously approved supplier(s). The validity of this report may be extended by a validation certificate issued by FIRELAB upon verification of the product(s) or sample(s).

Figure 3.1: Furnace temperatures recorded during the large-scale FR test

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The Test Report and results only relate to the product(s) and/or sample(s) submitted for testing as identified in Section 1 and Annexures and do not apply to any similar product(s) or sample(s) that has not been tested. This Test Report is only valid for 5 years or until there is a change to the product composition, manufacturing process or previously approved supplier(s). The validity of this report may be extended by a validation certificate issued by FIRELAB upon verification of the product(s) or sample(s).

Figure 3.2: Temperatures recorded on the specimen

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The Test Report and results only relate to the product(s) and/or sample(s) submitted for testing as identified in Section 1 and Annexures and do not apply to any similar product(s) or sample(s) that has not been tested. This Test Report is only valid for 5 years or until there is a change to the product composition, manufacturing process or previously approved supplier(s). The validity of this report may be extended by a validation certificate issued by FIRELAB upon verification of the product(s) or sample(s).

Figure 3.3: Smoke release

Figure 3.4: Joint opening

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The Test Report and results only relate to the product(s) and/or sample(s) submitted for testing as identified in Section 1 and Annexures and do not apply to any similar product(s) or sample(s) that has not been tested. This Test Report is only valid for 5 years or until there is a change to the product composition, manufacturing process or previously approved supplier(s). The validity of this report may be extended by a validation certificate issued by FIRELAB upon verification of the product(s) or sample(s).

Figure 3.5: Draping

Figure 3.6: Smoke release increase at front

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The Test Report and results only relate to the product(s) and/or sample(s) submitted for testing as identified in Section 1 and Annexures and do not apply to any similar product(s) or sample(s) that has not been tested. This Test Report is only valid for 5 years or until there is a change to the product composition, manufacturing process or previously approved supplier(s). The validity of this report may be extended by a validation certificate issued by FIRELAB upon verification of the product(s) or sample(s).

Figure 3.7: 2nd layer collapsing

Figure 3.8: Strip glowing red

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The Test Report and results only relate to the product(s) and/or sample(s) submitted for testing as identified in Section 1 and Annexures and do not apply to any similar product(s) or sample(s) that has not been tested. This Test Report is only valid for 5 years or until there is a change to the product composition, manufacturing process or previously approved supplier(s). The validity of this report may be extended by a validation certificate issued by FIRELAB upon verification of the product(s) or sample(s).

Figure 3.9: 3rd Layer collapsing

Figure 3.10: Smoke release from TC 6

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The Test Report and results only relate to the product(s) and/or sample(s) submitted for testing as identified in Section 1 and Annexures and do not apply to any similar product(s) or sample(s) that has not been tested. This Test Report is only valid for 5 years or until there is a change to the product composition, manufacturing process or previously approved supplier(s). The validity of this report may be extended by a validation certificate issued by FIRELAB upon verification of the product(s) or sample(s).

Figure 3.11: Smoke release at back

Figure 3.12: Glowing at left perimeter

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The Test Report and results only relate to the product(s) and/or sample(s) submitted for testing as identified in Section 1 and Annexures and do not apply to any similar product(s) or sample(s) that has not been tested. This Test Report is only valid for 5 years or until there is a change to the product composition, manufacturing process or previously approved supplier(s). The validity of this report may be extended by a validation certificate issued by FIRELAB upon verification of the product(s) or sample(s).

Figure 3.13: Glowing at right perimeter

Figure 3.14: Discolouration at TC 3 (middle section)

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The Test Report and results only relate to the product(s) and/or sample(s) submitted for testing as identified in Section 1 and Annexures and do not apply to any similar product(s) or sample(s) that has not been tested. This Test Report is only valid for 5 years or until there is a change to the product composition, manufacturing process or previously approved supplier(s). The validity of this report may be extended by a validation certificate issued by FIRELAB upon verification of the product(s) or sample(s).

Figure 3.15: Joint starting to open

Figure 3.16: Exposed side of specimen at test termination

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The Test Report and results only relate to the product(s) and/or sample(s) submitted for testing as identified in Section 1 and Annexures and do not apply to any similar product(s) or sample(s) that has not been tested. This Test Report is only valid for 5 years or until there is a change to the product composition, manufacturing process or previously approved supplier(s). The validity of this report may be extended by a validation certificate issued by FIRELAB upon verification of the product(s) or sample(s).

Figure 3.17: Flaming visible

Figure 3.18: Gap enlarged

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The Test Report and results only relate to the product(s) and/or sample(s) submitted for testing as identified in Section 1 and Annexures and do not apply to any similar product(s) or sample(s) that has not been tested. This Test Report is only valid for 5 years or until there is a change to the product composition, manufacturing process or previously approved supplier(s). The validity of this report may be extended by a validation certificate issued by FIRELAB upon verification of the product(s) or sample(s).

Figure 3.19: The specimen from the exposed side the day after the test

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The Test Report and results only relate to the product(s) and/or sample(s) submitted for testing as identified in Section 1 and Annexures and do not apply to any similar product(s) or sample(s) that has not been tested. This Test Report is only valid for 5 years or until there is a change to the product composition, manufacturing process or previously approved supplier(s). The validity of this report may be extended by a validation certificate issued by FIRELAB upon verification of the product(s) or sample(s).

4. DISCUSSION OF RESULTS

The CAPCO Fireshield satisfied the stability, integrity and insulation criteria for a 90 minutes ceiling system. The performance of the wall specimen was as follows:

Integrity (E): At approximately 1 hour 39 minutes, the joint started opening. Shortly after the test was terminated, the opening started enlarging and flaming was visible on the unexposed side. Integrity satisfied for 1 hour 40 minutes

Stability (R): The system did not collapse or fail structurally before the test was

terminated at 1 hour and 40 minutes. Stability satisfied for 1 hour 40 minutes

Insulation (I): The maximum allowed single temperature was 204.2 ºC and the

maximum allowed average temperature was 164.2 ºC. TC 6 reached above the single allowed temperature at 1 hour, 38 minutes and 50 seconds. TC 6 and the average temperature reached above the allowed temperatures shorty after.

Insulation satisfied for 1 hour 38 minutes Based on the performance during the test and inspection afterwards, we wish to make the following recommendations:

All but joints must be fitted into a steel plate to protect the upper board.

The support for the board should be 300 mm and not 400 mm.

Furring channels should have staggered joints and not straight joints.

The width of the main tees must be wider to ensure better fixing of the furring channel joints. The inspection showed the fixing was too close to the end, resulting in the metal tearing out due to the expansion.

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The Test Report and results only relate to the product(s) and/or sample(s) submitted for testing as identified in Section 1 and Annexures and do not apply to any similar product(s) or sample(s) that has not been tested. This Test Report is only valid for 5 years or until there is a change to the product composition, manufacturing process or previously approved supplier(s). The validity of this report may be extended by a validation certificate issued by FIRELAB upon verification of the product(s) or sample(s).

5. CONCLUSION

The CAPCO Fireshield Gypsum Board satisfied the criteria for a Fire Resistance Rating (FRR) of 90 minutes when tested in accordance with the SANS 10177 – Part 2 test protocol. The Fire Resistance Rating for the CAPCO Fireshield Gypsum Board is as follows:

SANS 10177 – 2 » FR90

Integrity (E) » 90 minutes

Stability (R) » 90 minutes

Insulation (I) » 90 minutes

Notes: » The fire rating might be increased should the recommendations in Section 4 be implemented.

» A ceiling is asymmetrical and tested from one side only (bottom), escape route ceilings require testing from the top and not from the bottom.

………………………… ……………………………….. Compiled by: E.M. Nel Approved by: J.S. Strydom

This copy has been produced from a .pdf format electronic file that has been provided by FIRELAB to the sponsor of the report and may only be reproduced in full. Extracts or abridgements of reports must not be published without permission of FIRELAB. The original signed paper version of this report is the sole authentic version. Only original paper versions of this report bear authentic signatures of the responsible FIRELAB staff.

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The Test Report and results only relate to the product(s) and/or sample(s) submitted for testing as identified in Section 1 and Annexures and do not apply to any similar product(s) or sample(s) that has not been tested. This Test Report is only valid for 5 years or until there is a change to the product composition, manufacturing process or previously approved supplier(s). The validity of this report may be extended by a validation certificate issued by FIRELAB upon verification of the product(s) or sample(s).

ANNEXURE “A”

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The Test Report and results only relate to the product(s) and/or sample(s) submitted for testing as identified in Section 1 and Annexures and do not apply to any similar product(s) or sample(s) that has not been tested. This Test Report is only valid for 5 years or until there is a change to the product composition, manufacturing process or previously approved supplier(s). The validity of this report may be extended by a validation certificate issued by FIRELAB upon verification of the product(s) or sample(s).

ANNEXURE “B”

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The Test Report and results only relate to the product(s) and/or sample(s) submitted for testing as identified in Section 1 and Annexures and do not apply to any similar product(s) or sample(s) that has not been tested. This Test Report is only valid for 5 years or until there is a change to the product composition, manufacturing process or previously approved supplier(s). The validity of this report may be extended by a validation certificate issued by FIRELAB upon verification of the product(s) or sample(s).

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The Test Report and results only relate to the product(s) and/or sample(s) submitted for testing as identified in Section 1 and Annexures and do not apply to any similar product(s) or sample(s) that has not been tested. This Test Report is only valid for 5 years or until there is a change to the product composition, manufacturing process or previously approved supplier(s). The validity of this report may be extended by a validation certificate issued by FIRELAB upon verification of the product(s) or sample(s).

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The Test Report and results only relate to the product(s) and/or sample(s) submitted for testing as identified in Section 1 and Annexures and do not apply to any similar product(s) or sample(s) that has not been tested. This Test Report is only valid for 5 years or until there is a change to the product composition, manufacturing process or previously approved supplier(s). The validity of this report may be extended by a validation certificate issued by FIRELAB upon verification of the product(s) or sample(s).

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The Test Report and results only relate to the product(s) and/or sample(s) submitted for testing as identified in Section 1 and Annexures and do not apply to any similar product(s) or sample(s) that has not been tested. This Test Report is only valid for 5 years or until there is a change to the product composition, manufacturing process or previously approved supplier(s). The validity of this report may be extended by a validation certificate issued by FIRELAB upon verification of the product(s) or sample(s).