flamebar applications technical manual

ApplicationsandTechnicalManual

B W 1 1 F i r e R a t e d D u c t w o r k

ApplicationsandTechnicalManual

In 1986, Fire Protection Limited began a research program to develop an entirely new firerated ductwork system.

This program, which is continuous, has resulted in the FLAMEBAR BW11 Fire RatedDuctwork System being manufactured and supplied worldwide.

As a result of continued growth, Firespray International was formed to carry out theongoing research and development program and also to market FLAMEBAR products ona global basis.

This Manual has been produced for everyone associated with the design and installation offire rated ductwork systems and illustrates how to satisfy the requirements of the regulatorybodies. It also clearly emphasizes our own commitment to fire safety.

FLAMEBAR BW11 FIRE RATED DUCT SYSTEMS SATISFY THE REQUIREMENT FORFIRE RATED DUCTWORK FOR VENTILATION, KITCHEN OR EXHAUST APPLICATIONS.

Introduction

2

Test Requirements – ISO 6944 (1985) Definitions 4

Fire Rated Ductwork – “When and Why” 6

FLAMEBAR BW11 Fire Rated Ductwork – Analysis and Performance 8

3.1 FLAMEBAR BW11 – Single Source Responsibility – Certificate of Conformity 8

3.2 FLAMEBAR BW11 – Flexibility in Design 8

3.3 FLAMEBAR BW11 – Construction of FLAMEBAR BW11 Fire Duct 9

3.4 FLAMEBAR BW11 – System Integrity – Ancillary Components 10

3.5 FLAMEBAR BW11 – Air Temperatures at Various Distances from DuctWithout Additional Insulation 10

3.6 FLAMEBAR BW11 – Supports and Hangers 12

Smoke Exhaust Ductwork Systems 14

Commercial Kitchen Extract Ductwork 15

Exit/Escape Route Ducts 16

Pressurization Ductwork Systems 17

Basement Smoke Exhaust Systems 18

Dual Ventilation/Smoke Exhaust Systems 19

Fume Hood Exhaust Systems 20

Penetration Seals Between Fire Compartments 21

Standards 22

System Advantages 24

Contents

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1

2

3

4

5

6

7

8

9

10

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Page

ISO 6944 (1985) is the accepted Standard forthe USA and Canada

ISO 6944 (1985) Fire Resistance Tests – Ventilation Ducts

The purpose of ISO 6944 (1985) is to measure the ability of a ductwork system to resist thespread of fire from one fire compartment to another without the aid of fire or smoke dampers.It should be noted that the test relates to a complete ductwork installation and therefore joints,supports and the fire stopping through the furnace wall all form an integral part of the test.

Giving temperature rise as a function of time for all ISO 6944 (1985) fire tests.

1 Test Requirements (Non-Grease)

4

2192

2012

1832

1652

1472

1292

1112

932

752

572

392

212

0

0 20 40 60 80 100 120 140 160 180 200 220 240

Time (minutes)

Temperature°F

Aluminium Melts

Fibre Glass Melts

Furnace Temperature Curveas Specified in ISO 6944 (1985)

ISO 834: 1975 (E) Fire Resistance TestStandard Time – Temperature Curve (Cellulosic)

Requirements of ISO 6944 (1985)

The fire rating of ventilation ductwork shall, according to the Standard, be expressed in minutesof duration of heating until failure occurs according to one or more of the following criteria:

1 Stability 2 Insulation 3 Integrity

Criteria of Failure:

1 Stability: Stability failure shall be deemed to have occurred in duct type A within the furnaceand in duct types A and B outside the furnace when the duct collapses in such a manner thatthe duct no longer fulfils its intended function. Included in this is the ability of a smokeexhaust duct to retain at least 75% of its cross sectional area along its whole length, bothinside and outside of the furnace.

2 Insulation: Insulation failure shall be deemed to have occurred when the temperature riseabove initial ambient temperature on the surface of the test specimen outside the furnaceexceeds either:

1 284°F as an average value, or2 356°F as a maximum value.

For kitchen exhaust duct type A, these temperature rise limits also apply to the inside surface ofthe duct within the furnace.

3 Integrity: The presence and formation of cracks, holes or other openings outside the furnacethrough which flames or hot gasses can pass shall constitute integrity failure.

Definitions of Types A & B Fire Exposure

The testing standard differentiates between types of fire exposure; two classifications apply asdetailed below.

5

Compartmentwith FireOutbreak

Fire Outside – Duct Type A

Adjacent Compartment

T1 TemperatureSensor

Duct ResistsPenetration ofFire fromOutside

Ventilation or Smoke Exhaust Opening –No Fire Penetration from inside Duct

Adjacent CompartmentT2 Temperature

Sensor

Fire Inside – Duct Type B

Compartment with Fire Outbreak

Duct Resists Penetration of Fire from Inside

Fire Penetratesinto Duct throughVentilator or SmokeExtract Opening

One of the most important factors to be considered when designing and constructing a buildingare effective zones to limit the spread of smoke and fire throughout the building via theventilation ducts. Under normal circumstances this zoning is achieved by the use of fire dampersor fire/smoke dampers within the duct systems. However, under certain applications the use offire dampers is inappropriate. In this case the ducts themselves must provide the same level offire rating afforded by the wall or floor of the zone.

Systems, which would not be fitted with fire dampers under normal circumstances, are as followsbut not exclusively:

1 Pressurization Ducts 5 Dryer Exhausts2 Grease Ducts 6 Fire Smoke Emergency Exhaust3 Non-Commercial Kitchen Exhausts 7 Dual Ventilation/Smoke Exhaust Systems4 Toilet Exhausts 8 Exit/Escape Corridors and Lobbies

Any duct system that is intended to operate or has a special use under a fire condition andcannot therefore utilize fire dampers will require to be fire rated.

Duct systems and applications, which have special or operational effect under fire conditions, areas follows:

1 Pressurization SystemsPressurization is a method of restricting the penetration of smoke into exit/escape routes,protected stairwells, corridors and fire fighting shafts for deep basements by maintainingpressure differential. Smoke contamination in these areas would jeopardize escape in the eventof a fire. NFPA 90A requires that pressurization ducts should be enclosed in a 2 hour fire ratedenclosure. The FLAMEBAR BW11 duct is classified by UL up to 4 hours Stability, Integrity andInsulation without any additional enclosure.

2 Grease Duct Systems (see also our Grease Duct Pamphlet [Blue Top])Exhaust systems serving commercial kitchen hoods are required, as per NFPA 96, to be separateand independent of any other systems because of the polluted nature of the extracted air. Firedampers should not be installed in any exhaust duct systems serving kitchens. Any ducts whichpenetrate fire resistive barriers should be fire rated to the same level of fire separation as thewall or floor through which they pass. The fire rating should be for both type B exposure (fire onthe inside) and Engulfment: Type A exposure (fire on the outside). All penetrations require to befire stopped. Grease ducts pose a particular hazard in that they contain deposits of accumulatedgrease on the internal surfaces. Fire in an adjacent zone through which the duct passes couldignite the internal deposits and cause a flashback to the served kitchen hood. It is importanttherefore that all grease ducts be insulated, to protect from a fire in an adjacent fire zoneigniting the accumulated grease. To minimize the build up of grease, fire rated access doors shallbe installed at maximum 10 feet centers to allow access for cleaning.

Grease duct installations shall be evaluated, tested and listed to the requirements of the IBC,IMC and UMC and these require compliance with ASTM E-2336 or UL 1978 or UL 2221.FLAMEBAR BW11 complies with ASTM E-2336 and UL 1978 and NFPA 96.

2 Fire Rated Ductwork“When and Why”

6

3 Non-Commercial Kitchen Exhaust SystemsNFPA 90A requires that non-commercial kitchen riser ducts on high rise apartments passing fromfloor to floor up through the building, shall be protected in a 2 hour fire rated enclosure. Since theFLAMEBAR BW11 duct system is a 2 hour rated assembly the need for a 2 hour enclosure iseliminated. However, as defined in NFPA 90A all branches serving each floor shall be fitted with afire damper, fire/smoke damper or a SMACNA type (sub-duct).

4 Toilet Exhaust SystemsNFPA 90A requires that toilet exhaust riser ducts on high rise apartments passing from floor tofloor up through the building shall be protected in a 2 hour fire rated enclosure. Since theFLAMEBAR BW11 duct system is a 2 hour rated assembly the need for a 2 hour enclosure iseliminated. However, as defined in NFPA 90A all branches serving each floor shall be fitted witha fire damper or a SMACNA sub duct.

5 Dryer Exhaust SystemsNFPA 90A requires that all dryer exhausts rising through a building passing from one fire zone tothe next be enclosed in a 2 hour rated duct/shaft. Since the FLAMEBAR BW11 Duct System isa 2 hour rated assembly the need for a 2 hour enclosure can be eliminated. The Building Codefurther stipulates that the internal face of the ducts be free from screws and protrusions whichcould cause lint to be trapped.

6 Fire Smoke Emergency Exhaust SystemsIf the duct system is intended to be used to remove hot smoke in an emergency ISO 6944 (1985)requires that the duct maintains 75% of its original free area. If a duct crosses from the firecompartment to an adjacent fire zone it must have the same fire resistance as the fire barrier itcrosses. Ducts used as smoke exhaust shall be rated for fire exposure type B (fire on the inside).

7 Dual Ventilation/Smoke Exhaust SystemsServe as normal ventilation systems, but in an emergency are converted to provide smokeexhaust in the event of a fire. Since the FLAMEBAR BW11 duct is already fire rated noadditional enclosures are necessary. By combining the two applications into one systemsignificant cost savings can be effected.

8 Exit/Escape Corridors and LobbiesIt is a requirement of the International Mechanical Code that any duct crossing an exit/escapecorridor or lobby must be fire rated for Stability, Integrity and Insulation, with the same rating asthe compartment through which it passes. It should be noted that with FLAMEBAR BW11only one fire damper is required, if either side of the exit corridor is constructed with non-firerated ductwork.

7

Analysis and Performance

3.1 FLAMEBAR BW11 – Single Source Responsibility – Certificate of Conformity3.2 FLAMEBAR BW11 – Flexibility in Design3.3 FLAMEBAR BW11 – Construction of FLAMEBAR BW11 Fire Duct3.4 FLAMEBAR BW11 – System Integrity – Ancillary Components3.5 FLAMEBAR BW11 – Air Temperatures at Various Distances from Duct without

additional insulation3.6 FLAMEBAR BW11 – Supports and Hangers

3.1 Single Source Responsibility– Certificate of Conformity

When considering the use of Fire Rated Ductwork, issues such as Single Source Responsibilityand Certificates of conformity are often overlooked.When specifying FLAMEBAR BW11 youare assured that every process from design to installation is directly controlled.

Single Source Responsibility means exactly what it states, that from design throughmanufacture, spray coating and installation there is a single source responsibility. Furthermore,once the installation is complete and all contractual commitments are fulfilled, a Certificate ofConformity is issued to the client. This confirms the periods of fire rating installed andcompliance with the relevant criteria of ISO 6944 (1985).

This certificate underlines our commitment to providing the best and ultimately most “fire safe”installations available.

3.2 Flexibility in DesignFLAMEBAR BW11 offers complete flexibility in design and can be fabricated to any requiredshape. Rectangular, flat oval and circular ducts are available.

The construction of the initial galvanized sheet steel duct means that all FLAMEBAR BW11Fire Ducts have normal standards of air tightness and are therefore easily capable of beingsuccessfully tested.

As well as profile flexibility as depicted in the previous illustrations, FLAMEBAR BW11 FireDucts can also be supplied as detailed below:

3 FLAMEBAR BW11Fire Rated Ductwork

8

Single Sided Two Sided Three Sided Four Sided

Flat Oval Circular

FLAMEBAR BW11Rectangular Fire Duct

FLAMEBAR BW11Flat Oval Fire Duct

FLAMEBAR BW11Circular Fire Duct

Any othershape

3.3 Construction of FLAMEBAR BW11Fire Duct

FLAMEBAR BW11 Fire Duct is constructed from galvanized sheet steel manufactured to anapproved and listed standard, then degreased and factory fire sprayed with FLAMEBAR BW11which is a specially formulated water based compound. This contains selected mineral filters in alow permeability elastomeric binder to a thickness of approximately 0.04 inches when dry togive a finished product which has been successfully tested for international use under CellulosicFire Conditions in excess of 4 hours duration. Ductwork is produced in sections and is assembledon site utilizing tested fireproof gaskets/sealants.

The unique properties of FLAMEBAR BW11 has enabled us to design a low density, highlydurable material which accommodates induced stress arising from extreme and varyingconditions, eg. Climatic Moisture and Structural Loading Variation and the effect of thermalshock during a fire.

The complete system has been tested and classified to ISO 6944 (1985) up to a temperature of2071°F therefore facilitating complete design freedom.

3.4 System Integrity – Ancillary Components

Some of the additional features that can be incorporated in FLAMEBAR BW11Fire Duct Systems.

1 Access Doors2 Control Device Housings3 Volume Control Dampers4 Internal Flanging5 Penetration Seals between Compartments6 Protection can be applied to fans, silencers etc.

(if suitably constructed)

9

FLAMEBAR BW11Fire Rating of Attenuators

FLAMEBAR BW11Fire Rating of Access Doors

FLAMEBAR BW11Fire Rating of Volume

Control Damper

3.5 Air Temperatures at Various Distancesfrom Duct Without Additional Insulation

Compartment walls and floors will have a prescribed fire resistance in terms of Stability, Integrityand Insulation for between 30 and 240 minutes. It is therefore essential for fire safety that wherecompartmentation boundaries are penetrated by fire duct, the fire separation and theperformance criteria of the penetration wall or floor is maintained and that the duct should notact as a conduit along which fire may spread to other areas.

In all cases, the time period for Stability and Integrity should be at least equal to that required bythe penetration element. However, controlling Authorities and engineered solutions have in manycircumstances waived the insulation requirement. If the duct work is within the firstcompartment (see example) it will not need to be insulated and if the fire duct has not been fireinsulated for a given period, sufficient distance must be maintained between the fire duct andany adjacent combustible material. NFPA 90A code recommends a minimum of 18 inches bemaintained.

The graph below gives the air temperature, taken at various distances away from ourFLAMEBAR BW11 Fire Duct. It should be noted that the insulation failure temperature, as perISO 6944 (1985), is a minimum of 284°F, plus ambient temperature.

FLAMEBAR BW11 Fire Duct without additional insulationIndicative temperature measurements in air adjacent to a duct B (fire inside) test toISO 6944 (1985)

FLAMEBAR Solution when Lower Insulation Temperature Required

All FLAMEBAR BW11 Fire Ducting has been fully tested to ISO 6944 (1985) for Stability andIntegrity up to 4 hours. However, where lower installation temperatures are required due toducting being rated the same as the smoke exhaust fan or a fire engineering consultant havingdetermined a fire engineering solution, we are able to offer our FLAMEBAR BW11 product, on itsown or with the addition of various thicknesses of insulation depending upon the insulationrating required.

10

0 50 68 86 104 122 140 158 176 194 212 230 248 266 284

20

18

16

14

12

10

8

6

4

2

0

Temp °F measured at various distances from duct

Distancefromsurfaceofductinins.

TIME60mins FURNACE TEMP 1697°F

TIME 120 mins FURNACE TEMP 1884°F

TIME 240 mins FURNACE TEMP 2071°F

Temperatures taken at 1 hour, 2 hours and 4 hours

IAS Feasibility Test No TE87473

Smoke Exhaust Duct Test – Fire Inside Duct

Mean furnace and duct surface temperatures

Minimum Periods of Fire Resistance for Fire Rated Ductwork

Example showing a typical fire duct run passing through different fire rated compartments

From the example, it can be seen that when the fire duct passes from the second to the third firecompartment, the fire resistance of the duct increases in line with the rating of the firecompartment wall. This rating is not reduced in the fourth compartment, despite the reducedrating of the fire compartment wall between the third and fourth fire compartments.

Important Note:If the fire duct is for exhausting smoke, it must also maintain a minimum of 75% of its overallcross sectional area over the total length of the duct, including the first fire compartment.Therefore, smoke exhaust ductwork in the first fire compartment must always be tested toISO 6944 (1985) for Stability and Integrity. 11

0 50 100 150 200 250 300 350 400 450

1292

1112

932

752

572

392

212

0

Time (minutes)

Temperature(°F)

482°F

572°F

752°F

1112°F

1202°F

INSULATION FAIL TEMP. 284°F + AMBIENT

BW11 BW11 with 1in insulation BW11 with 2in insulation

EXTERNAL TEMPERATURE OF DUCT

FURNACE TIME – TEMPERATURE CURVE

FIRE TEST Nos. 615, 616 & 621

1st FIRE COMPARTMENT 2nd FIRE COMPARTMENT 3rd FIRE COMPARTMENT 4th FIRE COMPARTMENT

30 MIN FIRERESISTANT DUCT



30 MIN FIRECOMPARTMENT WALL



3.6 Supports and HangersAs it is known that tensile strength of steel reduces with temperature, it has been calculated andtested by the Building Research Establishment which is an IAS Facility that based on the originalstrength of steel for support of 62350lbs/in2, fire duct supports should be sized based on:–

Fire duct rated for 60 minutes 1697°F – Tensile strength of 2175 lbs/in2



Weight of FLAMEBAR BW11 Fire Duct

Total weight of up to 2 hour fire duct without insulation = 2.24 lbs/ft2

Total weight of up to 2 hour fire duct with 2in insulation = 3.33 lbs/ft2


Total weight of up to 4 hour fire duct without insulation = 2.89 lbs/ft2



Above weights are based on 40in x 40in typical standard ductwork per linear 3ft length.

When designing and testing Fire Rated Ductwork it is critical that the reduction in tensilestrength of steel under fire load is given adequate consideration. This applies to hangers(threaded rods) and bearers, but it is equally important that due consideration is given to theperformance of the fixing system under fire load.

It must be recognized that the “pull out” load of an anchor under fire conditions is significantlyless than at ambient temperature. By specifying FLAMEBAR BW11 you can be confident thatthese issues have been adequately addressed.

12

Typical Vertical & Horizontal Support Arrangements

13

Duct Size Duct area per Total weight Bearer Weight on Weight on Max test load Size of3ft run per 3ft spacing in each bearer each anchor that Hilti HKD anchor and

of duct anchor will hanger used+ BW11 withstand in a to provide

fire situation added safety

Sum of 2 12ft2 32lbs 5ft 48lbs 24lbs 88lbs M10/sides 24in = 1/4in HKD 3/8in






Table showing typical anchor and hanger sizes required for2hr stability and integrity FLAMEBAR BW11 Smoke Duct

SUPPORT STEELTO SPAN HOLE

SIZINGOF GALLOWSBRACKET TOSUIT DUCT

CONCRETEFLOOR SLAB

TYPICAL ALTERNATIVEARRANGEMENTS FORSUPPORTS

Ensure that fixing into slabis capable of supporting theweight shown on the chart.(Note, all part of anchorto be steel)

Support sizes dependent onstability and integrity rating

2in 2in

• DUCTWORK USED IN SMOKE EXHAUST SYSTEMS SHOULD NORMALLY BE RATED FOR STABILITY,INTEGRITY AND INSULATION AT LEAST EQUAL TO THE COMPARTMENT WALL THROUGHWHICH IT PASSES.

• SMOKE EXHAUST DUCTWORK MUST RETAIN AT LEAST 75% OF ITS CROSS SECTIONAL AREA, BOTH INTHE FIRE COMPARTMENT AS WELL AS IN ADJACENT COMPARTMENTS.

IN THE DIAGRAM:

Office exhaust ductwork shown must be suitable for removal of smoke within the compartments andnormally rated for 2 hour for Stability and Integrity to resist heat smoke and fire from inside (type B).Insulation fire rating is not required in the first compartment.

Where the office exhaust duct crosses the escape corridor shown it must maintain Stability, Integrity andInsulation fire rating for the same period of time as the compartment through which it passes and this maybe required for the remainder of the ductwork route through the building to outside.

In some circumstances insulation requirements may be waived or varied by the regulatory authority if thereare no combustible materials within 20ins of the duct, such as in the plantroom shown

In order that the 75% cross sectional free area criteria be maintained, fire rated ductwork would be usedwithin the shaft requiring Stability and Integrity shown . However, if there are combustible materialswithin 20ins of the duct, insulation would still be needed.

The Building Regulations and ISO 6944 (1985) require that all fire rated ductwork shall be tested andinstalled to comply to the full “cellulosic” time/temp fire test curve (ISO 834 and E119). However, a fireengineered solution designed by a qualified fire engineering consultant for lower smoke temperatures, maybe allowed by the regulatory authority, thus reducing the insulation requirement. However, the duct shall betested and installed to maintain Stability and Integrity to the full test temperature.

All FLAMEBAR BW11 Fire Rated Ductwork and Penetration Seals have been tested to ISO 6944(1985) and manufactured and installed as tested or assessed by an International AccreditationServices Accredited Laboratory.

Note: Final approval must always be obtained from the Authority Having Jurisdiction prior tocommencement of construction.

4 Smoke Exhaust Ductwork Systems

14

ESCAPECORRIDOR

ESCAPECORRIDOR

FIRE RATED WALLS FIRE RATED FLOORS NON-FIRE RATED WALLS

FIRE RATED FAN

PLANT ROOM

MOTORIZEDSMOKE/FIRE DAMPERAT EACH FLOOR

PENETRATION SEAL

SHAFT

OFFICE

OFFICE

• COMMERCIAL KITCHENS MUST HAVE SEPARATE AND INDEPENDENT EXTRACT SYSTEMS (NFPA 96).

• FIRE DAMPERS MUST NOT BE USED IN A KITCHEN EXTRACT SYSTEM.

• ACCESS DOORS MUST BE INSTALLED AT 10FT INTERVALS WHERE POSSIBLE AND HAVE SMOOTHINTERNAL SURFACES TO ENABLE EASY CLEANING OF THE GREASE.

• CARE MUST BE TAKEN TO ENSURE COMBUSTIBLE DEPOSITS IN THE DUCT CANNOT IGNITE IN ADJACENTCOMPARTMENTS.

IN THE DIAGRAM:Grease ductwork presents a particular hazard in that combustible deposits such as greases are likely toaccumulate on its internal surfaces. Therefore, the ductwork should resist fire from inside (type B) and mustbe rated for Stability, Integrity and Insulation, for the same period of time as the compartment throughwhich it passes, shown As a fire in an adjacent compartment through which the kitchen exhaustductwork is passing could initiate a fire within the ductwork, in the absence of fire dampers this mightprejudice the safety of kitchen occupants, it should also be tested to fire outside engulfment (type A) withthe additional requirement that the internal surface of the ductwork within the compartment must meet theinsulation criteria.

In some circumstances, insulation requirements may be waived or varied by the regulatory authority, if theduct passes through an area where fire cannot be present shown such as a protected shaft. However,Stability and Integrity must still be maintained for the relevant period of time.

FLAMEBAR BW11 kitchen grease duct is tested and evaluated to ASTM-E2336-04 and UL 1978 andcomplies with NFPA 96 (2008 edition).

All our FLAMEBAR BW11 Fire Rated Ductwork and Penetration Seals have also been tested toISO 6944 (1985) and manufactured and installed as tested or assessed by an InternationalAccreditation Services Accredited Laboratory.


15

5 Commercial KitchenExtract Ductwork (See separate pamphlet)


SUITABLY FIRE RATED FAN

ROOF PLANT ROOM

PENETRATION SEAL

KITCHEN EXTRACTDUCTWORK

FIRE RATEDACCESS DOORS

SHAFT CONSTRUCTEDTO NFPA96

OFFICE

OFFICE

KITCHEN

ESCAPECORRIDOR

ESCAPECORRIDOR

ESCAPECORRIDOR

HOODHOOD

• ANY DUCT CROSSING AN ESCAPE CORRIDOR MUST BE FIRE RATED (NFPA 90A)

IN THE DIAGRAM:The pressurized air supply duct shown from the fire rated plantroom above crosses the cleaner’s roomand the exit corridor to provide air to the escape lobby. Pressurization ductwork systems are dealt with infull on page 18 but it should be noted that where any type of fire rated duct crosses the escape corridor itwill require Stability, Integrity and Insulation shown for the same period of time as the compartmentthrough which it passes.

Both the normal ventilation supply duct and exhaust duct follow a route from the riser shaft through theoffice using fire dampers and galvanized sheet steel duct shown Where the ducts cross and run in theescape corridor shown the duct must be fire rated and will require Stability, Integrity and Insulation forthe same period of time as the compartment through which it passes.

It will only require one fire damper if either side of the escape corridor is constructed with non fire rated duct.



6 Exit/Escape Route Ducts

16


PLANT ROOM ORRISER SHAFT

SUPPLY DUCT

FIRE DAMPERNON FIRE RATED DUCT

NOTE: ONE FIRE DAMPERWILL BE REQUIRED IFEITHER SIDE OF EXITCORRIDOR ISCONSTRUCTED WITHNON FIRE RATED DUCT

DUCTWORK INEXIT CORRIDORMUST BE FIRE RATED

NON FIRERATED DUCT

NON FIRERATED DUCT

WHERE DUCT CROSSESTHE ESCAPE CORRIDORSTABILITY, INTEGRITYAND INSULATION WILLBE REQUIRED

PRESSURIZED FRESHAIR SUPPLY DUCT TOESCAPE LOBBY

OFFICE

EXITCORRIDOR

STAIRWAY

LIFT FIREMANSLIFT

ESCAPELOBBY

OFFICE

17

• PRESSURIZATION DUCTS MUST BE ABLE TO MAINTAIN AN AIR SUPPLY TO CRITICAL AREAS FOR THEDURATION OF A FIRE.

• AIR SUPPLY MUST BE MAINTAINED IN A FIRE SO FIRE DAMPERS CANNOT BE USED.

• ALL DUCTWORK PENETRATING FIRE COMPARTMENTS MUST BE FIRE RATED, IN ORDER TO MAINTAINCOMPARTMENTATION.

• PRESSURIZATION PLANT SHOULD BE IN A DEDICATED PLANTROOM OR BE SEPARATED FROM OTHEREQUIPMENT BY A 1 HOUR FIRE RESISTANT ENCLOSURE.

IN THE DIAGRAM:A pressurization system is a special form of mechanical ventilation which maintains a positive pressure incritical areas to stop smoke from entering from adjacent areas, typically used in protected stairways,lobbies, corridors and fire fighting shafts.

Ductwork shown is passing through a dedicated plantroom supplying air and requires a minimum ratingof 1 hour for Stability and Integrity to resist fire from outside (type A).

Where it passes through the office shown it must maintain Stability, Integrity and may require Insulationfire rating for the same period of time as the compartment through which it passes and this may berequired for the remainder of the ductwork route through the building to the pressurized lobbies. Ductworkwithin the lobby or corridor shown need not be fire rated.

Ductwork shown is in a protected shaft constructed to NFPA 90A requirements with other services andin some circumstances insulation requirements may be waived or varied by the regulatory authority if thereare no combustible materials or other services within 18ins of the duct.



7 Pressurization Ductwork Systems

PENETRATIONSEALS


DEDICATED ROOFPLANT ROOM

OFFICE

LIFT

LOBBY

LIFT

LOBBY

PRESSURIZATIONSHAFT/STAIRCASE ESCAPE

CORRIDOR STAIRS

LOBBY

FIRE RATED FAN

FIRE RESISTINGPRESSURIZATIONDUCT TYPE A

NON FIRERATED DUCT

PRESSURIZATIONSTAIRCASE SHAFTCONSTRUCTED TOMETHOD 2 OFNFPA 90A

• EITHER A NATURAL OR MECHANICAL METHOD MAY BE USED TO VENTILATE SMOKE/HEAT FROMBASEMENTS.

• THE AIR EXHAUST SYSTEM SHOULD GIVE AT LEAST 10 AIR CHANGES PER HOUR.

• IF APPLICABLE THE FIRE DUCT MUST BE CONSTRUCTED TO RESIST WATER IMPINGEMENT FROM ANYSPRINKLER SYSTEM.

IN THE DIAGRAM:Smoke outlets/vents are needed to provide a route for heat and smoke to escape to the open air roombasement levels, either using natural or mechanical means. Mechanical exhaust may be used provided that thebasement levels are fitted with a sprinkler system, illustrated above the smoke exhaust duct shown . It mustbe suitable for clearing smoke within the compartments and normally rated for 1 hour Stability and Integrityto resist hot smoke and fire from inside (type B). Fire insulation rating is not required in the first compartment.

Where the basement duct rises through the shop above shown it must maintain Stability, Integrity andInsulation fire rating for the same period of time as the compartment through which it passes and this maybe required for the remainder of the ductwork route through the building to outside.

In some circumstances insulation requirements may be waived or varied by the regulatory authority if thereare no combustible materials within 18ins of the duct, such as in the plantroom shown .



8 Basement Smoke Exhaust Systems

18

NATURAL SMOKEOUTLETS 2.5% OFFLOOR AREA

PAVEMENT

FAN TESTED TO 752°F FOR AT LEAST 1 HOURAND OPERATES AUTOMATICALLY ON ACTIVATIONOF THE SPRINKLER SYSTEM

ATTENUATOR AT LEAST1 HOUR FIRE RATED

FLEXIBLE CONNECTIONS ATLEAST 1 HOUR FIRE RATED

PENETRATION SEALS

GROUND LEVEL

SHOP

SPRINKLER SYSTEM

BASEMENT ROOM

STORE

ROOF PLANT ROOM


19

• OPERATES AS A CONVENTIONAL DUCTWORK SYSTEM UNDER NORMAL CONDITIONS.

• OPERATES AS A SMOKE EXHAUST SYSTEM UNDER FIRE CONDITIONS.

• SMOKE EXHAUST DUCTWORK MUST RETAIN AT LEAST 75% OF ITS CROSS SECTIONAL AREA, BOTH INTHE FIRE COMPARTMENT AS WELL AS IN ADJACENT COMPARTMENTS.

IN THE DIAGRAM:Systems that can operate in two different modes may offer economical solutions for smoke exhaust. Theductwork shown must be suitable for clearing smoke within he compartments and normally rated for 1hour for Stability and Integrity to resist hot smoke and fire from inside (type B). Fire insulation rating is notrequired in the first compartment.

Where the duct crosses the escape corridor shown it must maintain Stability, Integrity and Insulation firerating for the same period of time as the compartment through which it passes and this may be requiredfor the remainder of the ductwork route through the building to outside.

In some circumstances insulation requirements may be waived or varied by the regulatory authority if thereare no combustible materials within 18ins of the duct, such as in the plantroom shown . But, Stabilityand Integrity must still be maintained for the relevant period of time.

In order that the 75% cross sectional free area criteria be maintained, fire rated ductwork would be usedwithin the service shaft requiring Stability and Integrity shown . However, if there are combustiblematerials within 18ins of the duct, insulation would still be needed.



9 Dual Ventilation/SmokeExhaust Systems


CHANGEOVER DAMPERS,TO CHANGE SYSTEMFROM SUPPLY AIR TOSMOKE EXHAUST

SERVICE SHAFT

DUCTWORK SUPPLY/EXHAUST SUITABLEFOR CLEARING SMOKE

FAN FIRE RATED

MOTORIZED SMOKE/FIRE DAMPERS

PLANT ROOM

OFFICE

OFFICE

ESCAPECORRIDOR

ESCAPECORRIDOR

STORE ROOM

PRINT ROOM

• FIRE DAMPERS SHOULD NOT BE USED WHERE PLASTIC DUCTWORK IS INSTALLED TO RESIST ACIDICFUMES AND SOLVENTS.

• ALTERNATIVE SOLUTIONS MUST BE FOUND FOR CROSSING EXIT CORRIDORS AND GOING FROM ONECOMPARTMENT TO ANOTHER.

• DUCTWORK CONVEYING POLLUTED AIR MUST TAKE INTO ACCOUNT THE PARTICULAR HAZARDINVOLVED AND THE LIKELY CONTRIBUTION TO FIRE SPREAD.

IN THE DIAGRAM:Plastic ductwork presents a particular problem where acidic fumes and solvents are exhausted in fumehood systems. Fire dampers are impractical and alternative solutions must be used.

Duct shown is a plastic duct installed inside an outer fire rated casing (duct within a duct).

The outer casing would resist fire from inside (type B) and from outside (type A) maintaining Stability andIntegrity.

Where the fume exhaust duct crosses the exit corridor shown the duct would require Stability, Integrityand Insulation for the same period of time as the compartment through which it passes and this may berequired for the remainder of the ductwork route through the building to the outside.



10 Fume Hood Exhaust Systems

20


PENETRATION SEAL

LABORATORY

OFFICE

OFFICE

EXIT CORRIDOR

STAIRS LIFT

LIFT

LIFTLOBBY

FUME HOOD EXTRACTDUCT INSULATED AS ITCROSSES ESCAPE CORRIDOR

FUME HOOD

21

If specified we can provide fire stopping compartments as part of our installation service. Detailsbelow are two typical fire rated ductwork stoppings, as tested to ISO 6944 (1985).

11 Penetration Seals BetweenFire Compartments

A PENETRATION SEAL MUST BE INSTALLED ATEVERY FIRE COMPARTMENT WALL OR FLOOR.THESE SEALS ARE NOT INCLUDED UNLESSSTATED. THE PENETRATION FIRESTOP SYSTEMTO BE EITHER CONSTRUCTED FROM MINERALWOOL OR FIRE MORTAR AS U.L. SYSTEM NO:–C-AJ 7029 or 7030orXHEZ F-A-7017XHEZ F-A-7005XHEZ W-L-7133XHEZ W-L-7160

Floor Penetration Seal

Wall Penetration Seal

Drill 20 Suit3/8in Bolts

U.L. ApprovedFire Stopping System



Stiffener or Flangewithin 2in of Wall

3in x 3in RSA Fixed to Duct@ 6in CRS with 3/8in Bolts

Plate Ends on Anglefor Site Fixing

The range of FLAMEBAR BW11 Fire Duct has been tested by UL and evaluated by Intertekand other International Accreditation Services test facilities in accordance with ISO Standard6944 (1985), for vertical and horizontal ductwork, with fire inside and outside the duct, in excessof 4 hours Stability, Integrity and Insulation for ventilation ductwork, smoke exhaust ductwork orgrease ductwork.

FLAMEBAR BW11 Fire Duct has the Underwriters Laboratory UL Classification and listed byIntertek for up to 4 hours fire rated ductwork.

FLAMEBAR BW11 has been tested by Underwriters Laboratory to determine compliance withNFPA 90A (Installation of Air Conditioning and Ventilation Systems) for flame spread and smokedevelopment with the following results:

Test conducted in accordance with UL Standard 723 “Test for Surface Burning Characteristics ofBuilding Materials” (ASTM E84).

FLAMEBAR BW11 Fire Duct has also passed the hose stream test to ASTM – E119 with waterpressure of 30 psi for 21/2 minutes.

Impact Test of FLAMEBAR BW11 Fire DuctImpact and Strength to UL 1978Ref sections:17 – Vertical Support Test.18 – Strength Test – 18-1 and 18-2 Impact Test.18 – Strength Test 18-1 and 18-3 Longitudinal Force Test.18 – Strength Test – 18-1 and 18-4 Load Test for Grease Elbows.18 – Strength Test – 18-1 and 18-5 Grease Duct Joint Load Test.

Impact test to BS 5669, in which a dart imparts 32.5ft pound force at maximum drop, resulting ina small indentation which passes under the criteria of BS 5669. FLAMEBAR BW11 Fire Ductalso has undergone impact testing to the requirements of Appendix A BS 5588 Part 5.

Exterior Weathering of FLAMEBAR BW11 Fire DuctDuplicate samples were placed on the exterior weathering frame and left totally exposed sinceJanuary 1993. The results so far show:

1 Some dirt pick-up which can be washed off2 No mold growth3 No chalking4 Material has remained totally intact

12 Standards (Non-Grease)

22

NFPA Requirement Flame Spreadnot to exceed 25

Smoke Developmentno higher than 50

FLAMEBAR BW11 Results 9.4 0.2

23

Durability ReportInspection report to Bodycote Warrington Fire an IAS facility confirming durability ofFLAMEBAR BW11 coating and duct system since 1995. Confirming no deterioration of thecoating or duct including thickness applied.

Considering the length of time the samples have been exposed, the material is in good condition.

Artificial Weathering of FLAMEBAR BW11 – OUV WeatherometerThe samples undergoing artificial weathering have undergone over 22,000 hours of alternate UVand condensation cycling which is extremely excessive in duration terms, normally 1,000 hours issufficient to predict whether a material is suitable for exterior/semi exposed conditions. 22,000hours is equivalent to 60 years external exposure.

Expansion of FLAMEBAR BW11 Fire DuctAs all steel expands with temperature, there will naturally be an expansion of fire duct under fireconditions as follows:At 2012°F an expansion of 0.016in per inchAt 1112°F an expansion of 0.008in per inchAt 806°F an expansion of 0.006in per inch

Thermal Properties of FLAMEBAR BW11 Fire Duct‘U’ value – thermal transmittance.FLAMEBAR BW11 without insulation = 0.88 Btu/ft2/hr°FFLAMEBAR BW11 with 2in insulation = 0.147 Btu/ft2/hr°FFLAMEBAR BW11 with 4in insulation = 0.08 Btu/ft2/hr°F

Chemical Resistance of FLAMEBAR BW11 Fire DuctThe coating has been tested in:Standard 10% solutions of the following acids:Hydrochloric, Nitric and Sulphuric.Standard 10% solutions of the following alkalies:Sodium Hydroxide and Potassium Hydroxide.The following solvents:Xylene and Acetone.After 10 days total immersion, all the above chemicals failed to cause a breakdown of theproduct structure.

24

Single Source Responsibility

1 The design of all FLAMEBAR BW11 Fire Duct Systems is to a certified standard.

2 All FLAMEBAR BW11 Fire Duct is manufactured and sprayed to UL classified constructionstandards.

3 All FLAMEBAR BW11 Fire Duct is erected to UL classified installation details.

4 A Certificate of Conformity will be issued by the manufacturer or the local UL approvedLicensee following final inspection certifying compliance with all necessary requirements ofthe UL classification.

TestingAll FLAMEBAR BW11 Fire Duct has been tested to:ISO 6944 (1985) for up to 4 hours Stability, Integrity and Insulation.UL 723 “Test for Surface Burning Characteristics of Building Materials” (ASTM E84) to ensurecompliance with NFPA 90 A & B.

Weight: FLAMEBAR BW11 Fire Duct is the lightest fire duct system available.

Shape: FLAMEBAR BW11 Fire Duct can be manufactured in rectangular, flat oval or circular.

Impact Resistance: FLAMEBAR BW11 systems are impact resistant to BS 5588 Part 5,Appendix A.

Moisture Absorption: FLAMEBAR BW11 systems are non-hygroscopic and have been testedin an artificial Weatherometer to an equivalent of 60 years external exposure.

Chemical Resistance: FLAMEBAR BW11 Fire Duct is chemically resistant to many acids andsolvents and has excellent resistance to chemical attack.

Mold Resistance: FLAMEBAR BW11 has been evaluated for resistance to fungal attackaccording to Thor Test Method 800.1.

Thor Test Method 800.1 – Dry Film Fungal Resistance Test – Humidity Cabinet Method –Micro-organisms tested:

• Alternaria alternata• Aspergillus versicolor• Aureobasidium pullalans• Cladosporium cladosporoides• Penicillium purpurogenum• Phoma voilaceae• Rhodotorula rubra• Sporobolomyces roseus• Stachybotrys chartarum• Ulocladium atrum

13 System Advantages

25

Table 1 – Dry Film Fungal Resistance Test

Growth Ratings:0 = No growth1 = Trace growth2 = 1-10% coverage of growth3 = 11-30% coverage of growth4 = 31-70% coverage of growth5 = 71-100% coverage of growth

Intensity Ratings:+ = light, ++ = moderate, +++ = dense

Technical Report B/03/0360 shows no growth on the surface of BW11 when spray inoculatedwith a mixed spore suspension and subsequently assessed according to BS 3900 Part 6.

Smoke and Toxic Fume Emission: FLAMEBAR BW11 Fire Duct has been tested to BS 6853for smoke emission and toxic fume emission.

Anti Drumming: FLAMEBAR BW11 Fire Duct has a damping co-efficient to BS AU125 (1966)of 19db per second decay rate.

Inline Plant: Inline plant such as fans and attenuators can be treated with FLAMEBARBW11, if suitably constructed.

Acoustic Properties: FLAMEBAR BW11 Fire Duct achieves a sound reduction index toBS 2750 Part 3 (1980) as tabled below:

Cleaning: The smooth internal finish of FLAMEBAR BW11 Systems enable easy cleaning ofthe ductwork therefore it is ideal for kitchen exhaust duct installations.

Color: FLAMEBAR BW11 Fire Duct without insulation has a monolithic spray texture withnatural buff finish.FLAMEBAR BW11 Systems can also be overpainted or sprayed with water based paint toobtain any desired colour.

Sample

P2/B001 – Firespray BW11 22 April 2003

P2/B002 – Firespray BW11 22 April 2003

Laboratory Blank

Laboratory Standard

Film Fungal GrowthRating/Intensity Replicate

(0) 0

(0) 0

(90+++) 5

(0) 0

Systems

FLAMEBAR BW11

FLAMEBAR BW11+4lb/ft2 2ins insulation

FLAMEBAR BW11+6lb/ft2 2ins insulation

Frequency (Hz)

63 125 250 500 1K 2K 4K 8K

10.2 11.7 16.7 21.7 27.7 32.7 37.7 43.7 dB

11.0 12.5 17.5 22.5 28.5 33.5 38.5 44.5 dB

13.4 14.9 19.9 24.9 30.9 35.9 40.9 46.9 dB

Flamebar BW11 Fire Rated Ductwork Systems are protected by design right.

STATE LICENSEE

Firespray International – North America

Tel: 540 292 9521 Fax: 540 949 7936

e-mail: [email protected]

www.firespray.eu.com

This Applications and Technical Manual has been produced by Firespray International Ltd who have a Policy ofcontinuous Product and System improvement and reserve the right to change Methods and Specifications without notice.

FIRESPRAY INTERNATIONAL LTD FLAMEBAR HOUSE SOUTH ROAD TEMPLEFIELDS HARLOW ESSEX CM20 2AR ENGLANDTEL: +44 1279 634 230 FAX: +44 1279 634 232 e-mail: [email protected] www. firespray.eu.com

Certificate No. 277aApproved to BS 476: Part 24

Assessed to ISO9001:2000Certificate Number 277

flamebar applications technical manual

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