helsel-fire resistant coatings_final.pdf

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Presented by: Jayson L. Helsel, P.E. KTA-Tator, Inc. Click to buy NOW! P D F - X C h a n g e w w w . t r a c k e r - s o f t w a r e . c o m Click to buy NOW! P D F - X C h a n g e w w w . t r a c k e r - s o f t w a r e . c o m

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Page 1: Helsel-Fire Resistant Coatings_final.pdf

Presented by:Jayson L. Helsel, P.E.

KTA-Tator, Inc.

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Page 2: Helsel-Fire Resistant Coatings_final.pdf

Learning ObjectivesComprehension of the Fire Resistant Webinar willenable the participant to:

Describe how intumescent coatings protect underlying steel from heat exposureIdentify the US authority that evaluates and approves intumescent coatingsList two fire rating classification tests that are used to qualify intumescentcoatings for use in building constructionIdentify two primary resin types that are used to formulate intumescent coatings

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Page 3: Helsel-Fire Resistant Coatings_final.pdf

Learning Objectives (cont.)List characteristics of the resin systems used to formulate intumescent coatingsExplain how steel size and structure design affect specified thickness and numberof coatsDescribe the methods used to improve the appearance of the texture ofintumescent coatingsDescribe a method to measure the hardness of the applied coating to assess cureIdentify the generic types of primer and finish coats commonly used inconjunction with intumescent coatings

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Page 4: Helsel-Fire Resistant Coatings_final.pdf

Fire Resistant Coatings

Sprayed Fire Resistive Materials (SFRM) are broadgroup of materials including:

Cementitious and gypsum based materialsIntumescent coatings

(Note: There is a separate category for “Fire Retardent”coatings, which are not reviewed here)

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Page 5: Helsel-Fire Resistant Coatings_final.pdf

Fire Resistant Coatings

Intumescent Coatings:Are categorized as SFRMsSimilar to conventional coatingsHave unique fire resistant properties

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Page 6: Helsel-Fire Resistant Coatings_final.pdf

Intumescent Coatings

How they function:Intumescent coatings char and swell when exposedto fire/heatThe charred layer acts to insulate the steel from fire

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Page 7: Helsel-Fire Resistant Coatings_final.pdf

Intumescent Coatings

Performance ratingsCoatings rated by how long steel is protected atspecified thicknessRatings from 1 to 3 hours (at 30 minute intervalsSpecific to shape/size of steel, e.g. W10x 49 column

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Page 8: Helsel-Fire Resistant Coatings_final.pdf

Fire Resistance Classifications

Underwriters Laboratories (UL) is recognizedauthority that evaluates and approves intumescentcoatings for a certain classification and fire ratingCertifications can be verified online at www.ul.com

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Page 9: Helsel-Fire Resistant Coatings_final.pdf

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Page 10: Helsel-Fire Resistant Coatings_final.pdf

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Page 11: Helsel-Fire Resistant Coatings_final.pdf

Fire Resistance Classifications

Certifications are “design” specific by coatingmanufacturerNumbering system defines an alphanumeric designnumber

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Page 12: Helsel-Fire Resistant Coatings_final.pdf

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Page 13: Helsel-Fire Resistant Coatings_final.pdf

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Page 14: Helsel-Fire Resistant Coatings_final.pdf

Fire Resistance Classifications

BeamsW, M or S shaped steel sections (AISC)Minimum beam size for fire resistance is expressed asW/D ratio

W = weight of beam per lineal footD = perimeter of protection material

Beams of same configuration with greater W/D ratiomay be used in design

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Page 15: Helsel-Fire Resistant Coatings_final.pdf

Fire Resistance Classifications

ColumnsMinimum column size and configuration specified in Xand Y series designsSame hourly rating applies when section with equal orgreater W/D ratio is substituted for same configuration

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Page 16: Helsel-Fire Resistant Coatings_final.pdf

Fire Resistance Classifications

Beams and ColumnsRequired coating thickness increases as weight of steeldecreases

Lighter steel heats up more rapidly and requires moreprotection

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Page 17: Helsel-Fire Resistant Coatings_final.pdf

Fire Resistance Classifications

Intumescent (and Mastic) CoatingsCoating thickness specification in a design is minimumaverage thickness measured in accordance withTechnical Manual 12-B

Average thickness should not exceed maximum thicknesspublished (if listed) in individual designs or byNo individual measurement <80% of specified designthickness

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Page 18: Helsel-Fire Resistant Coatings_final.pdf

Fire Resistance Classifications

Technical Manual 12-BPublished by Association of the Wall and CeilingIndustries (AWCI International)Individual measurement = average of 3 gauge readings(similar to SSPC-PA 2)Testing frequency one bay per floor or one test per10,000 square feet (further defines required shapes)

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Page 19: Helsel-Fire Resistant Coatings_final.pdf

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Page 20: Helsel-Fire Resistant Coatings_final.pdf

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Page 21: Helsel-Fire Resistant Coatings_final.pdf

Fire Resistance ClassificationsTechnical Manual 12-B

ScopeGeneral InformationSubstrate ConditionsSite ConditionsInspection ProceduresMethod of TestsConditions of Finished ApplicationPatching

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Page 22: Helsel-Fire Resistant Coatings_final.pdf

Fire Resistance Classifications

ANSI/UL 263Used for resistance to cellulosic fire (e.g. combustion ofwood or building materials)Slower rise in temperature

1000 F at 5 min.; 1550 F at 30 min.; 1700 F at 60 min.; 1925 F at180 min.; 2000 F at 240 min.

Interior and exterior exposures

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Page 23: Helsel-Fire Resistant Coatings_final.pdf

Fire Resistance Classifications

ANSI/UL 263 Classified CoatingsTypical use for structural steel in commercial structures

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Page 24: Helsel-Fire Resistant Coatings_final.pdf

Fire Resistance Classifications

ANSI/UL 1709Used for resistance to a hydrocarbon fireRapid rise in temperature

2000 F at 5 minutes

Interior and exterior exposuresEnvironmental tests include, accelerated aging, highhumidity, salt spray, thermal cycling for exterior exposure

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Page 25: Helsel-Fire Resistant Coatings_final.pdf

Fire Resistance Classifications

ANSI/UL 1709 Classified CoatingsTypical use for steel structures at petrochemcialfacilities, e.g.

Chemical plantRefineriesOffshore oil platforms

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Page 26: Helsel-Fire Resistant Coatings_final.pdf

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Page 27: Helsel-Fire Resistant Coatings_final.pdf

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Page 28: Helsel-Fire Resistant Coatings_final.pdf

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Page 29: Helsel-Fire Resistant Coatings_final.pdf

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Page 30: Helsel-Fire Resistant Coatings_final.pdf

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Page 31: Helsel-Fire Resistant Coatings_final.pdf

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Page 32: Helsel-Fire Resistant Coatings_final.pdf

Other Approvals

Intumescent coatings may also need approval by citybuilding codesCoating manufacturers should provide approvals asapplicable

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Page 33: Helsel-Fire Resistant Coatings_final.pdf

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Page 34: Helsel-Fire Resistant Coatings_final.pdf

Generic Coating Types

Intumescent coatings are generally the followinggeneric resin types:

Acrylic/vinylEpoxy

Intumescents are also generally categorized as “thin-film” or “thick-film” coatings

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Page 35: Helsel-Fire Resistant Coatings_final.pdf

Generic Coating Types

Acrylic/vinylThin-film coatingSolvent or water-basedSingle componentTypically rated under UL 263

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Page 36: Helsel-Fire Resistant Coatings_final.pdf

Generic Coating Types

Acrylic/vinylApplied in several coatsTime-frame for a complete application may span several daysAdditional time may be needed before application of anyrequired exterior finish coat.

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Page 37: Helsel-Fire Resistant Coatings_final.pdf

Generic Coating Types

EpoxyThick-film coatingApplied by plural component spray equipment in one or twocoatsRapid cureTypically rated under UL 1709

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Page 38: Helsel-Fire Resistant Coatings_final.pdf

Generic Coating Types

EpoxyMay require mesh reinforcement (e.g. metal, fiberglass,carbon)Typically requires the use of applicators licensed or approvedby the coating manufacturer

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Page 39: Helsel-Fire Resistant Coatings_final.pdf

Generic Coating ComparisonCoating Type Required

Thickness(mils)

Numberof Coats

RecoatTime

(betweencoats)@50ºF

Time toFinishCoat

@50ºF

Solvent-based acrylic 130 5 24 hours 25 days

Solvent-based vinyl 375 4 4 hours 20+ days

Water-based acrylic 180 6 8 hours 10+ days

Epoxy 180 1 n/a 24 hours

Epoxy w/mesh 340 1-2 n/a 48 hours

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Page 40: Helsel-Fire Resistant Coatings_final.pdf

Testing for Coating Cure

Intumescents may require testing for proper cureTypical test is Durometer Hardness (Shore D)

Resistance of coating film to indentation by DurometerinstrumentASTM D2240, “Standard Test Method for RubberProperty-Durometer Hardness”

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Page 41: Helsel-Fire Resistant Coatings_final.pdf

Testing for Coating CureClic

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Page 42: Helsel-Fire Resistant Coatings_final.pdf

Coating Appearance

Intumescents generally have a rough or orange peelappearanceMethods to improve include:

Back rolling following spray applicationSanding (not recommended)Finish coat application (may be required)

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Page 43: Helsel-Fire Resistant Coatings_final.pdf

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Page 44: Helsel-Fire Resistant Coatings_final.pdf

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Page 45: Helsel-Fire Resistant Coatings_final.pdf

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Page 46: Helsel-Fire Resistant Coatings_final.pdf

Coating Systems

Intumescent design approvals typically include aprimer and/or finish coat

When included in design primer/finish must be appliedto meet fire rating

Primer/finish must be endorsed by intumescentcoating manufacturer

Preference always for same manufacturer

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Page 47: Helsel-Fire Resistant Coatings_final.pdf

Use of Primers

Intumescent coating manufacturer may have approvedlist of primers

Types include alkyd, acrylic, epoxy and zinc-richApplication thickness important

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Page 48: Helsel-Fire Resistant Coatings_final.pdf

PrimersFunction of primer

Provides adhesion to substrateProvides suitable surface for intumescentProvides additional barrier protection

Can also provide inhibitive or sacrificial protection

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Page 49: Helsel-Fire Resistant Coatings_final.pdf

Use of Finish Coat

May be required in design approval for exteriorexposureIntumescent coating manufacturer must endorsefinish material

Types include 100% acrylic and aliphatic urethanecoatings

May affect/improve appearance

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Page 50: Helsel-Fire Resistant Coatings_final.pdf

Finish CoatsFunction of topcoat

Color and glossAbrasion resistanceChemical resistanceWashabilityResistance to the environment

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Page 51: Helsel-Fire Resistant Coatings_final.pdf

Finish CoatsAcrylics

AdvantagesSingle componentEase of applicationColor & gloss retentionFlexibilityLow VOC content for waterbased

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Page 52: Helsel-Fire Resistant Coatings_final.pdf

Finish CoatsAcrylics

LimitationsLimited alkali and solvent resistanceModerate abrasion resistanceApplication temperature >50ºF for waterbased

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Page 53: Helsel-Fire Resistant Coatings_final.pdf

Finish CoatsUrethanes

AdvantagesColor & gloss retention (aliphatic)AdhesionAcid, alkali resistantChemical resistantImpact/abrasion resistant

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Page 54: Helsel-Fire Resistant Coatings_final.pdf

Finish CoatsUrethanes

LimitationsMulti-componentShort recoat intervalsLimited pot lifeMoisture sensitive during cureDifficult to recoat

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Page 55: Helsel-Fire Resistant Coatings_final.pdf

Summary of Key Points

When specifying intumescents consider:Required UL approvalCity building code approvalInclude required primer and finish coatsApplicator certification if needed (e.g. plural componentmaterials)Include test sections to evaluate appearance

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Page 56: Helsel-Fire Resistant Coatings_final.pdf

Fire Resistive Coatings

Questions?

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