An assessment of the fire performance of a proprietary design for

An assessment of the fire performance of a proprietary design for vertical and horizontal ventilation, smoke outlet and kitchen extract duct systems

Prepared for: Firespray International Limited Flamebar House South Street Templefields Harlow Essex CM20 2AR

6 August 2012

Assessment report number CC 88343 Review 4 Issue 2

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Prepared on behalf of BRE Testing by

Name Andrew C Russell

Position Senior Consultant

~:3~ ~., " Signature

Authorised on behalf of BRE Testing by

Name Richard A Jones

Position Associate Director

Date 6 August 2012

Signature

Date of original report

Date of this re-issue

Date of next review

20 June 2001

6 August 2012

24 April 2017

BRE Global Bucknalls Lane Watford Herts WD25 9XX T

E enq [email protected] www.breglobal.com

This report may only be distributed in its entirety and in accordance with the terms and conditions of the contract. Assessments relate only to the items tested/assessed. We have no responsibility for the design, materials, workmanship or performance of the product or items tested/assessed. This report does not constitute an approval, certification or endorsement of the product tested/assessed

This report is made on behalf of BRE Testing. By receiving the report and action on it, the client accepts that o individual is personally liable in contract, tort or breach of statutory duty (including negligence). No third party has any right to rely on this report.

Assessment report number CC 88343 Review 4 Issue 2 Commercial in confidence

© BRE Global Ltd 2012 Page 2 of 75

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Contents

Summary

1 Objective

2

3

4

5

6

7

8

2.1 2.2 2.3 2.4 2.5

2.6 2.7 2.8 2.9 2.10 2.11

2.12 2.13

3.1 3.2 3.3 3.4

4.1

4.2 4.3 4.4 4.5

5.1 5.1.1

5.1.2 5.2 5.3 5.4 5.5

8.1

8.2

Supporting data LPC test report TE 82414 LPC test report TE 82724 LPC test report TE 84033 LPC test report TE 87473 WFRC test report WARRES no. 44509

Test re 3ort IFCI 322 Test re 3ort IFCI 328 Test re 3ort IFCI 329 Test re 3ort IFCI 330 Test re 3ort FC174 WF test report no. 156568 Issue 2 BRE assessment report no. CC 89277A BRE assessment report no. CC 218953

Comments on supporting data Addendum to test report TE 82414 Loss of shape of duct Penetration seal Seal used between lengths of duct

Appraisal of duct system

Penetration seal Hanger threaded rods Design and size of steel ducts used to construct Flamebar BWl 1 fire duct

Insulation system Orientation of duct

Supplementary assessments/additional data

Three-sided, two-sided and single-sided ducts Three-sided duct Two- and single-sided ducts

Flamebar BWl 1 ducts constructed with stainless steel Access doors Alternative seal between duct lengths Alternative fixings

Conclusion

Re-issue of report

Validity of the assessment

Declaration by applicant BRE Testing declaration

5

6

6 6 6 7 7 7

7 8 8 8 9 9

9 9

10 10 10 11 11

12 12

12 12 14 17

18 18 18

18 18 19 19 19

20

20

20 20

21

Appendix A - Design of hanger supports for four-sided horizontal ducts 27



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Appendix B - Horizontal and vertical ducts larger than 4m wide

up to 10m wide

Appendix C - Horizontal and vertical ducts larger than 4m wide

up to 25m wide

Appendix D - Flamebar construction standards drawings

28

29

3O



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Summary

An assessment has been carried out on your steel vertical and horizontal ventilation, smoke outlet and kitchen extract duct systems protected with Flamebar BW11 Fire Proofing and additionally, in some cases,

with stone mineral wool, as tested in TE 82414, TE 82724 and TE 84033 to BS 476: Part 24:1987 (ISO 6944:1985). The results of the assessment, involving fire ratings up to four hours, thicknesses of protection and other requirements are given in tables 1,2 and 3.



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Objective

To carry out an assessment of the fire resistance of your steel ventilation, smoke outlet and kitchen extract duct systems protected with Flamebar BW11 Fire Proofing and additionally, in some cases, with stone

mineral wool, on the basis of fire resistance tests WF no. 156568 Issue 2, TE 82414, TE 82724 and TE 84033, for variations in the duct system due to fire rating, duct function, duct orientation, size of duct, supporting system and penetration details.

2 Supporting data

This assessment is partly based on supporting test data which is more than five years old. This supporting data has therefore been reviewed against current test procedures.

2.1 LPC test report TE 82414

A fire resistance test in accordance with BS 476: Part 24:1987 was carried out on 2 June 1992 on a horizontal ventilation duct assembly, 6.50m long, for a heating period of 120 minutes. The duct assembly consisted of a steel duct, 1000ram wide x 250ram deep x 1.2ram thick, protected with Flamebar BW11 Fire Proofing, of mean thickness 0.9mm. The duct was exposed to hot furnace gases on the inside (duct B) and satisfied the stability, integrity and insulation criteria of the standard for 120 minutes, 36 minutes and four minutes respectively. See LPC test report TE 82414 for full details.

An exploratory fire test was carried out, at the same time as the standard test, on an identical duct assembly, with a mean thickness of Flamebar BW11 Fire Proofing of 0.9mm, except that the duct was exposed to fire on the outside. The duct was exposed to hot furnace gases on the outside (duct A) and satisfied the stability and integrity criteria of the standard for 120 minutes. See LPC letter report TE 82414, dated 9 June 1992, for full details.


A fire resistance test in accordance with BS 476: Part 24:1987 was carried out on 9 September 1992 on a horizontal ventilation duct assembly, 6.50m long, for a heating period of 240 minutes. The duct assembly consisted of a steel duct, 1000mm wide x 250mm deep x 1.6mm thick, protected with Flamebar BW11 Fire Proofing, of mean thickness 1.0ram and with Rockwool Firebarrier stone mineral wool, 50ram thick x 105kg/m3 density, on the length of duct outside the furnace. The duct was exposed to hot furnace gases on

the inside (duct B) and satisfied the stability, integrity and insulation criteria of the standard for 240 minutes, 230 minutes and 64 minutes respectively. See LPC test report TE 82724 for full details.

An exploratory fire test was carried out, at the same time as the standard test, on an identical duct assembly except that the steel of the duct was 1.2mm thick and the Rockwool Firebarrier, 50mm thick, extended for the whole length of the duct. The duct was exposed to fire on the outside (duct A) and

satisfied the stability, integrity and insulation criteria of the standard for 240 minutes, 240 minutes and 208 minutes respectively. See LPC letter report TE 82724, dated 17 September 1992, for full details.



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A fire resistance test in accordance with BS 476: Part 24:1987 was carried out on 12 October 1993 on a horizontal ventilation duct assembly, 6.52m long, for a heating period of 120 minutes. The duct assembly consisted of a steel duct, 1000mm wide x 250mm deep x 0.9mm thick, protected with Flamebar BW11 Fire Proofing, of mean thickness 0.7mm and with stone mineral wool, 50mm thickx 60kg/m3 density, on the

length of duct outside the furnace. The duct was exposed to hot furnace gases on the inside (duct B) and satisfied the stability, integrity and insulation criteria of the standard for 120 minutes, 112 minutes and 45 minutes respectively. See LPC test report TE 84033 for full details.

An exploratory fire test was carried out, at the same time as the standard test, on an identical duct assembly except that the 60kg/m3 density stone mineral wool, 50mm thick, extended for the whole length of

the duct. The duct was exposed to fire on the outside (duct A) and satisfied the stability, integrity and insulation criteria of the standard for 120 minutes, 120 minutes and 118 minutes respectively. See LPC letter report TE 84033 dated 27 October 1993 for full details.


A fire resistance test in accordance with BS 476: Part 24:1987 was carried out on 23 May 1996 on a horizontal ventilation duct assembly, 6.50ram long, for a heating period of 240 minutes. The duct assembly consisted of a steel duct, 1000mm wide x 250mm deep x 1.0mm thick, protected with Rockwool FPL Slab 110, of mean thickness 100mm. The duct was exposed to hot furnace gases on the inside (duct B) and satisfied the stability, integrity and insulation criteria of the standard for 240 minutes, 197 minutes and 89 minutes respectively. See LPC test report TE 87473 for full details.

2.5 WFRC test report WARRES no. 44509

A fire resistance test in accordance with BS 476: Part 22:1987 was carried out for Rockwool Limited on a stone mineral wool fire barrier for a heating period of 150 minutes. The test specimen, 3.0m high x 3.0m wide, consisted of two layers of foil faced, 105kg/m3 density mineral wool, each 60mm thick, separated by

40mm and with joints staggered. The fire barrier satisfied the integrity criteria of the standard for 150 minutes and the insulation criteria of the standard for 134 minutes. See WFRC test report WARRES no.

44509 for full details. (See Clause 4.4 for further details).

2.6 Test report IFCl 322

An exploratory fire test was carried out at the Mandoval Test Centre on 19 November 1998 on a Flamebar BWl 1 steel duct system for a heating period of 245 minutes. The test adopted the appropriate heating conditions, procedures and criteria of BS 476: Part 24: 1987. The duct specimen comprised a 400mm-wide x 400mm-high x 1.0mm-thick steel duct with beading at 300mm centres, protected with Flamebar BWl 1 Fire Proofing of mean thickness 0.9mm. The duct, of overall length 4545mm, consisted of four duct sections connected by 50mm lap joints fastened with M4 stainless steel rivets at 60mm centres. The duct was stiffened at the penetration through the wall with 50mm x 50mm x 3mm steel angles fastened with M8 steel bolts at 150mm centres. The duct was exposed to hot furnace gases on the inside (duct B). There was no collapse of the duct and no failure of integrity, applying the general criteria for integrity of BS 476: Part 20: 1987. The temperature rise limits of the standard were first exceeded at four minutes. The duct retained more than 75% of its original cross-sectional area throughout the heating period and therefore satisfied the smoke outlet requirements of the test standard. See test report IFCI322 for full details.



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An exploratory fire test was carried out at the Mandoval Test Centre on 17 December 1998 on a Flamebar BW11 steel duct system for a heating period of 45 minutes. The test adopted the appropriate heating conditions, procedures and criteria of BS 476: Part 24: 1987. The duct specimen comprised a 1000mm- wide x 250mm-high x 1.0mm-thick steel duct constructed in accordance with DW/144, protected with Flamebar BW11 Fire Proofing of mean thickness 0.9mm and with stone mineral wool blanket, 25mm thick x 45kg/m3 density. The duct, of overall length 4545mm, consisted of four duct sections connected by 40mm

flanged joints fastened with M8 steel bolts. The duct was stiffened at the penetration through the wall with 50mm x 50mm x 3mm steel angles fastened with M8 steel bolts at 150mm centres. The duct was exposed to hot furnace gases on the inside (duct B). There was no collapse of the duct and no failure of integrity,

applying the general criteria for integrity of BS 476: Part 20: 1987. The temperature rise limits of the standard were first exceeded at 31 minutes. See test report IFCI326 for full details.


An exploratory fire test was carried out at the Mandoval Test Centre on 10 February 1999 on a Flamebar BW11 steel duct system for a heating period of 245 minutes. The test adopted the appropriate heating conditions, procedures and criteria of BS 476: Part 24: 1987. The duct specimen comprised a 1000mm- wide x 250mm-high x 0.8mm-thick steel duct with beading at 300mm centres, protected with a Flamebar BW11 Fire Proofing of mean thickness 0.Tram. The duct, of overall length 4545mm, consisted of four duct sections connected by 50mm lap joints fastened with M4 stainless steel rivets at 60mm centres. The duct was stiffened at the penetration through the wall with 50mm x 50mm x 3mm steel angles fastened with M8 steel bolts at 150mm centres. Additional stiffening of the duct was provided by 40mm x 40mm x 4mm steel angle, welded to the duct, at approximately 1200mm centres. The duct was exposed to hot furnace gases on the inside (duct B). There was no collapse of the duct and no failure of integrity, applying the general criteria for integrity of BS 476: Part 20:1987. The temperature rise limits of the standard were first exceeded at four minutes. The duct retained more than 75% of its original cross-sectional area for the first 210 minutes of the heating period and therefore satisfied the smoke outlet requirements of the test standard for that time. See test report IFCI 329 for full details.


An exploratory fire test was carried out at the Mandoval Test Centre on 17 February 1999 on a Flamebar BW11 steel duct system for a heating period of 245 minutes. The test adopted the appropriate heating conditions, procedures and criteria of BS 476: Part 24: 1987. The duct specimen comprised a 400mm-wide x 400mm-high x 0.6mm-thick steel duct with beading at 300mm centres, protected with Flamebar BW11 Fire Proofing of mean thickness 0.Tmm. The duct, of overall length 4545mm, consisted of four duct sections connected by 50mm lap joints fastened with M4 stainless steel rivets at 60mm centres. The duct was stiffened at the penetration through the wall with 50mm x 50mm x 5mm steel angles fastened with M8 steel bolts at 150mm centres. The duct was exposed to hot furnace gases on the inside (duct B). There was no collapse of the duct and no failure of integrity, applying the general criteria for integrity of BS 476: Part 20: 1987. The temperature rise limits of the standard were first exceeded at four minutes. The duct retained more than 75% of its original cross-sectional area throughout the heating period and therefore satisfied the smoke outlet requirements of the test standard. See test report IFCI 330 for full details.



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2.10 Test report FC174

An exploratory fire test was carried out at the Cafco UK Ltd Development Department on 22 July 1999 on a Flamebar BW11 steel duct system for a heating period of 152 minutes. The test adopted the appropriate heating conditions, procedures and criteria of BS 476: Part 24: 1987. The duct specimen comprised a 1000mm wide x 250mm high x 1.20mm thick steel duct constructed in accordance with DW/144, protected with Flamebar BW11 Fire Proofing of mean thickness 0.9mm and with stone mineral wool insulation 120mm thick (2 x 60mm) x 105kg/m3 density. The duct, of overall length 4545mm, consisted of four duct

sections connected by 40mm Doby flanged joints fastened with M8 steel bolts. The duct was stiffened at the penetration through the wall with 50mm x 50mm x 5mm steel angles fastened with M8 steel bolts at 150mm centres. The duct was exposed to hot furnace gases on the inside (duct B). There was no

collapse of the duct and no failure of integrity, applying the general criteria for integrity of BS 476: Part 20: 1987. The temperature rise limits of the standard were first exceeded at 136 minutes. See test report FC174 for full details.

2.11 WF test report no. 156568 Issue 2

A fire resistance test in accordance with BS 476: Part 24:1987 was carried out on 8 December 2006 on a horizontal ventilation duct assembly, for a heating period of 157 minutes. The duct assembly consisted of a steel duct, 1000mm wide x 250mm deep x 0.8mm thick, protected with Flamebar BW11 Fire Proofing of

nominal thickness 0.Tmm. The duct was insulated with Rockwool FP110 stone mineral wool, 50ram thick x 110kg/m3 density, which was pushed over 64mm-long x 2mm-diameter fixing pins. Furthermore, Rockwool

FP110 stone mineral wool cover strips, 150mm wide x 25mm thick, were fitted around the duct perimeter at all joint locations in the steel duct and a Rockwool FP110 insulation collar, 500mm wide x 50mm thick, was applied to the duct on both sides of the furnace wall.

The duct, incorporating a tee piece and a 90° bend, was exposed to hot furnace gases on the outside (duct A) and satisfied the stability, integrity and insulation criteria for 157 minutes, 150 minutes and 150 minutes respectively. See WF test report no. 156568 Issue 2 for full details.

2.12 BRE assessment report no. CC 89277A

An assessment of the fire resistance of your insulated Flamebar BW11 duct system has been carried out for alternative fixing and support arrangements and thicknesses of the stone mineral wool insulation, in terms of the stability, integrity and insulation criteria of BS 476: Part 24:1987 (ISO 6944: 1985), for fire exposures of up to four hours for ducts A and B. See BRE assessment report no. CC 89277A for full details.

2.13 BRE assessment report no. CC 218953

An assessment of the fire resistance of your insulated Flamebar BW11 duct system has been carried out for modifications to the system used at wall and floor penetrations, in terms of the stability, integrity and insulation criteria of BS 476: Part 24:1987 (ISO 6944: 1985), for fire exposures of up to four hours for ducts A and B. See BRE assessment report no. CC 218953 for full details.



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3 Comments on supporting data

3.1 Addendum to test report TE 82414

The steel duct system protected with Flamebar BW11 compound, as tested in TE 82414, is designed to provide a fire resistance rating (uninsulated) when used as a ventilation duct. The duct was tested with the fire inside and outside (duct B) and satisfied the stability and integrity criteria of the standard for 120 minutes and 36 minutes respectively.

3.2 Loss of shape of duct

Both the type A and B ducts tested in TE 82414 and TE 82724 maintained the majodty of their section sha the heatinc



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3.3 Penetration seal

3.4 Seal used between lengths of duct


© BRE Global Ltd 2012 Pagellof75

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4 Appraisal of duct system

4.1 Penetration seal

As the design of the penetration seal system tested in WF no. 156568, TE 82414 (excluding the silicone mastic) and TE 84033 proved adequate for a fire exposure of two hours, as described in sections 3.1, 3.2 and 3.4 of this report, we consider this design to be suitable for ducts A and B for fire ratings up to two hours.

4.2 Hanger threaded rods

Fire tests TE 82414, TE 82724 and TE 84033 have demonstrated the suitability of the unprotected mild steel hanger assemblies, consisting of mild steel hanger threaded rods and mild steel bearers, at spacings of up to 1500mm for fire ratings up to two hours and at spacings up to 1000mm for fire ratings up to four hours. The diameter of the hanger rods must be of sufficient size that the tensile stress in the steel does not exceed 15N/mm2 for fire ratings up to one hour fire resistance, 10N/mm2 for fire ratings up to two hours fire resistance and 6N/mm2 for fire ratings up to four hours fire resistance. These values also apply to the

angle or channel-section supports under the ducts.

If stainless steel hanger rods are used instead of mild steel rods, the stress in the rods must not exceed 15N/mm2 for fire ratings up to one hour fire resistance, 10N/mm2 for fire ratings of up to two hours and 6N/mm2 for fire ratings of up to four hours. Suitable grades of stainless steel are types 304 and 316.

4.3 Design and size of steel ducts used to construct Flamebar BW11 fire duct

The basic design of the steel duct must be as those tested in WF no. 156568, TE 82414, TE 82724 and TE 84033 for the relevant fire resistance period. The design of the tested ducts is in accordance with the



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Firespray International Limited construction standards as listed hereafter in this assessment. These construction standards also take into account larger ductwork sizes.

The size of the steel duct tested was 1000ram wide x 250mm high as this is the size recommended by the test standard. This particular size can be adequately accommodated within the fire test furnaces without overcrowding. The width to height ratio of 1:4 is towards the maximum which would be installed in practice and results in greater distortion, slumping and bowing between hangers in the fire test than would occur in a square or circular duct. As the same design parameters are used with Firespray International Ltd. Construction Standards (see final section) for the specification of ducts with sizes larger than that tested we are satisfied that the construction details given are an adequate specification for larger sizes for fire-rated

ducts to enable the size of the steel ducts to be extended



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4.4 Insulation system



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b) Four type A ducts were tested - that in WF report no. 156568 and the exploratory ducts in TE 82414, TE 82724 and TE 84033.

c) The Flamebar BW11 ventilation duct assembly tested in TE 87473 was exposed to fire on the

inside and insulated



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J) An assessment has been carried out for alternative thicknesses of Rockwool insulation which will enable the Flamebar BW11 duct system to satisfy the insulation criteria of BS 476: Part 24: for exposure periods from 30 minutes to 240 minutes. See LPC assessment report CC 89277A for full details.

4.5 Orientation of duct

All of the above fire tests on the duct systems were carried out on horizontal duct assemblies. However most duct installations will also include some vertically orientated sections. In order to make an assessment of the fire performance of the duct systems in the vertical orientation, an evaluation must be made in relation to the three performance criteria of the standard.

a) Stability: In order to support the duct system in the vertical orientation, steel angles (minimum size

~are fastened to the steel duct, either along the two longer sides or on all

four sides. These angles may be covered (or partially covered~ The ends of these angles are

supported by further steel angles supported by a concrete floor slab or by steel brackets fastened

to a wall.

b)

See Firespray International drawing no. STD 1028D for further details of the arrangement. This arrangement will provide adequate support and restraint to the duct, as long as there is about one support per storey height of the building.

Insulation: The level of fire exposure for type A and type B ducts are the same in the standard fire

test for both vertical and horizontal ducts. The same thicknesses of~ can therefore be used for vertical ducts as are used for horizontal ducts.

Integrity: During the fire tests on the horizontal ducts no failure of the integrity criteria occurred through the duct sections. It was only at the wall penetration seals or adjacent to the seals that failure occurred and this has been corrected by modified designs of the penetration seals and insulation (see Sections 4.1 and 4.4 of this report). As vertical ducts are to be supported, as described in 4.5 (a), the same design of penetration seal will perform as effectively through concrete floors as through masonry walls.

Therefore it is our opinion that if the duct systems are positioned in the vertical orientation, as described above, then the fire performance of the duct systems would be very similar to the horizontally orientated ducts as tested.



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5 Supplementary assessments/additional data

5.2 Flamebar BW11 ducts constructed with stainless steel

This section covers the fire resistance of Flamebar BW11 duct systems when constructed with stainless steel, in terms of BS 476: Part 24:1987 for fire exposure up to 4 hours.



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The construction of the ducts tested in TE 82414, TE 82724 and TE 84033 which form the basis for this assessment have been constructed using mild steel sheet (galvanised or otherwise) with angle section/flanged cross joints and a folded longitudinal seam. The construction of the larger steel ducts detailed in this assessment is stronger than the tested ducts, with steel framing at 500mm maximum centres. Our experience of the usual grades of stainless steel for this type of construction, when exposed to the standard fire environment, is that they perform slightly better than mild steel and galvanised steel as they undergo less scaling and degradation.

These stainless steels have a slightly higher coefficient of expansion than mild steel (typically 13 to 15 x 10.6 as opposed to 12 x 10-6). This additional expansion must be taken into consideration when providing

the allowance and restraints for thermal expansion. However the better resistance to the effects of the fire of stainless steel means that the ducts will remain intact and retain their shape for slightly longer in a fire environment.

Therefore it is our opinion that if the steel duct systems protected with Flamebar BW11 Fire Proofing are constructed in stainless steel, as described above, and in accordance with the previously mentioned fire tests, then the use of stainless steel will not adversely affect the behaviour of the duct systems when exposed to fire and therefore the Flamebar BW11 duct systems made of stainless steel are suitable for the fire resistance ratings given in tables 1,2 and 3 of this assessment in terms of BS 476: Part 24: 1987, given the requirements and limitations described above and in this report.

5.3 Access doors

Within ventilation ductwork systems access doors are often required, for access to plant, such as fire dampers or for routine cleaning applications such as required on kitchen extract systems (BS 5588: Part 9 refers). Firespray International standard STD1001 F confirms constructional requirements for same.

5.4 Alternative seal between duct lengths

5.5 Alternative fixings

It is proposed that steel, self-drilling, self-tapping screws are used as an alternative to the tested rivets for fixing the duct flanges together. This is considered to be acceptable provided that the screws are not taken out and refitted more than once or twice. The fixings must be inserted in accordance with the manufacturer’s instructions for the gauge of steel being used, and care should be taken not to overturn the fixing once it is inserted.



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6 Conclusion

An assessment has been carried out on your steel ventilation, smoke outlet and kitchen extract duct systems protected with Flamebar BW11 Fire Proofing and additionally, in some cases, with stone mineral wool, as tested in WF report no. 156568, TE 82414, TE 82724 and TE 84033 to BS 476: Part 24: 1987, for variations in the duct system due to fire rating, duct function, duct orientation, size of duct, supporting system and penetration details. The results of the assessment and other requirements are given in tables 1,2 and 3, pages 22-24.

7 Re-issue of report

This assessment report was re-issued at the request of Firespray International in order to correct some

anomalies in tables 1 to 3.

8 Validity of the assessment

8.1 Declaration by applicant

8.1 Declaration by applicant

We the undersigned confirm lhat we have read and compl~ed wilh the obligations placed on us by the UK Fire Test Study Group Resolution No. 82 ’ 2001

We confirm that the component or element of structure, which is the subject of this assessment,

I~as not to our knowledge been subjected to a fire test to the Standard aga=nst which trois

assessment is being made

We agree to w~thdraw th~s assessment from circulation sl3ould the coml:~onent or element of structure be the subject of a fire test to the Standard against which th~s assessment ~s being made

¯ We are not aware of any reformation that could adversely affect the conclusions of this assessment

o If we subsequently become aware of any such information we agree to cease using assessment and ask BRE Testing to withdraw the assessment

\ For and on behalf of ....... . ~ L "



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This assessment report is not valid unless it incorporates the declaration duly signed by the applicant.

8.2 BRE Testing declaration

This assessment was reviewed on 24 April 2012. We have received written confirmation from Firespray International Limited that there have been no changes in the specification of their duct systems since the original date of the assessment. There have been no changes in the fire test procedures or methods of assessment, which would adversely affect the fire performance of the systems. We are therefore satisfied that the validity of this assessment may be extended for a further five years.

This assessment is based on test data, experience and the information supplied. If contradictory evidence becomes available to BRE Testing the assessment will be unconditionally withdrawn and the applicant will be notified in writing. Similarly the assessment is invalidated if the assessed construction is subsequently tested since actual test data is deemed to take precedence over an expressed opinion. The assessment is valid fora period of five years after which it should be returned for review to consider any additional data, which has become available or any changes in the fire test procedures. Any changes in the specification of the product will invalidate this assessment.

This assessment has been carried out in accordance with Fire Test Study Group Resolution No. 82. It relates to the fire performance of the product and does not cover aspects of quality, durability, maintenance

nor service requirements. This assessment relates only to the specimen(s) assessed and does not by itself infer that the product is approved under any Loss Prevention Certification Board approval or certification scheme or any other endorsements, approval or certification scheme.

Next review date: 24 April 2017



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Table 1 Normal ventilation ducts (fan on or off)

See Notes 1,3, 4.

Condition

Fire outside duct (type A)

a) Stability and integrity only

b) Stability, integrity and

insulation

Fire inside duct (type B)

a) Stability and

Type of insulation

45kg/m3

45kg/m3

60kg/m3

60kg/m3

60kg/m3

105kg/m3

105kg/m3

105kg/m3

60kg/m3

105kg/m3

105kg/m3

105kg/m3

Insulation thickness

25mm 60mm 40mm 50mm 120mm 50mm 80mm 50mm 120mm 80mm 120mm 100mm*

Fire resistance duration - min

Stability and integrity

120 24O

120 120 120 120 120 120 120 24O 24O 24O 24O 24O

120

Insulation

15 15

6O 6O 90 118 120 120 120 2O8 24O 24O 24O 24O



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integrity only


insulation

45kg/m3 45kg/m3 60kg/m3 105kg/m3 60kg/m3 105kg/m3 105kg/m3 105kg/m3 60kg/m3 105kg/m3 105kg/m3 105kg/m3

25mm 60mm 50mm 50mm 120mm 80mm 120mm 100mm* 120mm 80mm 120mm 100mm*

24O

120 120 120 120 120 120 120 120 24O 24O 24O 24O

* See Note 5

3O 3O 45 6O 9O 9O 120 120 9O 9O 120 120

Table 2 Smoke outlet ducts (fan on or off)

See Notes 1,2, 3, 4

Condition




insulation


Type of insulation

45kg/m3 45kg/m3 60kg/m3 60kg/m3 60kg/m3 105kg/m3 105kg/m3 105kg/m3 60kg/m3 105kg/m3 105kg/m3 105kg/m3


25mm 60mm 40mm 50mm 120mm 50mm 80mm 50mm 120mm 80mm 120mm 100mm*



120 24O

120 120 120 120 120 120 120 24O 24O 24O 24O 24O

Insulation

15 15

6O 6O 90 118 120 120 120 2O8 24O 24O 24O 24O



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insulation

45kg/m3

45kg/m3

60kg/m3

105kg/m3

60kg/m3

105kg/m3

105kg/m3

105kg/m3

60kg/m3

105kg/m3

105kg/m3

105kg/m3

25mm 60mm 50mm 50mm 120mm 80mm 120mm 100mm* 120mm 80mm 120mm 100mm*

120 24O

120 120 120 120 120 120 120 120 24O 24O 24O 24O

* See Note 5

3O 3O 45 6O 9O 9O 120 120 9O 9O 120 120

Table 3 Kitchen extract ducts or ducts containing combustible linings (fan on or off)

See Notes 1,3, 4.

Condition




insulation


Type of insulation

60kg/m3 60kg/m3 105kg/m3 60kg/m3 105kg/m3 105kg/m3 105kg/m3 60kg/m3 105kg/m3 105kg/m3 105kg/m3


50mm 60mm 50mm 120mm 80mm

100mm** 50mm 120mm 80mm 120mm

100ram**



120 24O

120 120 120 120 120 120 24O 24O 24O 24O 24O

Insulation

15 15

28* 30* 44* 45* 45* 60* 44* 45* 45* 60* 60*



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insulation

45kg/m3

45kg/m3

60kg/m3

105kg/m3

60kg/m3

105kg/m3

105kg/m3

105kg/m3

60kg/m3

105kg/m3

105kg/m3

105kg/m3

25mm 60mm 50mm 50mm 120mm 80mm 120mm

100mm** 120mm 80mm 120mm

100mm**

120 24O

120 120 120 120 120 120 120 120 24O 24O 24O 24O

* Refers to internal face inside furnace ** See Note 5

3O 3O 45 6O 9O 9O 120 120 9O 9O 120 120

Notes to Tables 1,2 and 3

1. All ducts are protected with 0.Tmm to 1.0mm nominal thickness Flamebar BW11 Fire Proofing.

Maximum hanger centres are 1500mm for fire ratings up to two hours and 1000mm for fire ratings up to four hours.

The 50mm thick x 60kg/m3 density stone mineral wool insulation may be in the form of either slabs

or wrap.

The minimum wall thicknesses for the steel ducts protected with Flamebar BW11 Fire Proofing are given in the Firespray International Manufacturing Standards Ltd given in this report.

Includes 500mm x 25mm thick x 105kg/m3 density stone mineral wool collar around duct on both sides of penetration seals through fire compartment walls and floors.



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Appendix A - Design of hanger supports for four-sided horizontal ducts

Sections 4.2 and 4.3 of this report give details of the construction, spacing and requirements for the hanger supports for the duct. In section 4.3 it states that:

"For horizontal ducts wider than 2m, an additional hanger drop rod must be fitted at approximately mid- width of the duct. This additional threaded rod passes through the angle section framing of the duct (holes sealed with Flamebar BW11) and is fitted with nuts and washers so that it supports the upper horizontal wall of the duct, the lower horizontal wall of the duct and the horizontal hanger member (on a four sided

duct)".

The following arrangement is a suitable alternative to the requirement for the additional hanger drop rod for ducts over 2m wide:

a) The bearer of each hanger support, with a drop rod at each end, is strong enough to meet the maximum stress limitations detailed in section 4.2 of the report, without any intermediate support.

b) On ducts over 1000mm wide, a tie rod is fitted to each duct section at one end which is designed to maintain the shape of the duct on a fire situation. Details of the tie rods are given in appendix A. The tie rods must be spaced at the same centres as the length of the duct sections.

c) The hanger supports are installed at maximum 1500mm centres for fire ratings up to two hours and at a maximum 1000mm centres for fire ratings up to four hours.

We are satisfied that the alternative hanger support arrangement will not adversely affect the fire resistance of the duct systems in terms of the performance criteria of BS 476: Part 24:1987.



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Appendix B - Horizontal and vertical ducts larger



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Appendix C - Horizontal and vertical ducts



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Appendix D - Flamebar construction standards drawings

This section contains 44 current construction standards detailing manufacturing and installation details of Flamebar BW11 systems. The standard detailed may alter in accordance with product development or future test data.

STD0200 "M" Flamebar BW11 rectangular, STD0201 "M" Flamebar BW11 rectangular, STD0202 "M" Flamebar BW11 rectangular, STD0203 "M" Flamebar BW11 rectangular, STD0204 "L" Flamebar BW11 rectangular, STD0205 "M" Flamebar BW11 rectangular, STD0206 "J" Flamebar BW11 rectangular, STD0207 "H" Flamebar BW11 rectangular, STD0208 "J" Flamebar BW11 rectangular, STD0210 "K"

2 hour fire duct, fire inside or outside Class "D".

2 hour smoke extract, fire inside or outside Class "D".

2 hour kitchen extract, fire inside or outside Class "D".

4 hour fire duct, fire inside or outside.

4 hour smoke extract, fire inside or outside.

4 hour kitchen extract, fire inside or outside.

2 hour low velocity fire duct, fire inside or outside Class "A".

2 hour low velocity smoke extract, fire inside or outside Class "A".

2 hour low velocity kitchen extract, fire inside or outside Class "A".

Flamebar BW11 circular 2 hour fire duct, fire inside or outside. STD0211 "K" Flamebar BW11 circular 2 hour smoke extract, fire inside or outside. STD0212 "L" Flamebar BW11 circular 2 hour kitchen extract, fire inside or outside. STD0213 "J" Flamebar BW11 circular 4 hour fire duct, fire inside or outside. 8TD0214 "K" Flamebar BW11 circular 4 hour smoke extract, fire inside or outside. STD0215 "K" Flamebar BW11 circular 4 hour kitchen extract, fire inside or outside. STD0220 "G" Flamebar BW11 fiat oval, 2 hour fire duct, fire inside or outside. STD0221 "G" Flamebar BW11 Flat oval, 2 hour smoke extract, fire inside or outside. STD0222 "H" Flamebar BW11 fiat oval, 2 hour kitchen extract, fire inside or outside. STD0223 "G" Flamebar BW11 fiat oval, 4 hour fire duct, fire inside or outside. STD0224 "G" Flamebar BW11 Flat oval, 4 hour smoke extract, fire inside or outside. STD0225 "H" Flamebar BW11 fiat oval, 4 hour kitchen extract, fire inside or outside.



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STD0230 "G" Flamebar BW11 rectangular, 2 hour fire duct, fire inside or outside Class "B". STD0231 "G" Flamebar BW11 rectangular, 2 hour fire duct, fire inside or outside Class "C". STD0232 "F" Flamebar BW11 rectangular, 2 hour smoke duct, fire inside or outside Class "B". STD0233 "F" Flamebar BW11 rectangular, 2 hour smoke duct, fire inside or outside Class "C". STD0234 "G" Flamebar BW11 rectangular, 2 hour kitchen extract, fire inside or outside Class "B". STD0235 "G" Flamebar BW11 rectangular, 2 hour kitchen extract, fire inside or outside Class "C". STD0250 "G" Flamebar BW11 2 hour rectangular fire duct, fire inside or outside based on SMACNA figure rigs. (metric) STD0251 "G" Flamebar BW11 2 hour rectangular fire duct, fire inside or outside based on SMACNA figure nos. (imperial). STD0252 "G" Flamebar BW11 2 hour rectangular smoke duct, fire inside or outside based on SMACNA figure nos. (metric). STD0253 "G" Flamebar BW11 2 hour rectangular smoke duct, fire inside or outside based on SMACNA figure rigs. (imperial). STD0254 "H" Flamebar BW11 2 hour rectangular kitchen extract, fire inside or outside based on SMACNA figure nos. (metric). STD0255 "H" Flamebar BW11 2 hour rectangular kitchen extract, fire inside or outside based on SMACNA figure nos. (imperial). STD0350 "J" Flamebar BW11 rectangular fire duct, fire inside based on SMACNA standards (metric) STD0351 "K" Flamebar BW11 rectangular fire duct, fire inside based on SMACNA standards (imperial) STD1000 "D" Rolled steel angle and flat bar flange drilling details. STD1001 "F" Fire duct access door details. STD1010 "F" Connection of control devices to BW11 fire duct. STD1011 "E" Construction of BW11 ducts up to 4m wide x 3m high. STD1017 "F" Fire rated smoke balancing dampers for Flamebar BW11 fire duct. STD1024 "E" Construction of BW11 transformation pieces. STD1025 "F" Construction of BW11 square bends. STD1026 "E" Construction of BW11 radius bends. STD1028 "D" Construction of riser supports.



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Figure 4 Drawing no. STD203 "M"



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Figure 5 Drawing no. STD204 "L"



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Figure 6 Drawing no. STD205 "M"



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Figure 7 Drawing no. STD206 "J"



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Figure 8 Drawing no. STD207 "H"



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Figure 10 Drawing no. STD210 "K"



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Figure 12 Drawing no. STD212 "L"



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Figure 16 Drawing no. STD220 "G"



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Figure 24 Drawing no. STD232 "F"



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Figure 36 Drawing no. STD1000 "D"



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Figure 39 Drawing no. STD1011 "E"



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Figure 41 Drawing no. 1024 "E"



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Figure 43 Drawing no. STD1026 "E"



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Figure 44 Drawing no. STD1028 "D"


REPORT ENDS


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Documents

An assessment of the fire performance of a proprietary design for